X 9130 1991 GMC RV P Wiring Manual

1991
ELECTRICAL DIAGRAMS
AND
DIAGNOSIS MANUAL
F t/V , P M O D E L S
When reference is made in this manual to a brand name, number, or specific tool, an equivalent product may be used in
place of the recommended item.
All information, illustrations, and specifications contained in this manual are based on the latest product information
available at the time of publication approval. The right is reserved to make changes at any time without notice.
No part of this publication may be reproduced, stored in any retrieval system or transmitted, in any fornror by any
means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of the GMC Truck Division of General Motors Corporation. This includes all text, illustrations, tables and
charts.
X-9140
1990 General Motors Corporation
June 1990
All rights reserved.
Printed in U.S.A.
NOTICE
CONTENTS SENSITIVE
TO
STATIC ELECTRICITY
F-05403
ELECTRONIC DISCHARGE WARNING
When handling an electronic part that has an ESD sensitive sticker, the service technician should
follow these guidelines to reduce any possible electrostatic charge build-up on the service
technicians body and the electronic part in the dealership.
1.
2.
3.
4.
Do not open the package until it is time to install the part.

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

TABLE OF CONTENTS
INTRODUCTION
Circuit
Operation
Page
Page
Introduction ......................................................................................
How to Use This Manual .................................................................
Handling Electrostatic Discharge
(ESD) Sensitive P a r ts ...................................................................
Circuit O p eratio n...............................................................................
Circuit Diagrams ...............................................................................
Component Locations ......................................................................
Diagnosis ......................................................................................
Basic Electricity .............................................................................
Circuit Malfunctions..........................................................................
Electrical Test Equipment.............................................................
Circuit Wiring Repair Procedures ................................................
Weather-Pack Connectors ...........................................................
Metri-Pack Connectors ..................................................................
Special T o o ls ......................................................................................
Regular Production Option (RPO) List ..........................................
Abbreviation List ...............................................................................
General Index ....................................................................................
.........
.........
3
3
.........
.........
.........
.........
3
3
3
3
4
4
4
4
.........
.........
.........
.........
.........
.........
.........
6
8
8
......... 9
......... 10
......... 10
Index 1
R/V TRUCK MODELS - SECTION A

Page
Phantom Views ...............................................................................
Symptom Index ...............................................................................
Power Distribution ..........................................................................
Fuse Block D e ta ils ..........................................................................
Bulb Data and Fuse Block Identification .......................................
Ground Distribution ........................................................................
......... A-2
......... A-8
. . . . A-10
. . . . A-14
. . . . A-15
A-16
Circuit
Operation
Page
Headlamps (B a s e )...............................................................................
Canadian Daytime Running Lamps...................................................
Quad H a lo g en ......................................................................................
Hazard L a m p s ......................................................................................
Front Park and Sider Marker Lam ps.................................................
Turn L am p s...........................................................................................
Horns ....................................................................................................
Cigarette Lighter .............................................................................
Windshield Wipers and Washers (Pulse)..........................................
Start and C h a rg e .................................................................................
Auxiliary Cooling F a n ..........................................................................
....
....
....
....
....
....
....
....
....
....
....
A-23
A-23
A-23
A-33
A-33
A-42
A-48
A-48
A-50
A-53
A-89
Circuit
Diagram
Page
A-25
A-26
A-32
A-34
A-36
A-44
A-49
A-49
A-52
A-55
A-90
Air Conditioning.............................................................................................. A-91

H e a te r............................................................................................................... A-91
Auxiliary Heater ............................................................................................... A-91
Gages and Warning Indicators.....................................................................A-100
Audio Alarm M odule....................................................................................... A-111
Rear Wheel Antilock Brakes/Brake Warning ............................................. A-114
Dome L a m p s ................................................................................................... A-118
Cruise Control .................................................................................................A-122
Four-Wheel D riv e ............................................................................................ A-125
Power Mirrors and Door L o c k s ........................................................... ..
A-127
Power W indow s...............................................................................................A-136
Radio AM and AM/FM S te re o .......................................................................A-143
Rear D efo g g er................................................................................................. A-146
Rear L a m p s ......................................................................................................A-149
Rear Park and Marker L a m p s .......................................................................A-149
Taillam ps.......................................................................................................... A-149
Trailer T o w ........................................................................................................ A-149
Backup Lam ps................................................................................................. A-149
License Lam ps................................................................................................. A-149
Vacuum S ystem s............................................................................................ A-161
Component Locator V ie w s ............................................................................A-166
Component Locater Index ............................................................................A-194
ECM Pinouts ...............................
PCM Pinouts ...............................
TCM Pinouts ...............................
PCM Inputs .................................
PCM O utputs...............................
TCM .............................................
Hot Fuel Handling .....................
Torque Converter Clutch Control
Ignition ........................................
ECM Inputs .................................
ECM O utputs...............................
Fuel Control and Idle Air Control
Instrument C lu s te r.....................
Circuit
Diagram
Page
A-94
A-96
A-99
A-104
A-112
A-116
A-119
A-124
A-126
A-129
A-139
A-144
A-147
A-156
A-150
A-160
A-154
A-158
A-164
A-57
A -66
A-67
A-68
A-70
A-72
A-79
A-74
A-76
A-63
A-64
A-78
A-103
TABLE OF CONTENTS
P TRUCK MODELS - SECTION B
P MOTORHOME - SECTION C
Page
Page
Phantom Views ................................................................................................. B-2

Symptom Index ................................................................................................. B-3
Power Distribution .............................................................................................B-4
Fuse Block D e ta ils .......................................................................................... B-10
Lamp Bulb D a ta ............................................................................................... B-14
Ground Distribution ........................................................................................ B-15
C irc u it
O p e ra tio n
Page
Headlamps (B a s e ).......................................................................................... .B-22
Canadian Daytime Running Lam ps...............................................................B-25
Park, Marker and Hazard Signal L a m p s .................................................... .B-30
Turn L a m p s ...................................................................................................... .B-33
Horns .................................................................................................................B-35
Windshield Wipers and Washers ................................................................ .B-37
Starting/Charging..............................................................................................B-39
Glow Plugs ...................................................................................................... .B-59
Fuel C ontrols.....................................................................................................B-62
Instrument Panel ..............................................................................................B-66
Indicator L a m p s ............................................................................................... .B-66
G a g e s .................................................................................................................B-66
Instrument Panel Lam ps..................................................................................B-66
Brake Warning S ystem ................................................................................... .B-73
Rear Exterior Lam ps.........................................................................................B-75
Backup Lam ps................................................................................................. .B-75
Taillamps, Rear Marker and License Lamps ............................................. .B-75
Vacuum S ystem ............................................................................................... .B-79
Component Locator V ie w s ............................................................................ .B-81
Component Locater Index ............................................................................ .B-87
ECM P in o u ts ..........
ECM In p u ts ............
ECM O utputs..........
PCM P in o u ts ..........
PCM In p u ts ............
PCM O utputs..........
TCM Pinouts ..........
TCM Inputs/Outputs
Instrument Cluster .
TABLE OF CONTENTS
Phantom Views ................................................................................................ C-2

Symptom Index ................................................................................................ C-3
Power Distribution ........................................................................................... C-4
Fuse Block D e ta ils ........................................................................................... C-8
Lamp Bulb D a ta .............................................................................................. C-10
Ground Distribution ....................................................................................... C-11
Circuit
Diagram
Page
B-23
B-27
B-31
B-34
B-36
B-38
B-40
B-60
B-63
B-70
B-71
B-72
B-74
B-76
B-77
B-78
B-80
B-43
B-44
B-46
B-49
B-50
B-52
B-55
B-56
B-69
Circuit
Operation
Page
Headlamps (B a s e )......................................................................................... .C-13
Canadian Daytime Running Lam ps............................................................ .C-16
Park, Marker and Hazard Signal Lamps ................................................... .C-21
Turn L a m p s ......................................................................................................C-23
Horns .............................................................................................................. .C-25
Windshield Wipers and Washers ................................................................C-27
Starting/Charging........................................................................................... .C-29
Glow Plugs ......................................................................................................C-43
Fuel C ontrols.................................................................................................. .C-46
Auxiliary Cooling F a n .................................................................................... .C-48
Provisions for Air Conditioning.....................................................................C-48
Cruise C o n tro l................................................................................................ .C-51
Instrument Panel ........................................................................................... .C-53
Instrument C lu s te r......................................................................................... .C-53
Indicator L a m p s ...............................................................................................C-53
G a g e s .............................................................................................................. .C-53
Instrument Panel Lam p s............................................................................... .C-53
Provisions for Dome Lamps ........................................................................ C-53
Rear L a m p s ......................................................................................................C-60
Taillam ps.......................................................................................................... C-60
Backup Lam ps................................................................................................ .C-60
Vacuum S ystem ...............................................................................................C-64
Component Locator Views
Component Locater Index
Ignition ...............................
PCM Pinouts .....................
PCM Inputs ........................
PCM O utp u ts.....................
Throttle Body Injection . . .
TCM Pinouts .....................
TCM Inputs/Outputs.........
DRAC .................................
Circuit
Diagram
Page
C-14
C-18
C-22
C-24
C-26
C-28
C-30
C-44
C-47
C-49
C-49
C-52
C-55
C-56
C-57
C-58
C-59
C-62
C-63
C-65
C-66
C-70
C-32
C-33
C-34
C-36
C-38
C-39
C-40
C-42
Circuit diagrams provide a schematic picture of how a

circuit is provided voltage, what the current path is to the
components, and how the circuit is grounded.
HOW TO USE THIS MANUAL
NOTICE
The purpose of this manual is to provide:

Clean and simple electrical circuit diagrams.
Discussion of circuit electrical operation.
Simplified diagnosis and testing procedures.
Component location views.
Each electrical system or circuit will provide the follow

ing information:
Circuit Operation.
Circuit Diagrams.
Component Location.
Diagnosis Charts.
1. Do not open the package until it is time to install the

part.
2. Avoid touching the electrical terminals of the part.
3. Before removing the part from its package, ground the
package to a known good ground on the vehicle.
4. Always touch a known good ground before handling
the part. This should be repeated while handling the
part and more frequently after sliding across the seat,
sitting down from a standing position or walking a dis
tance.
The following is a list of Zones for the vehicle:
C O N T E N T S S E N S IT IV E
TO
S TA TIC E L E C T R IC IT Y
HANDLING ELECTROSTATIC DISCHARGE

(ESD) SENSITIVE PARTS
When handling an electronic part that has an ESD sen
sitive sticker (Figure 1), the service technician should fol
low these guidelines to reduce any possible electrostatic
charge build-up on the service technicians body and the
electronic part in the dealership:
For ease of diagnosis, all connectors (C), splices (S),

grounds (G) and grommets (GT) are identified by their
own unique number. This number is used to reference
component locations and also for identification in the
diagnostic charts. The beginning digit designates the
ZONE at which the connector, splice or ground can be
found. For example: C302. The C is for connector, the
3 represents Zone 300 and 02 is the connector number.
ZONE
LOCATION
100 At and forward of bulkhead.
200 Within l/R
300 From l/P to rear of cab.
400 Rearward of cab.
500 Within left door.
600 Within right door.
900 Within rear doors.
H A N D L E I N A C C O R D A N C E W IT H S T A T I C C O N T R O L
P R O C E D U R E S G M 9107P A N D GM 9108P,
O R G M D IV IS IO N A L S E R V IC E M A N U A L S .
F -0 5 4 0 3
Figure 1 Electronic Discharge Warning
CIRCUIT OPERATION
The description of circuit operation provides a simpli
fied discussion of what is happening within each circuit.
The discussion includes power application, ground paths
and component operation. The explanation is tied to the
circuit diagram, and in some cases, to specific switch
movement or components in a circuit.
All connectors are shown with their part numbers and

are viewed from the mating end. The part number is used
to save time when ordering replacement parts. All compo
nents and switches are shown in their rest position,
unless otherwise marked.
COMPONENT LOCATIONS
When you are ready to locate the schematic compo
nents on the vehicle, use the Component Locations chart,
see Figure 3.
Listed in the LH column are the components shown on
the schematic. Next to the Fuse Block is the location,
Behind LH side of l/R Reference to LH and RH is made
as though the technician were sitting in the drivers seat.
On the same line, in the far right column, is the page-figure reference. In this case, you are directed to Figure 37
in the Component Locator Views.
Where connectors are listed, the number of cavities is
provided. This represents the total number of cavities in
the connector, regardless of how many are actually used.
This information is provided to help you identify connec
tors on the vehicle. Only in-line connector locations are
given.
Grounds are listed next in the table. The location
description for ground G302 reads, Behind LH side of
IIP, on ALDL bracket. You are directed to Figure 32.
Nearly every component, connector, ground or splice
shown on a schematic can be pinpointed visually by using
the Component Location Views in the back of this manual.
Each wiring circuit is identified by circuit number, size

(in mm2) and color. Wire colors are shown in the abbrevi
ated form. Figure 2 shows how the circuit numbers and
color abbreviations are identified in this manual.
There are three types of lines used to depict circuits
throughout the circuit diagrams. They are as shown:
CIRCUIT DIAGRAMS
The circuit diagrams show the circuits and components
that are covered in that particular system. By eliminating
circuits and components not related to the systems being
covered, the circuit diagrams are greatly simplified.
^ H
-s .o n E D B i^ Solid Color Circuit Line
2 - 3.0 r e d / w h t
mm Circuit Line With Tracer

RPO Variant Circuit Line
COMPONENT LOCATION
9-
-------------------- 1
COLOR OF WIRE INSULATION
WIRE
CIRCUIT -
NUMBER
Page - Figure
BRN
L WIRE SIZE
IN SQ. MM.
B L K ___ .........Black
BRN
.........Brown
GRN . . . .........Green
ORN . . .
GRA . . . ........... Gray
RST . . . . ...........Rust
P P L ___
YEL . . . . . . . . Yellow
W H T ___ ___ White
B L U .................... Blue
P N K ....................Pink
DK ......... ......... Dark
L T ........... .........Light
Headlamp Dimmer Switch...........................................

Low Beam Headlamp Relay........................................
C100 (36 Cavities) (Diesel)......................................... ....................
C100 (36 Cavities) (Gasoline).....................................
G104............................................................................
G105............................................................................
G302............................................................................
S101.............................................................................
S102.............................................................................
S103.............................................................................
S104..............................................................................
S307..............................................................................
..162-37
.. 162-36
..171-57
Engine compartment, on LH front of dash.................. ..159-28
..156-19
... 149-5
.. 166-47
..161-32
.166-47
.166-47
.166-47
steering column.......................................................
Grommet 10Q................................................................
F-05975
Figure 2 Wire Coding
. 167-37
159-29
Figure 3 Component Location Chart
Check for the cause of the problem

(Diagnosis Charts)
DIAGNOSIS
Before beginning any diagnosis, there are several
important steps that should be taken:
Verify the problem
The Diagnosis Charts (Figure 4) are a step-by-step

approach to diagnosis of the problem (or condition). Each
chart covers one symptom. For example, Horn(s) will not
operate.
Operate the system and list symptoms in order to:

Check the accuracy and completeness of the com
plaint.
Learn more that might give a clue to the nature and
location of the problem.
Analyze what parts of the system are working.
Check the circuit diagram

Refer to the Circuit Diagram for clues to the problem.
Location and identification of circuit components may give
some idea of where the problem is.
The circuit diagrams are designed to make it easy to
identify common points in circuits. This knowledge can
help narrow the problem to a specific area. For example, if
several circuits fail at the same time, check for a common
voltage or ground connection. If part of a circuit fails,
check the connections between the part that works and
the part that does not work.
For example, if the low beam headlamps work, but the
high beams and the indicator lamp do not, then voltage
and ground paths are good. Since the dimmer switch is
the component which switches this voltage, it is most
likely the cause of failure.
Read circuit operation

Read the Circuit Operation for the problem circuit. By
studying the circuit diagram and circuit operation, enough
information should be learned to narrow the cause to one
component or one portion of the circuit.
The charts are divided into three columns; Test, Result

and Action.
The Test procedures are listed in numerical sequence
and must be followed in that order. Each test step will
describe what must be done to the circuit, what test
equipment to use and where to connect the test equip
ment.
After the test procedure has been performed, refer to
the Result column. This will list possible results of the
test. Once the result has been found, follow it directly over
to the Action column.
The Action column will instruct what must be done to
correct the problem or will list the next test step to be per
formed.
It is important to remember that a problem in one sys
tem could result in a symptom in another system.
BASIC ELECTRICITY
Ohms Law states that voltage (E) is equal to resistance
(R) (ohms) time current (I) (amperes) in a circuit
(E = R x I). The equation can also be shown as I = E/R
or R = E/I.
If any two of the values are known for a given circuit,
the missing one can be found by substituting the values in
amperes, volts or ohms and solving for the missing value.
In a typical simple circuit, battery voltage is applied to a
bulb through a 10-amp fuse and a switch. Closing the
switch turns on the bulb.
To find the circuit current flow, use the equation:
Grounded Circuit (Figure 7)
I = 12 volts (E)/2 ohms (R), or I = 6 amps.

The bulb in this circuit operates at 6 amps and is rated
to operate at this level. With 12 volts applied to the bulb, it
will glow at the rated level.
CIRCUIT MALFUNCTIONS
There are three electrical conditions that can cause a
non-working circuit; an Open Circuit, a Short Circuit,
or a Ground Circuit.
1.
Repair the problem circuit as directed in the diagnosis

charts.
Verify that the repair is complete

Operate the system and check that the repair has
removed all symptoms, and also has not caused any new
symptoms.
2.
3.
4.
RESULT
Check condition of PARK LP fuse.
Open Circuit (Figure 5)

An open circuit occurs whenever there is a break in the
circuit. The break can be corrosion at the connector, a
wire broken off in a component, a wire that burned open
from too much current, or a component not operating as it
should.
GO to step 2.
Fuse is blown.
LOCATE and REPAIR source of

overload. Then, REPLACE fuse.
With the light switch ON,

connect a test lamp from ORN
(240) wire at light switch
connector C304 to ground.
Test lamp lights.
GO to step 3.
Test lamp does not light.
LOCATE and REPAIR open in ORN

(240) wire from light switch to
fuse block.
Connect a test lamp from YEL (10)

wire at light switch connector
C 304 to ground.
Test lamp lights.
GO to step 4.
REPLACE light switch.
Test lamp lights.
REPAIR open in LT GRN (11) wire

from dimmer switch to lights.
REPLACE dimmer switch.
Figure 4 Typical Diagnosis Chart
Figure 7 Grounded Circuit
JL JL
ACTION
Fuse is not blown.
Connect a test lamp from LT GRN

(11) wire at dimmer switch
A grounded circuit is like a short circuit but the current

flows directly into a ground circuit that is not part of the
original circuit. This may be caused by a wire rubbing
against the frame or body. Sometimes a wire will break
and fall against metal that is connected electrically to the
ground side of the voltage supply. A grounded circuit may
also be caused by deposits of oil, dirt or moisture around
connections or terminals, which provide a good path to
ground.
Make the repair
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS BOTH SIDES

TEST
Figure 6 Short Circuit
I = E/R. Filling in the numbers for the equation:
B-00723
Figure 5 Open Circuit
Short Circuit (Figure 6)

A short circuit happens when the current bypasses part
of the normal circuit. This bypassing is usually caused by
wires touching, salt water in or on a component such as a
switch or a connector, or solder melting and bridging con
ductors in a component.
ELECTRICAL TEST EQUIPMENT

Various electrical testers have been developed over the
years. A few of these are basic but are required to per
form a thorough electrical diagnosis. These include:
Jumper wires
Voltmeter
Test lamps
Ohmmeter
Self-powered test lamps
Ammeter
All of these testers come in a variety of models and any

working model will be adequate for simple tests. However,
accuracy becomes important when the value of a reading
obtained using a meter is critical to the diagnosis proce
dure. Make sure any electrical test meter used is of suffic
ient quality and accuracy to make the measurements
required in the electrical testing.
Jumper Wires
Jumper wires allow jumping across a suspected
open or break in a circuit.
If the circuit works properly with the jumper wire in
place, but does not work when the jumper wire is
removed, the circuit has an open spot.
A circuit without any opens or breaks has continuity
and needs no further testing.
The jumper is usually a long wire with alligator clamps.
A version of the jumper has a fuse holder in it with a 10amp fuse. This will prevent damaging the circuit if the
jumper is connected in the wrong way.
The jumper is used to locate opens in a circuit. One end
of the jumper is attached to a voltage source and the other
end is attached to the load in the circuit, i.e., lamps motor.
If the load works, try jumping to circuit points that are
progressively closer to the voltage supply. When the cir
cuit load stops working, the open has been located.
The jumper is also used to test components in the cir
cuit such as connectors, switches, and suspected high
resistance points.
Unpowered Test Lamp

This tool consists of a 12-volt lamp with leads. The ends
of the leads usually have alligator clamps, but various
kinds of probes, terminal spades, and special connectors
also are used.
The 12-volt test lamp continuity tester uses the vehicles
battery to provide voltage to the circuit under test. 12 -volt
testers are manufactured with a variety of tips, to permit
touching them to connectors, bare wires, insulated wires
or even wires within wiring harnesses. To check the tester
before use, briefly touch the clip to one side of the battery
and the probe to the other. 12-volt testers are NOT sensi
tive to polarity in a circuit, and can be connected either
way.
The 12-volt test lamp generally has a sharp probe tip so
it can be inserted into connector terminals or through the
wire insulation for testing. It is important to keep the probe
tip sharp to minimize the damage to wire insulation.
When the test is complete at a particular point, be sure to
tape any holes made in wire insulation.
The unpowered test lamp is used on an open circuit.
One lead of the test lamp is grounded and the other lead
is moved around the circuit to find the open. Depending
on the physical layout of the circuit, sometimes it will be
easier to start at the voltage supply and other times it is
easier to start at the circuit load or ground circuit.
NOTICE: Test lamps are to be used only on circuits

that do not contain solid state devices. If a test lamp
is used in a circuit containing a solid state device,
the current that the test lamp draws is above the
current that the solid state device is able to handle.
Using a test lamp on a solid state device may
destroy the device.
____________
Meters
Three types of meters are generally used for diagnosis.
They are:
1 . The Ammeter.
2. The Ohmmeter.
3. The Voltmeter.
Once one becomes familiar with the test lamp and the
brilliance of the bulb in a normal circuit, high-resistance
circuits can be recognized by the effect they have on the
bulb. As the current drops in a high-resistance circuit, the
bulb in the test lamp will glow less brightly. Although the
12-volt test lamp cannot be used as a foolproof test for
high resistance, a less than normal brilliance of the lamp
is an indication of circuit high resistance. Further testing
will verify the condition and locate the cause.
Powered Test Lamp

This lamp is a pencil shaped unit with a self-contained
battery, a 1.5 volt lamp bulb, a sharp probe and a ground
lead fitted with an alligator clip.
This test lamp is used mainly for testing components
that are disconnected from the vehicle voltage supply. The
powered test lamp is also useful for testing suspected
high resistance points in a circuit such as connectors and
ground circuits that are corroded or loose.
NOTICE: The following instruments: Ammeter,

Voltmeter, and Ohmmeter, each have a particu
lar application for diagnosing electrical circuits.
When using an ammeter or voltmeter, and the
value being tested is unknown, always use the
highest scale first and work downward to a
midscale reading whenever possible. This will
avoid damage to the instrument.
Never use an ohmmeter in a voltage circuit, or
as a substitute for a voltmeter or ammeter as
damage to the instrument will result.
These meters are available in two designs. They are:

1. Analog (Needle-Type).
2. Digital (Electronic Display-Type).
CAUTION: The correct type of meter must be

used when diagnosing circuits containing solid
state devices. Incorrect use of the meters will
result in damage to the solid state devices.
Analog meters may be used for any circuit not
containing a solid state device, while a digital
meter MUST be used to diagnose any circuit
with a solid state device. Circuits which contain
a solid state device, such as the Electronic Con
trol Module, should be tested only with a 10megaohm
or
higher
impedance
digital
multimeter (J 29125 or equivalent).
At normal operating voltage, most circuits have a char

acteristic amount of current flow, referred to as normal
current draw. Current draw is measured in amperes
(amps) with an ammeter. Comparing measured current
draw with the specified current draw rating provides use
ful diagnostic information.
Disconnect the circuit from the voltage source before
connecting the ammeter. The ammeter (Figure 8) must be
placed in series with the circuit being tested. Be sure that
the ammeters positive terminal is connected to the posi
tive (battery) side of the circuit and its negative terminal to
the negative (ground) side of the circuit.
CAUTION: Never connect an ammeter across a
circuit like a voltmeter. The ammeter could be
damaged by the vehicle electrical system.
Excessive current draw is responsible for blowing fuses
and, in some cases, draining the battery. An ammeter wiM
help diagnose these conditions by locating the cause of
the excessive current draw. On the other hand, there are
times when a reduced current draw at a component (a
power window motor for example) causes unsatisfactory
performance of an electrical system.
Ohmmeter (Figures 9 and 11)

Ammeter (Figures 8 and 11)
An ammeter is used to measure current flow (amper
age) in a circuit. Amperes are units of electron flow which
indicate how many electrons are passing through the cir
cuit. Ohms Law indicates that current flow in a circuit is
equal to the circuit voltage divided by total circuit resist
ance.
The ohmmeter is used to read resistance (ohms) or to

check for opens or shorts in a circuit or component. There
are both analog-type and digital-type ohmmeters.
An analog-type meter shows the actual resistance on a
scale by the movement of a needle.
On a digital-type meter, the resistance measured is con
verted inside the meter to a numerical output which is
shown on a display panel.
Ohmeters use a small battery to supply the voltage and
current which flows through the circuit being tested. The
current flows through the circuit, positions the needle on
analog-type meters, or converts to a digital readout on
digital-type meters. This is done in terms of resistance as
shown in Ohms Law - R = E/I.
Although there are several different styles of analog
ohmmeters, all will usually have the following features in
addition to the meter movement:
A range selector switch which permits the selection of
different ranges of resistance.
A set adjust control which allows the meter to be set at
zero for accurate measurements.
Some model ohmmeters also have a built-in feature
that allows the ohmmeter to be used as a self-powered
test lamp.
Digital meters do not have to be zeroed. They have vari

ous ranges just like the analog meters.
terminals, loose connections or other similar problems

reduce the voltage available across the key circuit com
ponents. The current flow is reduced in the circuit and
all of the affected components operate at less than
peak efficiency. A small drop across wires (conductors),
switches, connectors, etc., is normal. (This is due to the
resistance of the conductors but should be less than 10
percent of the total drop.)
Voltmeter (Figures 10 and 11)

The voltmeter (properly observed) will give the techni
cian more information than the ammeter, ohmmeter and
test lamp combined. Its application for diagnosis here is
to measure the electrical pressure (voltage) drop in a
resistance circuit (Figure 10). Voltage drop is a reduction
or using up of the voltage to push electricity through a
resistance. It can be compared to the pressure of water
flowing through a metering valve.
When using a voltmeter:

Be sure to connect the positive lead to the battery side
and the negative lead to the ground side of the compo
nent being checked.
Voltage drop occurs when electricity (current) flows
through a resistance. Make sure the voltage drop being
measured is only through the component being
checked, not through the component and a poor con
nection.
The circuit must be operating (lamp ON or motor run
ning, for example) to measure voltage drop.
CAUTION: Like a self-powered test lamp, the

ohmmeter can only be used on circuits where
voltage has been removed (Figure 9). It is
designed to be operated on its own voltage sup
ply. This voltage supply provides low voltage and
current levels for the meter to make resistance
measurements. The 12-volt electrical system volt
age in the automotive circuits could damage the
meter.
Electrical circuits can be checked for opens using basi
cally the same procedure as previously described for the
self-powered test lamp. The circuit must be separated
from all voltage sources. The ohmmeter is connected
across the two open ends of the circuit to be checked. A
high reading (infinity) is an indication of an open circuit. A
low reading (near zero) is an indication of a continuous cir
cuit.
Checks for short circuits are made in a similar manner
to that used for open circuits, except that the circuit being
checked must be isolated from both voltage and normal
ground.
Connecting the ohmmeter between an isolated circuit
and a good ground point will allow checking the circuit for
shorts to ground.
A short to ground in the circuit will be indicated on the
meter by a near zero reading. A good circuit (no short to
ground) will show up as infinity (very high resistance) indi
cated on the meter.
To measure the resistance of a component or a circuit,
the component or circuit must be isolated from all other
components (or circuits). The ohmmeter leads are then
placed across the component or circuit and the resistance
is read on the ohmmeter.
The instrument panel voltmeter (in the vehicle) should

also be observed for monitoring proper operation of the
generator, battery, cranking motor, and cranking circuit. In
this application, battery voltage drop can be monitored
while the engine is cranking; and after the engine is run
ning, generator output voltage can be monitored. This can
be a valuable first step before diagnosing other electrical
problems.
CIRCUIT WIRING REPAIR PROCEDURES

Maintenance and Repair
Low voltage to a lamp will make the lamp glow dimly.

This can be caused by low source voltage (battery dis
charge or low alternator output), or by high resistance in
the circuit due to a poor connection. Before making any
meter measurements, it is important to review the relation
ship between current, voltage and resistance (Ohms
Law).
All electrical connections must be kept clean and tight.

Loose or corroded connections may cause a discharged
battery, difficult starting, dim lamps, and possible damage
to the generator and regulator. Wires must be replaced if
insulation becomes burned, cracked, or deteriorated.
Always use rosin flux solder to splice a wire or repair
one that is frayed or broken and use insulating tape to
cover all splices or bare wires.
Being able to determine voltage drop is important

because it provides the following information:
Too high of a voltage drop indicates excessive resist
ance. If, for instance, a blower motor runs too slowly or
a lamp glows too dimly, one can be sure there is exces
sive resistance in the circuit. By taking voltage drop
readings in various parts of the circuit, the problem
(corroded terminals) for example can be isolated.
When replacing wire, it is important that the correct size

wire be used as shown on applicable wiring diagrams or
parts book. Each harness or wire must be held securely in
place to prevent chafing or damage to the insulation due
to vibration.
Wire size in a circuit is determined by the amount of
current, the length of the circuit and the voltage drop
allowed. Wire size is specified using the metric gage. The
metric gage describes the wire size directly in cross sec
tion area measured in square millimeters.
Too low of a voltage drop, likewise, indicates low resist

ance. If, for instance, a blower motor runs too fast, the
problem could be isolated to a low resistance in a resis
tor pack by taking voltage drop readings.
Maximum allowable voltage drop under a load is criti
cal, especially if there is more than one high resistance
problem in a circuit. It is important because like all
resistances, all voltage drops are cumulative. Corroded
Figure 11 Meter Scales
Wiring Connector Terminal Replacement

(Blade-Type)
CAUTION: Never replace a wire with one of a

smaller size or replace a fusible link with a wire
of a larger size.
Remove or Disconnect (Figure 14)

1. Terminal lock tang.
WIRE SIZE CONVERSION TABLE

METRIC
SIZE
(mm)"
AWG
SIZE
0.22
0.35
0.5
0.8
1.0
2.0
3.0
5.0
8.0
13.0
19.0
32.0
40.0
50.0
62.0
24
22
20
18
16
14
12
10
8
6
4
2
1
0
00
2. Terminal (61).
+ 4-
Install or Connect (Figure 15)
1. Pry up on the tang (70).

2. Terminal into the connector.
Wire Repair
The wire repair is very important for the continued reli
able operation of the vehicle. This repair must be done as
described in the following procedures.
Figure 14 Removing the Terminals from
Twisted Wires/Shielded Cable (Figure 13)
the Connector
Remove or Disconnect
Twisted Wires (Figure 12)

Remove or Disconnect
1. Jacket (90).
1. Jacket (100).
107
2. Unwrap aluminum/myiar tape (101).

3. Drain wire (102).
4. Leads.
2. Twisted wires (91).

3. Insulation from the wire.
5. Insulation on the leads.

+-
Install or Connect
Install or Connect
1. Splice clip (92).
2. Crimp and solder the splice clips (93).
3. Electrical tape wrap (94) on the splices.
4. Outer jacket electrical tape wrap (95).
1. Splice clips (103).

2. Crimp and solder the splice clips (104).
3. Electrical tape wrap (105) on the splices.
100.
101.
102.
103.
104.
105.
106.
Jacket
A lum inum /M ylar Tape
Drain Wire
Splice Clip
Crim p and Solder
Electrical Tape Wrap
Drain Wire Splice Clip, Crimped And
Soldered.
107. O uter Electrical Tape Wrap
4. Aluminum/mylar tape by wrapping and taping.

5. Drain wire with a splice clip (106). Crimp and solder the
splice clip.
6. Outer jacket electrical tape wrap (107).
B-06231
Figure 13 Twisted/Shielded Wire Repair
Figure 15 Resetting the Lock Tang
Wiring Connector Terminal Replacement

(Twin Lock-Type)
Tool Required:
J 22727 Terminal Remover
1. Connector lock tangs (81).
2. Terminal locks using J 22727 (82).
3. Terminal (80).
Install or Connect
1. Pry out the tangs.
2. Terminal (80) into the connector (81).
Molded-on connectors require complete replacement of

the connection. This means splicing a new connector
assembly into the harness. Environmental connections
cannot be replaced with standard connections. Instruc
tions are provided with the Weather-Pack connector and
terminal packages.
With the low current and voltage levels found in some
circuits, it is important that the best possible bond at all
wire splices be made by soldering the splices.
Use care when probing the connections or replacing
terminals in them. It is possible to short between two ter
minals. If this happens, it is possible that damage may be
done to certain components. Always use jumper wires
between connectors for circuit checking. Never probe
through the Weather-Pack seals.
When diagnosing for possible open circuits, it is often
difficult to locate them by sight because oxidation or ter
minal misalignment is hidden by the connectors. Merely
wiggling a connector on a sensor or in the wiring harness
may pinpoint the open circuit condition. This should
always be considered when an open circuit is indicated
while diagnosing. Intermittent problems may also be
caused by oxidized or loose connections.
METRI-PACK CONNECTORS
The Metri-Pack connectors use a pull-to-seat type ter
minal, as shown in Figure 17. The special tool required to
remove the terminal is J 35689-A terminal remover. If
removal is attempted with an ordinary pick, there is a
good chance that the terminal will be bent or deformed.
Refer to Figure 17.
Weather-Pack Connector Replacement

+-

1. Terminal insulator (134) on the wire. Slide the insulator
back on the wire about 8 cm (3 inches).
2. Terminal (131) on the wire.
Roll crimp (132) and solder the terminal.
3. Terminal insulator (134) and the roll crimp (133).
4. Terminal into the connector.
5. Secondary lock (125).
6. Connector sections until the primary lock (121)

engages.
Metri-Pack Connector Replacement

-4-
Tool Required:
J 35689-A Terminal Remover
1. Primary lock (121) by lifting.
2. Connector body (137).
3. Connector seal (120) by pulling the seal back onto the
wires away from the connector body (137).
4. Terminal (136) by inserting J 35689-A (139) into the
connector body (137) to depress the locking tang (138),
then push the wire and terminal through the connector
body (Figure 17).
Snip off the old terminal unless the terminal is to
be reused, reshape the locking tang.
5. 5 mm (0.2 inch) of the wire insulation (130).

Tool Required:
J 28742-A Terminal Remover (Figure 18)
1. Primary lock (121) by lifting.

2. Connector sections.
WEATHER-PACK CONNECTORS
Special connectors known as Weather-Pack connec
tors (Figure 17) require a special tool J 28742-A (Figure
18) for servicing. This special tool is required to remove
the pin and sleeve terminals. If removal is attempted with
an ordinary pick, there is a good chance that the terminal
will be bent or deformed. Unlike standard blade-type ter
minals, these terminals cannot be straightened once they
are bent.
Make sure that the connectors are properly seated and
all of the sealing rings ( 120) are in place when connecting
the leads. The hinge-type flap (123) provides a back-up, or
secondary locking feature for terminals. They are used to
improve the connector reliability by retaining the terminals
if the small terminal lock tangs (138) are not positioned
properly.
Clean
Terminal cavity of the connector body.
+ 4-
3. Secondary lock (125) by spreading the sides of the

hasp, thus clearing the staples and rotating the hasp
(127).
1. Terminal (136) on the wire.

Crimp and solder the terminal.
4. Terminal (136) by using J 287842-A (128, 139).

Snip off the old terminal assembly.
2. Terminal (136) into the connector cavity by pulling the

wire on the seal side of the connector until the locking
tang (138) is fully seated.
5. 5 mm of the wire insulation (130).
Clean
Terminal Barrel (124).
3. Seal (120) by pressing the seal into the connector body

(137) until it is fully seated.
4. Connector sections until the primary lock (121)
engages.
J 22727
1. Weather-Pack II Terminal Remover

2. Electrical Terminal Remover
3. Signal Generator and Instrument Panel Tester
F-02438
Figure 18 Special Tools
133
138
VIEW B
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
Connector Seal
Primary Lock
Secondary Lock Staple
Secondary Lock
Terminal Barrel
Secondary Lock
Lock Opened
Lock Opened
Wire
130.
131.
132.
133.
134.
136.
137.
138.
139.
5 mm (0.2 inch)
Terminal
Roll Crimp
Roll Crimp
Terminal Insulator
Metri-Pack Series 150 Female Terminal
Connector Body
Locking Tang
F -02349
Figure 17 Weather-Pack and Metri-Pack Connectors
REGULAR PRODUCTION OPTION (RPO) LIST

AU3
A31
B3D
C36
C60
C65
C69
C7P
D48
E63
K34
K68
LB4
LH6
LL4
L05
L19
M20
MD 8
MT1
MT 8
MY 6
NA1
NA4
R05
TP2
TR9
TVR
T61
UJ1
UM 6
UM7
UY1
UY7
U89
V22
Power Side Door Locks
Power Side Windows

School Bus Equipment
Auxiliary Heater
Air Conditioning
Auxiliary Air Conditioning
Roof Mounted Air Conditioner
16.000LB GVW Rating
Electric Remote Control Outside Mirror
Fleetside Body
Cruise Control
Generator-105 AMP
Engine, 4.3L (262 CID) V 6 Gasoline
Engine, VIN Z
Engine, 6.2L (378 CID) V 8 Diesel Engine, VIN C
Engine, 6.2L (378 CID) V 8 HD Diesel Engine,
VIN J
Engine, VIN K
Engine, VIN N
Man Trans, 4-Spd.

Auto Trans, 4-Spd., With Overdrive
Auto Tans, 5 Spd., With Overdrive
Man Trans, 5-Spd.. With Overdrive
Man Trans, 4-Spd.

- Emission System, Less Than 8500 GVW
Emission System, Above 8500 GVW

Dual Rear Wheels
Auxiliary Battery
Auxiliary Lighting Package
Rear Dome and Reading Lamp
Canadian Daytime Running Lamps
Brake Warning Indicator System
Radio, ETR AM/FM Stereo, Cassette
Radio, ETR AM/FM Stereo, W/O Cassette

Wiring Harness, Camper
Truck Trailer Wiring Harness, HD
Trailer Wiring Harness
Quad Halogen Headlamps
ABBREVIATION LIST
The following is a list of abbreviations used in the
wiring diagrams. The abbreviations have been developed
in such a way that their meaning should be clear.
10
Use this page as a reference to determine the

meaning of an abbreviation if necessary.
A -- Ampere
A/C -- Air Conditioner
AC -- Alternating Current
ACC -- Accessory
AIR -- Air Injection Reaction
AIR/COND - Air Conditioner
ALDL -- Assembly Line Diagnostic Link
ALT - Alternator
AMP -- Ampere
ANTI - Anticipate
ASM -- Assembly
ASSY - Assembly
AUD -- Audio
AUTO -- Automatic
AUX -- Auxiliary
BAT -- Battery
BATT -- Battery
BI-LEV - Bi-Level
BLK - Black
BLT - Belt
BLU -- Blue
BOT - Bottom
BRK - Brake
BRN - Brown
BU - Backup
BUZZ - Buzzer
CID -- Cubic Inch Displacement
CIR/BRK - Circuit Breaker
CIRC -- Circuit
CLSTR - Cluster
CNTRL -- Control
COMP -- Compartment
COMP -- Compressor
CONN -- Connector
CONV -- Convenience
CTSY - Courtesy
CYL - Cylinder
DC -- Direct Current
DEF - Defrost
DK - Dark
DIAG - Diagnostic
DIM -- Dimmer
DIR -- Directional
RPO CODES AND ABBREVIATION LIST
DISC - Discrete
DIST - Distributor
DIV - Diverter
DM - Dome
DR -- Door
DRAC - Digital Ratio Adapter Controller
DRL - Daytime Running Lamps
ECM - Electronic Control Module
EFE - Early Fuel Evaporation
EGR - Exhaust Gas Recirculation
ELEC -- Electric
ENG - Engine
EPR - Exhaust Pressure Regulator
ESC -- Electronic Spark Control
EST - Electronic Spark Timing
ETR - Electronically Tuned Radio
EVRV - Electronic Vacuum Regulator Valve
EXC - Except
LO - Low
LP - Lamp
LPS -- Lamps
LT - Light
LTR - Lighter
M - Motor
MAN - Manual
MAP - Manifold Absolute Pressure
MAX - Maximum
MED - Medium
MRKR - Marker
MULT - Multiple
NAT - Natural
NEU - Neutral
NO - Normally Open
NC - Normally Closed
ORN - Orange
F-PUMP - Fuel Pump

FLASH - Flasher
FRT - Front
4WD - Four-Wheel Drive
GEN
GRA
GRD
GRN
- Generator
- Gray
-- Ground
-- Green
HAND -- Handling
HZ - Hazard
HD -- Heavy Duty
HD LP -- Headlamp
HEI - High Energy Ignition
HI - High
HTR -- Heater
IAC - Idle Air Control
IGN - Ignition
ILLUM - Illumination
l/P -- Instrument Panel
INC - Increased
IND - Indicator
INJ -- Injector
INST - Instrument
INTER -- Interior
LD - Light Duty
LH - Left Hand
PK - Park
PLR - Puller
PNK - Pink
PNL -- Panel
PPL - Purple
PRESS - Pressure
PWR - Power
RCVR - Receiver
REF -- Reference
RESIST - Resistance
RH - Right Hand
RPO - Regular Production Option
RST - Rust
RWAL - Real Wheel Antilock
SEN - Sensor
SEND - Sender
SIG -- Signal
SIL - Silver
SKT - Socket
SOL - Solenoid
SPEEDO -- Speedometer
STR - Stripe
SW - Switch
TACH - Tachometer
TBI - Throttle Body Injection
TCC -- Torque Converter Clutch
TEMP -- Temperature
TP -- Throttle Position
T/L -- Tail Lamp
TRANS -- Transmission
TYP -- Typical
V - Volt
VAC -- Vacuum
VLV - Valve
VSS -- Vehicle Speed Sensor
W/ -- With
W/O -- Without
W/S -- Windshield
W WASHER -- Window Washer
WDO -- Window
WHT - White
WGR -- Wiring
YEL -- Yellow
RPO CODES AND ABBREVIATION LIST
11
SECTION A
R/V MODELS
SECTION A A-1
LIGHTED
VANITY MIRROR
(SEE PAGE 119)
ECM/PCM/TCM
(SEE PAGES 59, 68, 72)
RH TAIL,
STOP AND TURN
LAMPS
(SEE PAGE 150)
&
BLOWER MOTOR
(SEE PAGE 98)
A-2
PHANTOM VIEW
ROOF MARKER
LAMPS
(SEE PAGE 40)
REAR A/C
BLOWER
(SEE PAGE 95)
DOME LAMPS
(SEE PAGE 119)
RADIO
(SEE PAGE 144)
COURTESY
LAMP
(SEE PAGE 119)
BATTERY
(SEE PAGES 10, 12)
RH HEADLAMP
(SEE PAGES 25, 26, 32)
LH REAR TAIL
STOP AND TURN LAMPS
(SEE PAGE 150)
POWER DOOR
LOCK ACTUATOR
(SEE PAGES 131, 132, 134)
AUXILIARY
HEATER BLOWER
(SEE PAGE 99)
RH TURN
LAMP
(SEE PAGES 44, 46)
WINDSHIELD
WASHER MOTOR
(SEE PAGE 52)
HORNS
(SEE PAGE 49)
LH HEADLAMP
(SEE PAGES 25, 26, 32)
LH TURN
LAMP
(SEE PAGES 44, 46)
LH SIDE
MARKER LAMP
(SEE PAGE 35)
PHANTOM VIEW A-3
LIGHTED
VANITY MIRROR
(SEE PAGE 119)
ECM/PCM/TCM
(SEE PAGES 59, 68, 72)
RH REAR TAIL,
STOP AND TURN LAMP
(SEE PAGE 150)
POWER DOOR
LOCK ACTUATOR
(SEE PAGE 130)
POWER WINDOW
MOTOR
(SEE PAGE 139)
A-4 PHANTOM VIEW
BLOWER
MOTOR
(SEE PAGE 98)
DOME LAMP
(SEE PAGE 119)
RADIO
(SEE PAGE 144)
COURTESY
LAMP
(SEE PAGE 119)
BATTERY
(SEE PAGES 10, 12)
RH HEADLAMP
(SEE PAGES 25, 26, 32)
LH REAR TAIL
STOP AND TURN LAMPS
(SEE PAGE 150)
POWER DOOR
LOCK ACTUATOR
(SEE PAGES 131, 132, 134)
RH TURN
LAMP
(SEE PAGES 44, 46)
HORNS
(SEE PAGE 49)
LH HEADLAMP
(SEE PAGES 25, 26, 32)
LT TURN
LAMP
(SEE PAGES 44, 46)
LH SIDE
MARKER LAMP
(SEE PAGE 35)
PHANTOM VIEW A-5
LIGHTED
VANITY MIRROR
(SEE PAGE 119)
ECM/PCM/TCM
(SEE PAGES 59, 68,
RH REAR TAIL,
STOP AND TURN LAMPS
(SEE PAGE 151)
-6 PHANTOM VIEW
RADIO
(SEE PAGE 14)
ROOF MARKER
LAMPS
(SEE PAGE 40)
DOME LAMP
(SEE PAGE 119)
CARGO LAMP
(SEE PAGE 120)
FUEL TANK
SENDING UNIT
(SEE PAGES 77, 78, 79, 87, 88)
COURTESY LAMP
(SEE PAGE 119)
BATTERY
(SEE PAGES 10, 12)
RH HEADLAMP
(SEE PAGES 25, 26, 32)
LH REAR TAIL,
STOP AND TURN LAMPS
(SEE PAGE 151)
RH TURN
LAMP
(SEE PAGES 44, 46)
POWER MIRROR
WINDOW AND DOOR
LOCK SWITCHES
(SEE PAGES 129, 139)
HORNS
(SEE PAGE 49)
LH HEADLAMP
(SEE PAGES 25, 26, 32)
LH TURN
LAMP
(SEE PAGE 44, 46)
LH SIDE
MARKER LAMP
(SEE PAGE 35)
WINDSHIELD
WIPER MOTOR
(SEE PAGE 52)
PHANTOM VIEW A-7
SYMPTOMS INDEX
SYMPTOM
PAGE
AIR CONDITIONING
A/C compressor does not engage ...................................................................................................................... a -91
Blower motor does not operate in any m o d e ......................................................................................................A-92
Blower motor does not operate in H I .................................................................................................................... A-92
Blower motor does not operate in M E D ............................................................................................................... A-92
Blower motor does not operate in L O ......................................................................... ....................................... A-92
AIR CONDITIONING,
Blower motor does
Blower motor does
Blower motor does
REAR
not operate at all ..................................................................................................................A-93
not operate in HI but only in LO ........................................................................................A-93
not operate in LO but only in HI ....................................................................................... ..A-93
AUDIO ALARMS
Key-in warning alarm does not o p erate............................................................................................................... A-111
The safety belt warning buzzer does not operate ............................................................................................ A-111
The safety belt warning buzzer operates when safety belt is buckled........................................................... A-111
Lamps-on warning alarm does not o p e ra te ........................................................................................................A-111
AUXILIARY COOLING FAN
Cooling fan does not run .......................................................................................................................................A-89
Cooling fan runs continuously............................................................................................................................... A-89
BRAKE SYSTEMS
Brake indicator remains on with ignition switch in run and park brake o ff.................................................... A-114
Brake indicator does not light during a warning condition or during the antilock system check ............A-114
CRUISE CONTROL
Cruise control does not disengage when clutch or brake pedal is depressed .......................................... A-122
Cruise control does not o p e ra te .......................................................................................................................... A-122
DIESEL ENGINE FUEL CONTROL
Fuel heater does not o p e ra te ............................................................................................................................... A-86
Service fuel filter indicator lights with no water in fuel .....................................................................................A-86
Sen/ice fuel filter indicator does not light briefly with ignition switch turned to run ................................... A-86
TURN SIGNAL LAMPS
Turn signals do not work on one s id e .................................................................................................................A-42
Turn signals do not operate ................................................................................................................................. A-43
Turn signal lamps flash ra p id ly ............................................................................................................................ A-43
FRONT PARK, MARKER, ROOF AND HAZARD LAMPS
Front park and side marker lamps do not operate............................................................................................A-33
Roof marker lamps do not o p e ra te ..................................................................................................................... A-33
Hazard warning lamps do ont operate .............................................................................................................. A-33
FOUR-WHEEL DRIVE INDICATOR LAMPS
Four-wheel drive indicator lamp will not turn o ff................................................................................................ A-125
Four-wheel drive engages but 4WD indicator lamp does not light (V100, V 2 0 0 ) ........................................ A-125
Four-wheel drive engages but 4WD indicator lamp does not light (V 3 0 0 )....................................................A-125
A-8 SYMPTOM INDEX
HEADLAMPS
Headlamps do not illuminate high or low beams -- both s id e s ......................................................................a -23
Low beam lamp(s) do not operate .....................................................................................................................a -23
High beam lamps(s) do not o p e ra te .................................................................................................................. a -24
Daytime running lamps do not operate (Canada o n ly ).................................................................................... a -24
Daytime running lamps stay on (Canada only) ............................................................................................... a -24
HEATER, FRONT
Blower motor does not operate at all ................................................................................................................ a -96
Blower motor does not operate in HI but only in LO and/or M E D ................................................................. a -96
Blower motor does not operate in LO and/or MED but only in H I ................................................................. a -96
HEATER, AUXILIARY
Auxiliary heater blower motor does not operate at all ....................................................................................a -96
Auxiliary heater blower motor does not operate in L O .................................................................................... a -96
HORNS
Horn(s) will not operate ....................................................................................................................................... a -48
Horn sounds continuously without depressing horn switch .......................................................................... a -48
Cigarette lighter does not operate....................................................................................................................... a -48
INSTRUMENT PANEL: GAGES AND INDICATORS
Fuel gage indicates full or beyond at all tim es..................................................................................................A-100
Fuel gage indicates empty when there is fuel in the ta n k ............................................................................... A-100
Fuel gage is inaccurate ....................................................................................................................................... A-100
Temperature gage indicates hot with engine coolant below operating temperature
and ignition switch in R U N ................................................................................................................................ A-101
Temperature gage indicates cold all the time .................................................................................................. a -101
Temperature gage is not accurate .....................................................................................................................A-101
Oil pressure gage indicates low pressure when oil pressure is g o o d .......................................................... A-101
Oil pressure gage indicates high pressure at all tim es....................................................................................A-101
Oil pressure gage is not accurate....................................................................................................................... A-101
Voltmeter is not accurate ..................................................................................................................................... A-101
Speedometer is inoperative or inaccurate......................................................................................................... A-102
Low coolant indicator does not light with coolant level low (diesel only)......................................................A-102
Low coolant indicator is lit when coolant level is g o o d ....................................................................................A-102
COURTESY LAMPS,CARGO LAMPS AND UNDERHOOD LAMP
Courtesy lamps do not operate............................................................................................................................A-118
Dome lamp does not work or stays on all the time .........................................................................................A-118
Cargo lamp does not w o r k ...................................................................................................................................A-118
l/P compartment box lamp does not w o rk ......................................................................................................... A-118
UnderhOod lamp does not w o rk ......................................................................................................................... A-118
POWER DOOR LOCKS (WITH SWING OUT SIDE DOOR)
None of the door lock motors lock or u n lo c k .................................................................................................... A-128
One door lock motor does not lock or unlock from a particular switch........................................................ A-128
One door lock motor does not operate from any switch ............................................................................... A-128
No door lock motors lock or unlock from any switches ................................................................................. A-128
POWER WINDOWS
Power windows does not operate or only go in one direction ......................................................................A-136
Power windows only operate from drivers side window switch ................................................................... A-137
Power windows do not operate from drivers side window switch................................................................. A-137
Tailgate window does not operate from tailgate window s w itc h ................................................................... A-137
Tailgate window does not operate from key operated tailgate window switch.............................................A-138
GLOW PLUGS
Wait indicator does not flash or flashes for the incorrect amount of time when engine is below
normal operating tem perature............................................................................................................................ A-82
Wait indicator stays on or flashes when engine is at normal operating temperature and ignition
switch in run position (6.2L diesel engine) ..................................................................................................... A-83
HEADLAMPS
Headlamps do not illuminate high or low beams - both s id e s .......................................................................A-23
Low beam lamp(s) do not operate ..................................................................................................................... A-23
High beam lamps(s) do not o p e ra te ...................................................................................................................A-24
Daytime running lamps do not operate (Canada o n ly ).....................................................................................A-24
Daytime running lamps stay on (Canada only) ................................................................................................ A-24
HEATER, FRONT
Blower motor does not operate at all ................................................................................................................ A-96
Blower motor does not operate in HI but only in LO and/or M E D ..................................................................A-96
Blower motor does not operate in LO and/or MED but only in H I ..................................................................A-96
HEATER, AUXILIARY
Auxiliary heater blower motor does not operate at all .....................................................................................A-96
Auxiliary heater blower motor does not operate in L O .....................................................................................A-96
HORNS
Horn(s) will not operate ....................................................................................................................................... A-48
Horn sounds continuously without depressing horn switch ........................................................................... A-48
Cigarette lighter does not operate....................................................................................................................... A-48
INSTRUMENT PANEL: GAGES AND INDICATORS
Fuel gage indicates full or beyond at all tim es...................................................................................................A-100
Fuel gage indicates empty when there is fuel in the ta n k ................................................................................A-100
Fuel gage is inaccurate ....................................................................................................................................... A-100
Temperature gage indicates hot with engine coolant below operating temperature
and ignition switch in R U N ................................................................................................................................ A-101
Temperature gage indicates cold all the time ...................................................................................................A-101
Temperature gage is not accurate ..................................................................................................................... A-101
Oil pressure gage indicates low pressure when oil pressure is g o o d ...........................................................A-101
Oil pressure gage indicates high pressure at all tim e s .....................................................................................A-101
Oil pressure gage is not accurate....................................................................................................................... A-101
Voltmeter is not accurate ..................................................................................................................................... A-101
Speedometer is inoperative or inaccurate......................................................................................................... A-102
Low coolant indicator does not light with coolant level low (diesel o n ly )...................................................... A-102
Low coolant indicator is lit when coolant level is g o o d .....................................................................................A-102
COURTESY LAMPS,CARGO LAMPS AND UNDERHOOD LAMP
Courtesy lamps do not operate............................................................................................................................A-118
Dome lamp does not work or stays on all the time ......................................................................................... A-118
Cargo lamp does not w o r k ...................................................................................................................................A-118
l/P compartment box lamp does not w o rk ......................................................................................................... A-118
UnderhOod lamp does not w o rk ......................................................................................................................... A-118
POWER DOOR LOCKS (WITH SWING OUT SIDE DOOR)
None of the door lock motors lock or unlock..................................................................................................... A-128
One door lock motor does not lock or unlock from a particular sw itch........................................................ A-128
One door lock motor does not operate from any switch ................................................................................A-128
No door lock motors lock or unlock from any switches .................................................................................. A-128
POWER WINDOWS
Power windows do not operate or only go in one direction ......................................................................... A-136
Power windows only operate from drivers side window switch .....................................................................A-137
Power windows do not operate from drivers side window switch.................................................................. A-137
Tailgate window does not operate from tailgate window s w itc h .....................................................................A-137
Tailgate window does not operate from key operated tailgate window switch............................................. A-138
POWER MIRRORS
Neither mirror is operational ..................................................................................................................................A-127
LH mirror will not adjust UP and DOWN .............................................................................................................A-127
LH mirror will not adjust LEFT and R IG H T .......................................................................................................... A-127
RH mirror will not adjust UP and DOWN .............................................................................................................A-128
RH mirror will not adjust LEFT and R IG H T.......................................................................................................... A-128
SYM PTOM
PAGE
AM RADIO
Radio does not appear to work (no display lights, no sound) .......................................................................A-143
Clock does not operate .........................................................................................................................................A-143
Panel lamp does not come on .............................................................................................................................A-143
Display dimming function will not o p e ra te .......................................................................................................... A-143
No sound or distorted sound from a speaker ................................................................................................... A-143
REAR DEFOGGER
Rear window defogger does not work and on indicator does not lig h t........................................................ A-146
On indicator works but rear window defogger does not defrost.................................................................... A-146
Rear defogger panel lamp does not w o r k ..........................................................................................................A-146
REAR EXTERIOR LAMPS
Backup lamps do not operate............................................................................................................................... A-149
Rear park, marker and license lamps do not operate .....................................................................................A-149
START AND CHARGE
Engine does not crank and starter solenoid does not click ........................................................................... A-53
Starter solenoid clicks, engine does not crank or cranks slowly.................................................................... A-54
Battery is undercharged or overcharged...................................................................... - .................................. A-54
VACUUM SYSTEMS
Little or no heat from auxiliary heater .................................................................................................................A-161
Improper air distribution from outlets................................................................................................................... A-161
Cruise control does not o p e ra te .......................................................................................................................... A-161
WINDSHIELD WIPERS AND WASHERS (PULSE)
Wipers do not operate in any mode ................................................................................................................... A-50
Wipers do not operate in HI ................................................................................................................................. A-50
Wipers do not operate in LO or d e la y ................................................................................................................ A-50
Washer motor does not o p e ra te ..........................................................................................................................A-51
Washer motor does not shut o f f .......................................................................................................................... A-51
SYMPTOM INDEX A-9
RPO CODES
- AIR CONDITIONING
ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
GENERATOR-105 AMP
- AUTO TRANS, 4-SPD., WITH OVERDRIVE
- MAN TRANS, 4-SPD
- AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
AUXILIARY BATTERY
- WIRING HARNESS, CAMPER
TRUCK TRAILER WIRING HARNESS, HD
1-32.0 BLK I
I I 150*8.0 BLK I
dcm
o 55
CO p
AUXILIARY
BATTERY
.2-1.0 R S T ---"(FUSIBLE LIN K)1
AUXILIARY
COOLING FAN
RELAY
(L19 AND C60)
S105
(SEE PAGE 90)
AUXILIARY BATTERY
JUNCTION
BLOCK
hi
CC
BATTERY
JUNCTION
BLOCK
(TP2)
S118
I 2-8.0 RED I
CM
g
3
IN-LINE FUSE
30 AMP
1 ^ 1 ^ - 1 2 - 5 . 0 RED
S103 I J
I
I
CC CO
I mm
I-Hi
O(/>
2-5.0 RED
CO - I
CC Q
fUJ
(O -I
CC CD
CM
A/C
TRANSMISSION
CONNECTOR
(SEE PAGE S
C172
CO
C3P
12084690
CAMPER AND TRAILER
WIRING (SEE PAGE 160)
0 H i 2-8.0 RED
S104
AUXILIARY
BATTERY
RELAY
C106
12045896
(TP2)
I ________
GENERATOR
I 6-3.0 PPL I
1-32.0 BLK
STARTER MOTOR
A-10 POWER DISTRIBUTION

GASOLINE ENGINE
SHEET
METAL
GROUND
G111
ENGINE
GROUND
G112
SHEET
METAL
GROUND
G109
vj
T++1++
--------- H
k\
'-------
--------- fcH
>h
|t
J
<
Hi
m
T t
..
-------' H I D
RPO CODES
LH6 ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE, VIN J
M20 * MAN TRANS, 4-SPD
MT1 - AUTO TRANS, HD, 4-SPD. WITH OVERDRIVE
UY7 - TRUCK TRAILER WIRING HARNESS, HD
COLD ADVANCE
TIMER RELAY
(LH6 ONLY)
(SEE PAGE 64)
\
1-32.0 BLK I
--------1-------- I1
3.0 B L K ^ H " M M K
|
1-32.0 BLK M H H
COLD
ADVANCE FAST
IDLE TEMPERATURE
SWITCH
(SEE PAGE 87)
FUEL HEATER
(SEE PAGE 87) '
WATER IN FUEL
SENSOR
(SEE PAGE 87)
RH
BATTERY
1 39-.8 PNK/BLK I
I 39-.8 PNK/BLK I
3S-.8 PNK/BLK r
I 39-.S PNK/BLK I
1 39-.S PNK/BLK I
l 39-.8 PNK/BLK I
EGR DUMP
(LH6 o n ly )
(SEE PAGE 64)
i mmm
EPR SOLENOID
(LH6 ONLY)
(SEE PAGE 64)
EGR SOLENOID
PULSE WITH MODULATION
(LH6 ONLY)
(SEE PAGE 64)
FUEL SHUTOFF
SOLENOID
(SEE PAGES 87, 88)
S109
GENERATOR
C
n^ M 1
> r ---- i
/ !I1 T \11t
>
-n--- I
9 0 6 -.5 G R A ^ B B
(FUSIBLE LINK)
0106
12045896
Hi
-m
-m
5-
ENGINE
m
2-3.0 RED I
STARTER MOTOR
I 2-3.0 RED I
I 2-1.0 RST I
(FUSIBLE LINK)
I 6-3.0 PPL I
BATTERY
JUNCTION
BLOCK
13-3.0 P N K * i
(LL4 ONLY)
sios
/
12-1.0 RST1
(FUSIBLE LINK)
i 906-1.0 PPL E
I 2-3.0 RED I
S106
12-8.0 BLK/REDI
LEFT BANK
GLOW PLUGS
GROUND
G113
& 1
RIGHT BANK
GLOW PLUGS
GROUND
G114
SHEET
METAL
GROUND
G111
A-12 POWER DISTRIBUTION

D1ESEJLEN G IN E3_
C119
A/C
i 2-5.0 R E D i
1906-1.0 PPL
S121 (LH6 ONLY)
S130 (LL4 ONLY)
(SEE PAGE 94)
531-.8 LT GRN/BLK (LH6 ONLY)

12-5.0 DK BLU/WHT I
IN-LINE FUSE
30 AMP
.* 5 3 1 - .8 LT G RN/BLKI
I 531-.8 LT GRN/BLK
COLD ADVANCE
CONTROL (LH6 ONLY)
(SEE PAGE 64)
13-3.0 PNK *
FUEL SOLENOID
(LL4 ONLY)
(SEE PAGES 87, 88)
3*3.0 PNK (LL4 ONLY)
TRAILER WIRING
(SEE PAGE 160)
GLOW PLUG
CONTROLLER
C168
12015982
COLD ADVANCE
TIMER REL/Y
(LH6 ONLY)
(SEE PAGE)
COWL
RPO CODES
LH6 - ENGINE, 6.2L <378 CID) VS DIESEL ENGINE, VIN C
MD8 - AUTO TRANS, 4-SPD., WITH OVERDRIVE
POWER CIRCUIT 76
30-A M P CIRCUIT BREAKER
AUTO TRANS/CONV CLUTCH

M D 8 DIESEL ONLY
TAIL GATE POWER WINDOW

POWER WINDOW S
NOTE: L U ENGINES DO NOT USE THE CRANK, ECM I OR ECM B FUSES.

LH6 ENGINES DO NOT USE THE CRANK FUSE
NOTE: DRL ARE ONLY ON VEHICLES FOR SALE IN CANADA WITH T61.
AUXILIARY BATTERY
FOUR WHEEL DRIVE ILL LP
PANEL LAMPS
REAR DEFOGGER
REAR DEFOGGER LAMP
CRUISE CONTROL
FOUR-WHEEL DRIVE IND. LP
DIESEL AUXILIARY FUEL

TANK SELECTOR SWITCH
POWER CIRCUIT 6 0
30-A M P CIRCUIT BREAKER
REAR HEATER
TAIL GATE-POWER W INDOW
CLOCK
REAR A/C
REAR DEFOGGER
2 5 0 -3 .0 B R N -A U X HEATER A/C
DOME & -CARGO LAMP
POWER LOCKS
43-1.0 YEL - RADIO

250-3.0 BRN AUX HEATER A/C
7 6 -3 .0 PNK IGN PWR W D O -
8 .5 GRA INSTRUMENT LPS

2 4 0 -1 .0 O R N -B A T T FUSED HORN/DM
4 4 -1 .0 DK GRN LT SW RHEOSTAT
1 2 0 4 1 2 3 5 SHUNT
2 5 0 -3 .0 B R N -A U X HEATER A/C
T U R N B /U
PW RW DO
W IPE R
GiO K ]
ECM i
2 3 .0 R ED -B ATTER Y
1 4 0 . 8 O R N -H A Z A R D FLASHER
3 0 0 -3 .0 ORN IGNITION
4 3 -1 .0 Y E L -R A D IO
4 3 -.5 YELRADIO
DR L
D3 0 0
D)
CRANK
------------------
\
/
v ___ /
3 -3 .0 P N K -IG N SW ENG-IGN
39-.8 PNK/BLK - IGN - ON AND CRANK - FUSED
4 0 .8 ORN TAIL LPS/CTSY LPS/PARK LPS
5 0 -2 .0 B RN -HEA TER A/C
2 -3 .0 R E D -IG N S W -B A T T
440 .8 ORN - ECM B
3 8 .8 DK B L U -D IR SIG FLASHER---------
4 3 .0 BRN IGNITION S W -A C C
9 3 - 8 W H T - W /S WASHER
9 3 .8 W H T - W /S WASHER
7 5 - 8 DK B LU -BACKUP LP SW
4 3 9 .8 PNK/BLK-ECM-FUSED
16 .8 PPL DIRECT SIG SW
FRONT
1 2 0 3 4 3 5 9 BLOCK MOLD
1 2 0 5 9 4 5 2 PRINTED BLOCK
CAUTION: Determine If non-cycling circuit

breakers are hot before removing them.
Hot non-cycling circuit breakers can cause
personal injury.
A
B
C
D
E
W
F
A-14 FUSE BLOCK
COLOR
MALE CONN
NAT
BRN
BLK
GRN
RED
BLU
DK GRA
12004888
12004887
12004886
12004885
12004883
12004884
12004740
3 -3 .0 PNK IGN 1
38 .8 DK BLU DIRECT SIG FUSE

340-.8 ORN DRL
2-3.0 RED - BATTERY
6 3 .0 PPL-STARTER SOLENOID FEED

8 0 6 .8 PPL/WHTECM CRANK FUSED
7 6 -3 .0 P N K -IG N PWR W D O ----------------
REAR
LAMP BULB DATA

AC Type Guide Lamps are recommended when replacement becomes necessary.
Lamp Usage
FUSE AND CIRCUIT BREAKER IDENTIFICATION
6025
H6054
(Opt.)
66/65
35/65
(4) Headlamp System - Lo

- HI
2
2
2
H4703
H4701
55
65
H4651
(Opt.)
50
Dome Lamps
211-2
12
Instrument Cluster Lamps
168
1
2
1
4**
168
2057
2-32
67
3057NA
1.5-24
Turn Signal Indicator Lamp
168
Park Lamps (W/4 Headlamps)
194NA
1.5
194
Rear Side Marker Lamps
2
2
2
168
Roof Marker Lamps
194
Brake Warning Indicator
Cargo Lamp*
1
2
1
1
RADIO
AUXILIARY BATTERY RELAY
FOUR-WHEEL DRIVE INDICATOR
LAMP
AUTOMATIC TRANSMISSION
CONVERTER CLUTCH (MD8 ONLY)
Fender Clearance Lamp*

Rear Identification*
Radio Dial Lamp
Four-Wheel Drive Indicator
COLOR
AND
AMPERE
HOT
CONDITION
AUX HTR A/C
12004010
WHITE
25 AMP
HOT IN
RUN
AUXILIARY HEATER AND AIR

CONDITIONING
CRANK
12004003
VIOLET
3 AMP
HOT IN
START
ECM
CRANK CIRCUIT
DRL
12004008
LTBLU
15 AMP
HOT AT
ALL TIMES
RED
10 AMP
HOT IN
RUN OR START
ECM B
12004007
RED
10 AMP
HOT AT
ALL TIMES
GAGE/IDLE
12004009
YELLOW
20 AMP
HOT IN
RUN OR START
HORN/DM
12004009
YEL
20 AMP
HOT AT
ALL TIMES
HTR A/C
12004010
WHITE
20 AMP
HOT IN
RUN
IGN
12004009
YELLOW
20 AMP
HOT IN
RUN OR START
INST LPS
PWR ACC
PWR WDO
RADIO
12004005
(CIRCUIT
BREAKER)
DRL
ECM 1
ECM
IGNITION
CRANK
HORN
DOME AND CARGO LAMPS
CLOCK
REAR DEFOGGER
CRUISE CONTROL
DIESEL AUXILIARY FUEL TANK
SELECTOR SWITCH
HOT W/LIQHT SWITCH

IN HEAD OR PARK
INSTRUMENT PANEL LAMPS
30 AMP
HOT AT
ALL TIMES
TAIL GATE POWER WINDOW

REAR DEFOGGER
POWER LOCKS
30 AMP
HOT IN
FUN
12004008
LT BLUE
15 AMP
HOT IN
ACC OR RUN
Candle Power
Headlamp Beam Indicator Lamp

Taillamp and Stoplamp1
License Lamp
Turn Signal (Front Park Lamps)1
HEATER AND AIR CONDITIONING
TAN
5 AMP
(CIRCUIT
BREAKER)
POWER WINDOWS
Front Side Marker Lamps
Backup Lamp
Heater or A/C Control
STOP HAZ
12004008
LTBLU
15 AMP
HOT AT
ALL TIMES
HAZARD FLASHER
T/L CTSY
12004009
YELLOW
20 AMP
HOT AT
ALL TIMES
TAILLAMPS
COURTESY LAMPS
PARKING LAMPS
Low Coolant Lamp2
TURN SIGNALS
BACKUP LAMPS
Safety Belt Warning
WINDSHIELD WIPERS
Glow Plugs Indicator2
TURN/BU
12004008
LT BLUE
15 AMP
HOT IN RUN
OR START
WIPER
12004010
WHITE
25 AMP
HOT IN
ACC OR RUN
Power Rating
at 12V, Watts
2
2
FUSE
PART NO.
12004007
Trade
No.
Headlamps (2) Headlamp System

DESCRIPTION
FUSE
LOCATION
ECM 1
Quantity
Courtesy Lamp
Clock
Four-Wheel Drive Shift Lever

Water In Fuel2
SERVICE ENGINE SOON" Lamp
(W/Gasoline Engine)
(W/LH6 Diesel)
Underhood Lamp
Reading Lamp
168
1156
32
194
1142
2
21
168
Part of
Lens
1
1
1
1
1
1
1
1
1
1893
161
2
1
1003
15
194
168
168
194
194
2
2
2
1
1
1
2
194
1893
2
2
19/10
9.9
906
194
2. Diesel only.
* Not used on Suburban and Utility.
** 2 Required with 4 headlamp system.
BULB DATA AND FUSE BLOCK A-15
jn
__
H~
I150-.8 BLK I
AUXILIARY
BATTERY
BATTERY
A/C COMPRESSOR
(L19) (SEE PAGE 94)
ECM/PCM
I 551 -.8 TAN/BLK
3
CD
[ (FLEETSIDE, WIDESIDE, STEPSIDEJ

(SEE PAGE 59)
LH PARK AND
TURN LAMP A/22)
I 150-.8 BLK
(SEE PAGE 35)
LH PARK LAMP (V22)

(SEE PAGE 35)
150-.8 BLK
1150-.8 BLK I
RWAL (W/O C60)

(SEE PAGE 116)
I 1-32.0 BLK I
S113
RH HIGH-LOW
HEADLAMP
151-.8 BLK I
I 150-.8 BLK I
(SEE PAGE 25)
151-.8 BLK I
RWAL (W/C80)
(SEEPAGE 116)
RH PARK AND
TURN LAMP
(SEE PAGE 34)
r
L
150-.8 BLK
LH LOW BEAM
HEADLAMP (V22)
(SEE PAGE 32)
150-.8 BLK
LH HIGH BEAM
HEADLAMP (V22)
(SEE PAGE 32)
RH PARK LAMP
(SEE PAGE 35)
151-.8 BLK
LH PARK AND
TURN LAMP
(SEE PAGE 34)
I 150-.8 BLK
AUXILIARY ENGINE
COOLING FAN
(L19 WITH C60)
151-2.0 BLK
551-.8 TAN/WHTr
ECM/PCM (W/O C60)

(SEE PAGE 68)
(SEE PAGE 90)
S122
LH HIGH-LOW
HEADLAMP
(SEE PAGE 25)
\ 150-.8 BLK
S111
RH HIGH BEAM
HEADLAMP (V22)
151-.8BLK
*- j
tu
(SEE PAGE 32)

RH LOW BEAM
HEADLAMP (V22)
(SEE PAGE 32)
151-.8 BLK
I 150-.8 BLK I
LH PARK LAMP
(SEE PAGE 34)
I 151-3.0 8LK
G107
G106
SHEET
METAL
GROUND
FRAME
GROUND
A-16 GROUND DISTRIBUTION

GASOLINE ENGINE
G109
G112
ENGINE
GROUND
SHEET
METAL
GROUND
/ 1
G105
ENGINE
GROUND
RPO CODES
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN K
L19 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
M20 - MAN TRANS, 4-SPD.
C60 - AIR CONDITIONING
V22 - QUAD HALOGEN HEADLAMPS
C200
ECM/PCM
1413- 8 TAN
DRL MODULE
(SEE PAGE 26)
150-.8 BLK I
(SEE PAGES 59, 68)
(M20 ONLY)
. (M20 ONLY)
450-.8 BLK/WHT |
450- 8 BLK/WHT I
LIGHT SWITCH
150-.8 BLK I
(SEE PAGE 25)

Mmm
^m m r
450-.8 BLK/WHT T
450-.8 b lk /w h T
419/450
FUEL PUMP RELAY

f 450-.8 BLK/WHT*
HEATER CONTROL
LAMP
(SEEPAGE 110)
150-.8 BLK I
(SEE PAGE 60)

4 450-.8 BLK/WHT
*m m r *m m r
mmm*
RADIO
1S0-.8 BLK '

I 450-.8 BLK/WHT 1
(SEE PAGE 144, 145)
ECM/PCM
(SEE PAGE 59)
WINDSHIELD
WIPER SWITCH
S117
150-.8 BLK I
(SEE PAGE 59)
450-.8 BLK/WHT I
486-.8 BRN I
ECM/PCM
450-.8 BLK/WHT
EVRV
(SEE PAGE 60)
ESC HYBRID
MODULE
S215
! w/
450-.8 BLK/WHT
(SEE PAGE 79)
450-.8 BLK/WHT
<\
FUEL PUMP
CYCLE RELAY
(SEE PAGE 52)

S201
ALDL
(SEE PAGE 59)
l/P CLUSTER
(SEE PAGE 107)
150-.8 BLK I
DRAC
450-.8 BLK/WHT
[ (SEE PAGE 75)
(SEE PAGE 58)

Z
<
150-.8 BLK
I _______
450-.8 BLK/WHT
PARK/NEUTRAL
SWITCH (L05 WITH MD8)
(SEE PAGE 59)
1150:.
8 BLK m
150:.8BLK
CONVENIENCE CENTER
(SEE PAGE 21)
SAFETY BELT
RETRACTOR SWITCH
(SEEPAGE 112)
ENGINE
GROUND
DASH PANEL
GROUND
G200
IIP GROUND
GROUND DISTRIBUTION A-17

GASOLINE ENGINE
i i
-
1*32.0 BLK I
h
LH
BATTERY
-h
RH
BATTERY
TCM (LL4 WITH MT1)

(SEE PAGE 72)
1-32.0 BLK
FUEL HEATER
(SEE PAGE 87)
5 1-.8 B LK I
151-.8 BLK |
RH HIGH-LOW
HEADLAMP
(SEE PAGE 25)
WATER IN FUEL SENSOR

(SEE PAGE 87)
RH PARK AND
TURN LAMP
(SEE PAGE 34)
151-.8 BLK I
RH PARK LAMP
(SEE PAGE 34)
151-.8 BLK I
RH HIGH BEAM
HEADLAMP (V22)
(SEE PAGE 32}
151-.6 BLK I
RH LOW BEAM
HEADLAMP (V22)
(SEE PAGE 32)
W/O C60
151-3.0 BLK
1
SHEET
METAL
GROUND
FRAME
GROUND

DIESEL ENGINES
G114
G107
y i
G113
0
12020183
C100
RIGHT BANK
GLOW PLUG
GROUND
LEFT BANK
GLOW PLUG
GROUND
ENGINE
GROUND
RPO CODES
LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
MT1 - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
1151-.8 BLK (LH6 ONLY)l
ALDL
(SEE PAGE 63)
150-.8 BLK I
ALDL (LL4 ONLY)

(SEE PAGE 73)
150-.8 BLK I
WINDSHIELD
WIPER SWITCH
(SEE PAGE 52)
1150-.8 BLK 1
DRL MODULE
(SEE PAGE 26)
I150-.8 BLK I
CHECK ENGINE LAMP

DRIVER MODULE (LH6 ONLY)
(SEE PAGE 105)
HEATER CONTROL LAMP

(SEE PAGE 110)
1150*.8 BLK I
LOW COOLANT
WARNING MODULE
(SEE PAGE 106)
1150-.8 BLK I
RADIO
GLOW PLUG LAMP

(SEE PAGE 105)
l/P CLUSTER
1150-. 8 BLK I
(SEE PAGE 107)
K150-.8BLKI
1150-.8 BLK I
DRAC MODULE (LL4 ONLY)

(SEE PAGE 75)
I150-.8 BLK
CONVENIENCE CENTER
(SEE PAGE 21)
SAFETY BELT
RETRACTOR SWITCH
(SEE PAGE 112)
COPPER BRAID
,
G200
i/p
= GROUND
CO)
G102
ENGINE
GROUND
__
G103
DASHPANEL
GRAND
GROUND DISTRIBUTION A-19

DIESEL ENGINES
RPO CODES
R05 - DUAL REAR WHEELS
1150-.8 BLK I
1150-. 8 BLK I
1150-.8 BLK I
1150*.8 BLK I
I150-.8 BLK |
LH FRONT AND
REAR CLEARANCE
LAMPS (R05)
(SEE PAGE 157)
RH FRONT AND
CLEARANCE LAMPS (R05)
(SEE PAGE 157)
I 150-.8 BLK I
LH SIDE
MARKER LAMP
(SEE PAGE 156)
I 150-.8 BLK I
RH SIDE
MARKER LAMP
(SEE PAGE 156)
LH BACKUP
LAMP
(SEE PAGE 153)
I150-.8 BLK 1
RH BACKUP
LAMP
(SEE PAGE 153)
LH TAIL, STOP
AND TURN LAMP
(SEE PAGE 150)
1150-.8 BLK I
RH TAIL, STOP
AND TURN LAMP
(SEE PAGE 150)
I 150-.8 BLK I
1150-.8 BLK I
(FLEETSIDE, WIOESIDE ONLY)
1150-.8 BLK I
S402
G402
G403
G406
SHEET
METAL
GROUND
SHEET
METAL
GROUND
LH TAIL, STOP, AND TURN

LAMP GROUND
G405
FRAME
GROUND
FLEETSIDE, WIDESIDE, SUBURBAN AND UTILITY

STEPSIDE

REAR LAMPS
G407
RH TAIL, STOP, AND TURN
LAMP GROUND
AUDIO ALARM
238.
SAFETY BELT
RETRACTOR SWITCH
150'
GROUND
237'
SAFETY BELT
INDICATOR LAMP
39'
80'
140'
8'
KEY IN
SWITCH
(SEE PAGE 113)
IGNITION
STOP HAZ
FUSE
(SEE PAGE 36)
I 80-.5 LT GRN
KEY IN SWITCH
BATTERY
LIGHTS ON SWITCH
INSTR LPS
(SEE PAGE 110)
GAGE/IDLE
FUSE
(SEE PAGE 26)
INSTRUMENT
PANEL
(SEE PAGE 105)
SAFETY BELT
RETRACTOR
SWITCH
(SEE PAGE 112)
39-.S PNK/BLK
I 237-.8 YEL
HORNS
(SEE PAGE 49)
HORN/DM
FUSE
(SEE PAGE 49)
HORN
RELAY
CIGARETTE
LIGHTER
(SEE PAGE 49)
HAZARD
FLASHER
SWITCH
(SEE PAGE 36)
I 27-.8 BRN
HORN
SWITCH
(SEE PAGE 49)
CONVENIENCE CENTER
D U
HAZARD
FLASHER
(Q )
="
l/P
GROUND
G200
CONVENIENCE CENTER A-21
RPO CODES
TP2 - AUXILIARY BATTERY
1-32.0 BLK
o
o
GT 105
8911214
BATTERY
I I 141-.8 BRN/WHT 11
CC
AUXILIARY
BATTERY RELAY
t^BAT-t
(cj (g
(Aj
HTR
i
IS
1T11V11
VrTa1
V11Tni i'
y1
[D] U
in m
WDO
[c ]
[c ]
ra ra no Ei tu
M gnJ
SHUNT
SHUNT
ACC LPS PWR

30
ii
n i
u M
L s
in i In i
ii
INSTR LPS PWR ACC
iL s Ik 0 i p l a m
BIGN__AUX_HTR
d B 3* D
dHAi
................... .. _A/C
STOP HAZ
20AJ
j^25A^ |
T/L CTSY GAGE/tDLE H TR A/d
S105
ECM B
S118
I
I 2-8.0 RED
2-8.0 RED
TURN B/U PWR WDO
I 15A
r~15A
kS I k 0 ( kS
_RADlO
RADIO
W3 I k fi I kS
KWIPERl
a
^
ECM 1
150-8.0 BLK
K J
DRL
B^S

REAR
FUSE
BLOCK
<S>
12103404
w
SHEET
METAL
GROUND
G111
A-22 AUXILIARY BATTERY
AUXILIARY
BATTERY
SHEET
METAL
GROUND
G109
AUXILIARY
BATTERY
JUNCTION
BLOCK
SHEET
METAL
GROUND
G108
o'
CIRCUIT OPERATION
LOW BEAM LAMP(S) DO NOT OPERATE

TEST
HEADLAMPS
Voltage is applied to the Light Switch at all times.
The Light Switch includes a Self-Resetting Circuit
Breaker. The Circuit Breaker opens when the Headlamp
circuit draws too much current. When the Circuit
Breaker opens, it interrupts the current flow. With no
current flow the Circuit Breaker cools off and resets
automatically. When the Light Switch is in HEAD, the
Dimmer Switch directs voltage to either the Low Beams
or the High Beams. The High Beam Indicator also
receives voltage along with the High Beams. When the
Light Switch is in PARK or HEAD, voltage is directed to
parklamps.
CANADIAN DAYTIME RUNNING LAMPS

Voltage is applied to the Daytime Running Lamp
(DRL) relay at all times through the ORN (240) wire from
the DRL Fuse and when the Ignition Switch is in RUN
through the PNK/BLK (39) wire from the GAGE/IDLE
Fuse. The DRL Relay provides voltage to the LH High
Beam through the DK BLU/ORN (593) wire. This wire also
becomes the ground wire when the Headlamps are

operated normally.
Voltage is applied to the DRL
Module when the Ignition Switch is in RUN through the
PNK/BLK (39) wire from the GAGE/IDLE Fuse.
When the Ignition Switch is placed in RUN the DRL
Module energizes the DRL Relay connecting the ORN
(240) circuit (hot at all times) with the DK BLU/ORN (593)
circuit, turning on the Headlamps.
GO to step 5.
Test lamp lights.
GO to step 2.
2.
LOCATE and REPAIR open in BLK

(150 or 151) wire(s) from
headlamp connector(s) C138 or
C144 (Base), C149 or C154 (Quad
Halogen) to ground terminal(s)
G105, G106 or G107. (For
Canadian vehicles w/o Quad
Halogen, GO to step 3.)
Test lamp lights.
REPLACE headlamp(s).
Connect a test lamp from BLK

(150) wire at DRL relay
Test lamp lights.
GO to step 4.

(150) wire from DRL relay to
ground G105.
Connect a self powered test

lamp from DK BLU/ORN (593) at
DRL relay connector C126 to
ground.
Test lamp lights.
LOCATE and REPAIR open in DK

BLU/ORN (593) wire from
headlamp connector C138 to DRL
relay C126.
REPLACE DRL relay.
GO to step 6.
Test lamp lights.
LOCATE and REPAIR open in TAN

(12 ) wire from headlamp dimmer
switch to headlamp.
LOCATE and REPAIR open in YEL

( 10) wire from headlamp dimmer
switch to light switch.
Test lamp lights.
REPLACE headlamp dimmer

switch.
3.
4.
DIAGNOSIS - HEADLAMPS
PRELIMINARY CHECKS:
Check condition of T/L CTSY fuse. If fuse is blown,
LOCATE and REPAIR source of overload, then REPLACE
5.
TEST
1. Connect a test lamp from RED
2. With the light switch on and

the headlamp dimmer switch to
HIGH BEAM, connect a test lamp
from YEL (10) wire at light
switch connector C202 to
ground.
3.

(1 1 ) wire at headlamp dimmer
ground.
Connect test lamp from TAN

(12) to BLK (150 or 151)
wire(s) at headlamp
connectors C138 or C144
(Base), C149 or C154 (Quad
Halogen) to ground. (For
Canadian vehicle w/o quad, DK
BLU/ORN (593) is used in place
of BLK (150) wire at connector
C138).
fuse. If fuse is in good condition, use the following

diagnostic procedures.
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMSBOTH SIDES

RESULT
Connect a test lamp from TAN

(12 ) wire at headlamp dimmer
ground.
ACTION
Test lamp lights.
GO to step 2.
LOCATE and REPAIR open in RED

(2) wire from light switch to
junction block.
Test lamp lights.
GO to step 3.
Test lamp lights.

from headlamp dimmer switch to
headlamps.

switch.
ACTION
1. Turn light switch ON and

headlamp dimmer switch to LOW
BEAM position. Connect a test
lamp from TAN (12) wire at
inoperative lamp(s) to
ground.
When the Headlamps are turned on manually, or the

Ignition Switch is turned OFF, the DRL Module de
energizes the DRL Relay connecting the DK BLU/ORN
(593) circuit to the BLK (150) ground circuit. This allows
normal operation of the Headlamps.
If the dimmer switch is put into the High Beam
Position, the DRL Module will supply voltage through the
WHT (629) wire, to the Instrument Panel Cluster to turn
on the High Beam Indicator bulb.
RESULT
6. Connect a test lamp from YEL

(10) wire at headlamp dimmer
ground.
HEADLAMPS A-23
HIGH BEAM LAMP(S) DO NOT OPERATE

1.
2.
3.
4.
5.
GO to step 5.
Test lamp lights.
GO to step 2.
Connect test lamp from LT GRN

(11) wire to BLK (150 or 151)
wire(s) at headlamp connectors
C138 or C144 (Base), C150 or
C155 (Quad Halogen). (For
Canadian vehicles, DK BLU/ORN
(593) wire is used in place of BLK
(150) wire at connector C138 or
C155).
Test lamp lights.
REPLACE headlamp(s).

(150) wire at DRL relay connector
C126 to ground.
Test lamp lights.
GO to step 4.

(150) wire from DRL relay
connector to ground G105.
Connect a self powered test lamp

from DK BLU/ORN (593) wire to
ground to DRL relay connector
C126 to ground.
Test lamp lights.

BLU/ORN (593) wire at headlamp
connector C138 or C150 to DRL
relay C126.
6. Connect a test lamp from YEL (10)
2.
(150 or 151) wire(s) at headlamp
connector(s) C138 or C144 (Base),
C150 or C155 (Quad Halogen) to
ground connection(s) G105, G106
or G107. (For Canadian vehicles:
GO to step 3).
REPLACE DRL relay.
GO to step 6.
Test lamp lights.
LOCATE and REPAIR open in LT

GRN (11) wire from headlamps to
headlamp dimmer switch.
Test iamp does not light.

( 10) wire headlamp dimmer switch
to light switch.
Test lamp lights.

switch.
wire at headlamp dimmer switch

PRELIMINARY CHECKS:
Lamp(s) are inoperative, refer to the HIGH BEAM
LAMP(S) DO NOT OPERATE test procedures. If the
High Beam Lamp(s) are operative, use the following
diagnostic procedures, after placing the Light Switch
to OFF position.
Before checking the DAYTIME RUNNING LAMPS

system, do the following:
1. Place Park Brake in the OFF position.
2. Place Light Switch to ON and Headlamp Dimmer
Switch to HIGH BEAM position. If the High Beam
5.
Fuse is blown.

Test lamp lights.
GO to step 3.

connector C126 to C125 and/or
ORN (340) wire between C125 to
fuse block.
Fuse is not blown.
GO to step 4.
Fuse is blown.

Place ignition switch to run.

Connect a test lamp from
PNK/BLK (39) wire at DRL relay
Test lamp lights.
GO to step 5.
LOCATE and REPAIR open in

PNK/BLK (39) wire between DRL
relay and fuse block.

PNK/BLK (39) wire at DRL module
Test lamp lights.
GO to step 6.

PNK/BLK (39) wire between DRL
module and fuse block.
Daytime Running lamps light.
GO to step 7.
Daytime Running Lamps do not

light.
GO to step 9.
Test lamp lights.
GO to step 8.

(150) wire between DRL module
connector C 2 1 1 and ground G 200.
Test lamp lights.
REPLACE DRL relay.

GRN/BLK (592) wire between DRL
relay connector C126 and DRL
module connector C211.
Test lamp lights.

BLU/ORN (593) wire between DRL
relay connector C126 and LH
headlamp connector C138 or
C150.
REPLACE DRL module.
Connect a test lamp from ORN

C126 to ground.
6. Using a jumper wire, apply ground

to LT GRN/BLK (592) wire at DRL
7.
Connect a self-powered test lamp

from LT GRN/BLK (592) wire to
BLK (150) wire at DRL module
connector C211.
8. Connect a self-powered test lamp

from LT GRN/BLK (592) wire at
DRL relay connector C 126 to
ground.
9. Connect a test lamp from DK

BLU/ORN (593) wire at DRL relay
DRL STAY ON
RESULT
TEST
1.
Disconnect DRL module

connector C211. Place
ignition switch to RUN and
light switch to ON position.
Connect a J 34209-A multimeter
(or equivalent) to YEL (10)
wire from module connector to
ground. Measure voltage.
A-24 HEADLAMPS
ACTION
Battery voltage.
REPLACE DRL module.
No voltage.

(10) wire from DRL module to
light switch.
ACTION
GO to step 2.
3. Check condition of GAGE/IDLE

fuse.
4.
RESULT
Fuse is not blown.
1. Check condition of DRL fuse.
Place light switch to ON and

dimmer switch to HIGH BEAM
position. Connect a test lamp from
LT GRN (11) wire at inoperative
lamp(s) to ground.

( 1 1 ) wire at headlamp dimmer
switch connector C201 to ground.
TEST
ACTION
RESULT
TEST
DRL DOES NOT OPERATE
RPO CODES
(SEE POWER DISTRIBUTION)
C60 - FRONT MANUAL AIR CONDITIONING

L05 - 5.7L (350 CU. IN.) V8 GAS ENGINE VIN K
L19 - 7.4L (454 CU. IN.) V8 GAS ENGINE VIN N
LH6 - 6.2L (378 CU. IN.) V8 DIESEL ENGINE VIN C
LL4 - 6.2L (378 CU. IN.) HD V8 DIESEL ENGINE VIN J
M20 - MANUAL 4-SPEED TRANSMISSION
pJ=U .
rînrî
BATTERY
JUNCTION
BLOCK
QDUCZJ
B nB
S nS
tz fe
n O
QDu
ClI
C203
12066261
l/P CLUSTER
CONNECTOR
(SEE PAGE 103)
m um
J Z r
2-1.0 R S T B H
(FUSIBLE LINK)
I 2-3.0 RED I
12-1.0 RST I
(FUSIBLE LINK)
5100 (LH6, LL4)

5101 (L05, L19)
420 440
439 806
AUXILIARY
ENGINE COOLING FAN (L19 AND C60)
151-2.0 BLK
(SEE PAGE 90)

PARK AND
TURN LAMPS (SEE PAGE 34)
151-.8 B L K i
: 18
120
: 24
30
19 I
C100
12020184
140
39
120
31
D ]
r
50
436
35
93
97
422
91
92
l/P
11-1.0 L T G R N l
| 12-.8 TAN
lA
GENERATOR
(SEE PAGE 10)
151-.8 BLK
151-3.0 BLK
HEAD
. OFF
40-
C138
12034372
C144
12034372
''P A R K
HEAD
RH
HIGH-LOW
HEADLAMP
SHEET
METAL
GROUND
G106
FRAME
GROUND
G107
LH
HIGH-LOW
HEADLAMP
SHEET
METAL
GROUND
G105
LIGHT
SWITCH
HEADLAMPS A-25
BASE
HOT IN START
OR RUN
GAGE/
IDLE
20 AMP
V22
t~ ...-J
ni
r ii ^ a
LH
HIGH-LOW
HEADLAMP
| 440 I 420 HI
r a
[ 1 2 0 | 140 | | [ ] |
! 31
| 436 | 50 |
i p
( " 2 1 35 i l m
I , | 422 | 97 | 93 |
A-26 HEADLAMPS
W/DRL 5.7L, 7.4L V 8 GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL W/MAN TRANS
FLEETSIDE, WIDESIDE, CREW-BONUS CAB
SHEET
METAL
GROUND
G105
SHEET
METAL
GROUND
G106
FRAME
GROUND
G107
. |
6
1
| 92 | 91
2
|
C3
C100
12020183
c = i
RPO CODES
P t
s
m
_
O
Z * i ifl h =
==o5m=32'^: P; Qi
d :5Z nO
<
< ^ S 2
o
c l
w
j
clq
^ o
I
DIODE
ASSEMBLY
DRL
MODULE
C291
12040549
(UTILITY ONLY)
(FLEETSIDE, WIDESIDE
CREW/BONUS CAB)
PARK BRAKE
WARNING SWITCH
RWAL
(UTILITY ONLY)
(SEE PAGE 116)
o c c
o o
060 - AIR CONDITIONING

L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN E
LL4 - ENGINE, 6.2L (378 CID) V8, HD DIESEL ENGINE, VIN J
DIODE
ASSEMBLY
(CLOSED WITH PARK BRAKE APPLIED)
inn
T.
592-.8 LT GRN/BLK I
_ J
C293
12004267
33-.5 TAN/WHT
sc
m
I
i
33-.5 TAN/WHT
&
onifpEi
G]nljD
592-.a l t g r n / b lk M r -
jm m r
jm m r j h
(SEE PAGE)
131 lir a
4 OH[][II]
_ .='-------------------------"L _ L I_iHoili
____
_____
I 39*.8 PNK/BLK |
_____________________
* 33-.5 TAN/WHT .
(SEE PAGE 116)
12-.8 TAN
39-.S PNK/BLK I
PNK/BLK I
V
......... .....
- - - ......r
^
\ ^ a
(SEE
(SEE PAGE
PAGE 105)
105)
LOW COOLANT WARNING MODULE i

(SEE PAGE 104)
39-. 5 p n k /b lk m w
,= ^
m um r
J
I
.
I
I
(L| 4 0 N | Y)
J
a r
r = j
IS n O D
dt=M
UdI d
V- | P 7
I
1 1-------------------------------^
U
12066261
I
I
I
-.m
--------- 39-.S PNK/BLK

(LL4 ONLY)
r-
S201
110-1.0 YEL I
150-
(SEE PAGES 17, 19)
LIGHT
SWITCH
I 150-.8 BLK I
156
I 12-.8 TAN
CIRCUIT
BREAKER
25 AMP
IGNITION
SWITCH
I 11-1.0 LT GRN I
39-.S PNK/BLK 1 ^ ^
WATER IN FUEL LAMP .

^ 1 3 9 -1
1
CONVENIENCE CENTER
(SEE PAGE 21)
FUEL PUMP CYCLE RELAY

(SEE PAGE 78)
S202
i i
I 11-1.0 LT GRN
m m 1 jm
l/P
CLUSTER
CONNECTOR
(UTILITY ONLY)
RWAL
__________ I
33-. 5 TAN/WHT
33-.5 TAN/WHT
I 11-.8 LT GRN
33-.5 TAN/WHT
33-.5 TAN/WHT
DIMMER
SWITCH
G2O0
l/P
'
GROUND
10-1.0 YEL
HEADLAMPS A-27
W/DRL 5.7L, 7.4L V8 GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL W/MAN TRANS
FLEETSIDE, WIDESIDE, CREW-BONUS CAB_____________________________________
W/LL4
50-2.0 BRN I
vMWMAMM
<
HOT AT ALL TIMES <
m w w vw s
HTR/AC
25
AMP
DRL
15
AMP
GAGE/IDLE
20 AMP
592-.8 LT GRN/BLK .
I PNK/BLK
L ______ J
RH
HIGH-LOW
HEADLAMP
DRL
RELAY
GT105
12020457
jLoxmju
592-.8 LT GRN/BLK .
I
340-,8 ORN I
12052641
592-.S LT GRN/BLK
RH LOW BEAM
HEADLAMP
RH HIGH BEAM
HEADLAMP
11-.8 LT GRN I
V22
ONLY
11-1.0 LT GRN
11
39-.5 PNK/BLK
LH HIGH BEAM
HEADLAMP
J
r
1
39
14
29
15
12-.8 TAN
C102
12020100
39-.8 PNK/BLK I
GENERATOR ^
(SEE PAGE 12)
LH LOW BEAM
HEADLAMP
I 151-3.0 BLK
LH
HIGH-LOW
HEADLAMP
593- 8 DK BLU/ORN^
___________________________ i
A-28 HEADLAMPS
W/DRL 5.7L DIESEL ENGINES AND 4-SPD., AUTO TRANS SUBURBAN/UTILITY
(Q )
(q )
SHEET
METAL
GROUND
G105
SHEET
METAL
GROUND
G106
FRAME
GROUND
G107
RPO CODES
___ W/LL4
S203
I 50-2.0 BRN I
DRAC
(SEE PAGE 75)
a n 50-1.0 BRN
TTl
m
5 _3
I
2 5 i
<fl I- kO 5
g
h tc
aa:*S(/>i-00
; 0 5 3 3 i uZ
03
111 3
DIODE
ASSEMBLY
DIODE
ASSEMBLY

LL4 - ENGINE, 6.2L (378 CID) V8, HD DIESEL ENGINE, VIN J
MD8 - AUTO TRANS, 4 SPD.pWITH OVERDRIVE
(EXCEPT LL4)
(W/LL4)
DRL
MODULE RWAL
(SEE PAGE 116)
f^ r Ps rQ f i Wo - i ZI go
HTR SW
(SEE PAGE 9 6 )'
PARK BRAKE
WARNING SWITCH
RWAL
(SEE PAGE 116)
{CLOSED WITH PARK BRAKE APPLIED)
o
592-.8 LT GRN/BLK
33-. 5 TAN/WHT
I
I
W/MD8
C293
12004267
%
I _____________
39 -.8 p n k /b lk r
mmmr
Mmm
33 -. 5 t a n / w h t w a rn
k.^1
jm m w ja m m
33
-. 5 TAN/WHT
ta n /w h t I
33-.
jm m w
33-. 5 TAN/WHT I
33-.5 TAN/WHT I
133-.8 TAN/WHT
33-. 8 TAN/WHT
~ l
.___ ,
fcJ
629-.8 w h t mm
l/P
CLUSTER
I CONNECTOR
(SEE PAGE 103)
G]n[jD
150-.8 BLK
| 31 I U [ 4 1 9 |
HGilnljD
111-,8 IT GRN
5Q DnS
6
LH
J 592 | U | 2 3 t [
U n ra
r ~
- 'r a t e
dDuQD
39-.S PNK/BLK
WATER IN FUEL
I 11-1.0 LT GRN
I V
39' 8 PNK/BLK 1
I 39-,8 PNK/BLK
...............
__ J
P
t
^
39-.5 PNK/BLK b t
I 12-,8 TAN I
j v
j w
(SEE PAGE 105)
(LH6 ONLY)
^ ^ N
T
WARNING MODULE
(SEE PAGE 104)
jm m r
I
I
I
I
^ 1
J H T
1
|
I
m am l
12,8 TAN
1 11-1.0 LT GRN I
^ I
I 150-1.0 BLK
S201
(SEE PAGES 17, 19)
110-1.0 YEL
I 150-.8 BLK I
LIGHT
SWITCH
C203
12066261
150-
I 12-. 8 TAN
DIMMER
SWITCH
CIRCUIT
BREAKER
25 AMP
IGNITION
SWITCH
10-1.0 YEL
G200
l/P
GROUND
HEADLAMPS A-29
W/DRL 5.7L DIESEL ENGINE AND 4-SPD., AUTO TRANS SUBURBAN/UTILITY
HOT IN RUN '
HTR
A/C
25
AMP
a
|
!
RH LOW BEAM
HEADLAMP
RH HIGH BEAM
HEADLAMP
V22
ONLY
LH HIGH BEAM
HEADLAMP
LH LOW BEAM
HEADLAMP
LH
HIGH-LOW
HEADLAMP
A-30 HEADLAMPS
W/DRL 5.7L, 7.4L GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL ENGINE W/HEAVY DUTY AUTO
TRANS, SUBURBAN, FLEETSIDE, WIDESIDE, CREW-BONUS CAB
SHEET
METAL
GROUND
G105
SHEET
METAL
GROUND
G106
C 100
12020183
FRAME
GROUND
G107
39*. 8 PNK/BLK I
S202>k
Ovv
I 11-1.0 LT GRN I
39-.8 PNK/BLK
m 3 9 - 8 p n k /b lk m m m m b
^ r 1 m k
l o w c o o l a n t w a r n in g m o d u le
(SEE PAGE 104) (LL4 ONLY)
I
I
I
I
39- 5 p n k /b lk v
^ I
1 2,8 TAN
k
I
0203
12066261
v'
^ m r
I 11-1.0 LT GRN I
S201
(SEE PAGES 17, 19)
I 10-1.0 YEL I
44
(L05/L19 W/O RWAL BRAKES)
LIGHT
SWITCH
L _ y _ _
150-
I 12-. 8 TAN
DOME
IL/
OFF
CIRCUIT
BREAKER
25 AMP
'P A R K
HI 1
I 11 r l*jf
12^
10
i *-
HEAD
OFF
IGNITION
SWITCH
DIMMER
SWITCH
T\
'P A R K
HEAD
G200
l/P
^
GROUND
10-1.0 YEL
HEADLAMPS A-31
W/DRL 5.7L, 7.4L GASOLINE ENGINE, 6.2L HEAVY DUTY DIESEL ENGINE W/HEAVY DUTY AUTO
TRANS, SUBURBAN, FLEETSIDE, WIDESIDE, CREW- BONUSCAB
RPO CODES
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, V1N K
LH6 - ENGINE, 6.2L (378 CID) V8 DIESEL-ENGfNE, VIN C
BATTERY
DIMMER
SWITCH
GROUND
G105
A-32 QUAD HALOGEN HEADLAMPS
GROUND
G106
LIGHT
SWITCH
ROOF MARKER LAMPS DO NOT OPERATE
CIRCUIT OPERATION
TEST
HAZARD LAMPS
Voltage is applied at all times, through the STOP/HAZ
Fuse and the Hazard Flasher to the normally open
contact of the Hazard Switch in the Turn Signal Switch
Assembly. With the Hazard Switch in HAZARD FLASH,
voltage is applied to both Front and Rear Turn Lamps.
All of the Turn Lamps and both Turn Indicators flash on
and off.
The Front Marker Lamps flash in HAZARD FLASH just
as they do in RIGHT TURN and LEFT TURN. If the Lamp
Switch is in OFF, they flash on when the Hazard Lamps
are on. If the Light Switch is in either PARK or HEAD,
they flash on when the Hazard Lamps are off and off
when the Hazard Lamps are on.
1.
RESULT
Connect test lamp from ORN (40)

C202 to ground.
Test lamp lights.
GO to step 2.

(40) wire between light switch and
fuse block or REPLACE (T/L CTSY)
fuse.
Test lamp lights.
GO to step 3.
Test lamp lights.
GO to step 4.

WHT (45) and BRN (9) wires from
marker lamp to light switch.
Test lamp lights.
CHECK condition of light socket.

(150) wire from marker lamps to
bus bar ground.
In Hazard, this circuit is always open, and the Hazard

Flasher control the Lamps.
PARK AND MARKER LAMPS

Voltage is applied through the T/L CTSY Fuse to the
Light Switch at all times. With the Light Switch in PARK
or HEAD, voltage is applied to the Park, Tail, Marker,
License Lamp and Roof Marker Lamps (if so equipped).
2.
3.
4.
DIAGNOSIS - FRONT PARK, MARKER

ROOF AND HAZARD LAMPS
Connect test lamp from BRN (9)

C202 to ground.
Connect test lamp at WHT (45)
wire at LH marker lamp terminal to
ground.
Connect test lamp from WHT (45)

wire to BLK (150) wire at LH
marker lamp.
ACTION
FRONT PARK AND SIDE MARKER LAMPS DO NOT OPERATE

TEST
1.
2.
3.
Place light switch in PARK

ORN (40) wire at light switch

C202 to ground.
Connect a test lamp at BRN (9)
wire at LH park lamp connector
C140 to ground.
Test lamp lights.
GO to step 2.

(40) wire between light switch and
fuse block or REPLACE T/L CTSY
fuse.
Test lamp lights.
GO to step 3.
Test lamp lights.
CHECK conditions of bulb sockets

and BLK (150 and 151) wires from
park lamps to ground terminals
G106 and G107.
HAZARD WARNING LAMPS DO NOT OPERATE
ACTION
RESULT
LOCATE and REPAIR open in BRN

(9) wire from park lamps to light
switch.
TEST
1. Place ignition switch in RUN and
position turn signal lamps as if
making a turn.
RESULT
ACTION
Turn signal lights operate.
GO to step 2.
Turn signal lights do not operate.
GO to step 3.
2. Turn off turn signal lamps and put

hazard warning lamps on.
Connect a test lamp from BRN
(27) wire at turn signal switch
Test lamp lights.
REPLACE turn signal switch.
CHECK condition of fuse

(STOP/HAZ) and an open in ORN
(140) wire and BRN (27) wire. If
fuse and wiring are good,
REPLACE hazard flasher.
3. Place hazard lamps on. Connect

test lamp from LT BLU (14) wire at
turn signal switch connector C205
to ground.
Test lamp flashes.
LOCATE and REPAJR open in

wires from turn signal switch to
convenience center.
FRONT, PARK AND MARKER LAMPS A-33
RPO CODES
wvwwwww/
>
RADIO/CLOCK
(SEE PAGES 144,
145)
40-.8 O B N I
HOT A T ALL TIM ES <
^wwwwwv^T

T61 - CANADIAN DAYTIME RUNNING LAMPS
T/L CTSY
20 AMP
AUXILIARY ENGINE
COOLING FAN (L19 WITH C60)
(SEE PAGE 90)
RH PARK AND
TURN LAMP
1S6
I 151-2.0 B LKl
RH HIGH-LOW
HEADLAMP
(SEE PAGE 25)
151-.8 BLK
LIGHT
SWITCH
RH PARK AND
TURN LAMP
RADIO/CLOCK
115-. 8 DK BLU I
I1 4 -.8 L T B L U I
LH PARK AND
TURN LAMP
\
I
r
i
LH HIGH-LOW
HEADLAMP
(SEE PAGE 25)
- i
~7)
t
i^
J
"s'
m z
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m
8g
eq O
94
9
29
39
33
12
: 93
11
15
14
420
J
1 (
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r
93
co
91
1 1 50-.8
B LK l
C100
1202184
D
m
b
CO
LH PARK AND
TURN LAMP
C137
12077765
LH SIDE
MARKER LAMP
A-34 FRONT, PARK AND MARKER LAMPS

BASE
SHEET
METAL
GROUND
G105
SHEET
METAL
GROUND
G106
FRAME
GROUND
G107
440
806
2
39
140
120
31
SO
436
35
97
422
92
TURN LAMPS SWITCH

(SEE PAGE 45)
RPO CODES
<
HOT AT ALL TIMES <
<W yVVVWWWs*
T/L CTSY
20 AMP
RH PARK
AND TURN
LAMP
RH PARK
LAMP
RH LOW BEAM
HEADLAMP
(SEE PAGE 32)
RH HIGH BEAM
HEADLAMP
(SEE PAGE 32)
LH HIGH BEAM
HEADLAMP
(SEE PAGE 32)
LH LOW BEAM
HEADLAMP
(SEE PAGE 32)
LH PARK
LAMP
LH PARK
AND TURN
LAMP
LH SIDE
MARKER
FRONT, PARK AND MARKER LAMPS A-35

W/QUAD HALOGEN HEADLAMPS
yvwwwwvVf
>
HOT AT ALL TIMES <
>V V W V W V V W N
STOP HAZ
15 AMP
RH PARK AND
TURN LAMP
RH PARK AND
TURN LAMP
LH PARK AND
TURN LAMP
LH PARK AND
TURN LAMP
A-36 HAZARD LAMPS

BASE
HAZARD LAMPS A-37

_________________ BASE________
vjViMWWVvV*
S
140-.8 0RN
HOT AT ALL TIMES <
Vw m w v w n
140-.8 0RN
(L0S/L19 WITH M20 FLEETSIDE, WIDESIDE,
CREW/BONUS CAB)
STOP HAZ
15 AMP
RH PARK AND
TURN LAMP
C153
12077753
A-38 HAZARD LAMPS

SHEET
METAL
GROUND
G105
SHEET
METAL
GROUND
G106
FRAME
GROUND
G107
vAAWMAAAM
<
T/LCTSY
20 AMP
*)
Ui
HOT AT ALL TIMES <
> W W V W V \W S
CTSY LAMPS
I 40-.8 ORN |
I 40-.8 ORN I
S204
(SEEPAGE 119)
40-.8 ORN |
RH
MARKER
LAMP
( 5 )
FRONT
IDENTIFICATION /
LAMPS
M
m
G *D
LH
MARKER
LAMP
r r t u
f
I 45-. 8 W H TI
A-40 ROOF MARKER LAMPS
RADIO/CLOCK
BLANK
BLANK A-41
DIAGNOSIS TURN SIGNAL LAMPS
CIRCUIT OPERATION
PRELIMINARY CHECKS:
TURN SIGNAL LAMPS

With the Ignition Switch in RUN or START, voltage is
applied through the TURN/BU Fuse and Turn Signal
Flasher to the normally closed contact of the Hazard
Flasher Switch in the Turn Signal Switch Assembly.
ground. The Marker Lamp will flash with the Turn

Lamps. The Lamps used for the ground path will not
flash, however, since the voltage drop across the Marker
Lamp is much higher than that across the other Lamps.
With the Turn Signal Switch in LH Turn position,

voltage is applied to both the LH Turn Indicator and the
LH Front Park/Turn Lamp (LT BLU wires). Voltage is
applied to the LH Rear Turn Lamp (YEL wire).
When the Light Switch is in either PARK or HEAD,

voltage is applied through the T/L CTSY Fuse, Lamp
Switch and splice S112 to the Marker and Park Lamps.
If the Turn Signal Switch is in LEFT TURN, the LH Front
Marker Lamp will have voltage at both connections and
will go out. When the flasher removes voltage to the
Turn Lamp, the Marker Lamp will be grounded through
the Turn Lamp and will go on. In this way, the LH Front
Marker Lamp will flash on when the LH Front Park and
Turn Lamp goes off, and off when the Turn Lamp goes
on.
The Lamps go on immediately. They begin to flash

when the current flow heats up the timing element in the
flasher and it repeatedly opens and closes the circuit.
The voltage applied to the LH Front Park and Turn
Lamp will also be applied to the LH Front Marker Lamp.
If the Light Switch is in the OFF position, the LH Front
Marker Lamp will find a path to ground through splice
S112 and the many Lamps connected in parallel to
ground. These Lamps provide low resistance paths to
With the Turn Signal Switch Assembly in RIGHT

TURN, voltage will be applied to the RH Lamps in a
similar manner.
1. Check condition of TURN/BU fuse. If fuse is blown,

LOCATE and REPAIR source of overload, then
REPLACE fuse.
2. Place Headlamp Switch in PARK position. If any park
or marker lamps do not operate, refer to FRONT
TURN SIGNALS DO NOT WORK ON ONE SIDE

TEST
1. Turn hazard warning system ON.
Observe lights on side of turn
signals that did not work.
RESULT
ACTION
Lights flash.
CHECK for improper bulb.

REPLACE if necessary.
Lights do not come on.
GO to step 2.
2. Turn hazard warning system off.

Place ignition switch to RUN and
turn signal to side that does not
work. Connect test lamp from LT
BLU (14) or DK BLU (15) wire
(depending on which side does
not work) at turn signal switch
Test lamp lights.
GO to step 4.
lamp does not light.
GO to step 3.
3.
Connect a test lamp from PPL (16)

at turn signal switch connector
C205 to ground.
Test lamp lights.
REPLACE turn signal flasher.
Connect a test lamp from LT BLU

(14) or DK BLU (15) wire
(depending on which side did not
work) at park and turn lamp
connector C137, C140, C145,
C146, C147 (Base) or C151, C152,
C153, C156, C157, C158 (Quad
Halogen) to ground.
Test lamp lights.
GO to step 5.

either LT BLU (14) or DK BLU (15)
wires.

(14) or DK BLU (15) wire to BLK
(150 or 151) wire at park and turn
lamp connector C139, C140,
C146, C147 (Base) or C151, C156
(Quad Halogen).
Test lamp lights.
CHECK condition of bulb sockets.

(150 or 151) wire.
4.
5.
A-42 TURN SIGNAL LAMPS
PARK AND SIDE MARKER LAMPS DO NOT OPERATE

diagnostic procedure in this manual. If the park or
marker lamps are operative, use the following
diagnostic procedure.
TURN SIGNALS DO NOT OPERATE

RESULT
TEST
1.
2.
3.
ACTION
Hazard lamps operate.
GO to step 2.
Hazard lamps do not operate.
GO to step 3.

wire are turn signal switch
Test lamp flashes.

(TURN/BU) and an open in PPL
(16) wire, DK BLU (38) wire, or BLK
(150) wire. If fuse and wiring are
good, REPLACE turn signal
flasher.
Place ignition switch in RUN

position and put turn signal switch
as if making a LH turn. Connect a
test lamp from LT BLU (14) wire at
turn signal switch connector C205
to ground.
Test lamp flashes.

wires from turn signal switch to
convenience center.
Place hazard warning lamps to

ON position.
TU R N S IG N A L LAM PS FLASH RAPIDLY

TEST
Turn hazard lamp switch ON.
Check front signal lamps and rear
taillamps.
RESULT
ACTION
One side of turn signal lamps flash

rapidly.
REPLACE inoperative turn signal

bulb.
Only one side of turn signals light

but do not flash rapidly.
REFER to Turn Signals Do Not

Operate On One Side" symptom.
TURN SIGNAL LAMPS A-43
I 16-.8 PPL I
i/P
CLUSTER
CONNECTOR
(SEE PAGE 103)
C203
12026261
D u n a
|lSO|U|~39~]
Q iln E H l
U D T3
rn n U r^
B n C ID p
E 3 n l3 D
QDUE3
14-.8 LT BLU I
94
29
15
14
39
33
12
93
11
II (i
RH SIDE
MARKER LAMP
I 15-. 8 D K B LU I
420 440
439 806 / 39
140
120
I1 4 -.8 L T B IU I
31
50
436
r
93
35
97
422
91
92
RH PARK AND
TURN LAMP
19-.8D KG R N I
18-.8YEL^H
RH PARK AND
TURN LAMP
15-.8 DK BLUi
151-.8 BLK
RH HIGH/LOW
HEADLAMP
(SEE PAGE 25)
AUXILIARY
ENGINE COOLING
FAN (L19 WITH C60)
(SEE PAGE 90)
151-2.0 B L K M
LH PARK AND
TURN LAMP
LH PARK AND
TURN LAMP
|A-44
LH SIDE
MARKER LAMP
t u r n s ig n a l l a m p s
base
SHEET
METAL
GROUND
G105
SHEET
METAL
GROUND
G106
FRAME
GROUND
G107
RPO CODES
E63 FLEETSIDE BODY
C60 AIR CONDITIONING
17
16
27
- 17-.8 WHT
19-.8 DK GRN
- 18-.8 YEL
16-.8 PPL
27-.S BRN
- 15-.5 DK BLU
14-.5 LT BLU
28-.5 BLK
- 80-. 5 LT GRN
- 159-.8 TAN
SHEET
METAL
GROUND
G403
SHEET
METAL
GROUND
G402
(SURBURBAN/UTIUTY ONLY)
C412
8911035 (SUBURBAN)
(SURBURBAN ONLY)
TURN SIGNAL LAMPS A-45

_______________________ BASE________
HTR
II a
^BAT-1
B
! 16-.8 PPL I
m
id
hi
id
I!
FUSE BLOCK
m
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12103404
WDO
ID [c] B
MGNJ
SHUNT
ACC LPS PWR
LPL
1 111111A111111
t i [ ] A in i ] ei i i
SHUNT
.NSTR
[I
m \
__
Jhi
15-.8 DK BLU
n m
K L D I lL d O
UE
LsJ
T/L CTSY
LH PARK AND
TURN LAMP
15-.8 DK BLU
K
l
ECM B
KECM l1
KDRL]
c d
B 'f l'x
AUXILIARY
ENGINE COOLING
FAN (L19 WITH C60)
(SEE PAGE 90)
cCRANK
*a
RH PARK
LAMP
(SEE PAGE 40)
FRONT
151-.8 BLK
RH LOW BEAM
HEADLAMP
(SEE PAGES 25, 32) '
S111
1 151-2.0 BLK
J\
RH HIGH BEAM
HEADLAMP
]
(SEE PAGES 25, 32)
TURN SIGNAL
FLASHER
Ai
LH HIGH BEAM
HEADLAMP
(SEE PAGES 25, 32)
LH LOW BEAM
HEADLAMP
(SEE PAGES 25, 32)
1150-.8 BLK
LH PARK
LAMP
(SEE PAGE 40)
I150-.8 BLK
150-.8 BLK I
150-.8 BLK
RH PARK AND
TURN LAMP
14-.8 LTGRN I
151-.8 BLK I
14-.8 LTGRN I
SHEET
METAL
GROUND
G105
A-46 TURN SIGNAL LAMPS

fl
SHEET
METAL
GROUND
G106
FRAME
GROUND
G107
15-.8 DK BLU
RPO CODES
CIGARETTE LIGHTER DOES NOT OPERATE
CIRCUIT OPERATION
TEST
When the Horn Switch is depressed, one side of the

cojl of the Horn Relay is grounded. The relay is
energized. The relay contacts close and battery voltage

is applied to the horns.
DIAGNOSIS - HORNS
PRELIMINARY CHECKS:
Check condition of HORN/DM fuse. If fuse is blown,
LOCATE and REPAIR source of overload, then REPLACE
fuse. If fuse is in good condition, use the following

diagnostic procedure.
HORN(S) WILL NOT OPERATE

TEST
RESULT
ACTION
1. Connect a test lamp from BLK/LT

GRN (29) wire at horn connector
(C142, C143) to ground. Press
horn switch.
Test lamp lights.
REPLACE horn.
GO to step 3.
2.
Remove horn relay. Connect a

test lamp from ORN (240) wire at
convenience center to ground.
Test lamp lights.
GO to step 3.

(240) wire between convenience
center and fuse block.
Disconnect turn signal switch

connector C205. Use a jumper
wire to ground BLK (28) wire at
turn signal switch connector C205.
Horn does not sound.
GO to step 4.
Horn sounds.
Disconnect horn relay. Install a

jumper wire from ORN (240)
terminal to DK GRN (29) terminal
at convenience center.
Horn sounds.
REPLACE horn relay.

GRN (29) wire from convenience
center to C100 and/or LT
GRN/BLK (29) wire between C100
and horn(s).
3.
4.
HORN SOUNDS CONTINUOUSLY WITHOUT DEPRESSING HORN SWITCH

RESULT
TEST
1.
2.

connector C205.
Disconnect horn relay. Check for
a short to ground in DK GRN (29)
and BLK (29) wires.
A-48 HORNS
ACTION
Horn stops.
Horn continues to sound.
GO to step 2.
No shorts found.
REPLACE relay.
Short(s) found.
REPAIR or REPLACE as required.
1.
Connect a test lamp at cigarette

lighter connector C299 from ORN
(240) wire to ground.
RESULT
ACTION
Test lamp lights.
REPLACE cigarette lighter.

(240) wire between fuse block and
cigarette lighter connector C299.
v/AAAW W W W
S
HOT AT ALL TIMES <
m A /w W W V S
HORN/DM
20 AMP
J)
C
CONVENIENCE
CENTER
1240-1.0 ORN I
RH
HORN
(STEERING C O L SW ITCHES)
C143
y
<
-* z
o
12004267
<75
17-.0 WHT 19-.8 DK GRN 18-.8 YEL 16-.8 PPL 27-. 8 BRN -
-C -J
15-.5 DK BLU-
I
*_ l
I
a:
o
14-.5 LT BLU
2S-.5 BLK
80-.5 LT GRN
159-.8 TAN
TURN
SIGNAL SWITCH
LH
HORN
C142
12004267
m
z
C102
12020100
HORNS A-49
WIPERS DO NOT OPERATE IN ANY MODE
CIRCUIT OPERATION
TEST
1.
PULSE WIPERS
PULSE
In addition to MIST, LO and HI speed operation the

pulse-type Wiper/Washer System includes an operating
mode in which the wipers make single strokes with an
adjustable time interval between strokes. The time
interval is controlled by a Solid-State Pulse/Speed/Wash
Control in the Wiper Motor Module. The duration of the
relay interval is determined by the Pulse Delay
Resistance in the Wiper/Washer Switch.
With the Wiper/Washer Switch in PULSE (Delay),

voltage is applied to the GRA (91) wire, the Wiper Motor
Module, and the Solid-State Control Board. Voltage is
applied to Park/Run Relay coil which is momentarily
grounded by the Pulse/Speed/Wash Control circuit and
the relay closes. Battery voltage is supplied through the
closed contacts of the relay to the run Wiper Motor. The
relay remains energized as long as the contacts of the
Park/Run Switch remain closed. When the wiper blades
have reached PARK, the Park/Run Switch opens, de
energizing the Park/Run Relay. The wiper blades remain
in PARK until the Control Board grounds the Park/Relay
coil to start another sweep. The delay time between
sweeps is controlled by the pulse delay resistors. The
delay can be adjusted from 0 to 43 seconds.
LOW SPEED
In the LO position, the Wiper/Washer Switch supplies
voltage in the GRA (91) wire and the Pulse/Speed/Wash
Control.
The Pulse/Speed/Wash Control provides
ground to the Park/Run Relay which is energized and
supplies voltage to the brushes of the Wiper Motor. The
wipers run at low speed until they are turned off.
2.
With the Wiper/Washer Switch in the HI position,

battery voltage is supplied from the PPL (92) wire directly
to a second armature terminal of the Wiper Motor. The
wipers run at high speed. When the Wiper/Washer
Switch is turned to OFF, the wipers complete the last
sweep at low speed and park.
PARK
When the wipers are turned off, the Wiper Motor runs
at low speed until the wiper blades reach the PARK
position. At that time the Park/Run Relay opens and
shuts the Wiper Motor to stop it immediately. The wiper
blades remain in the PARK position.
MIST
When the control is moved to MIST and released, the
wipers make one sweep at low speed and return to
PARK. The circuit operation is the same as low speed.
2.
The Wiper Motor is equipped with a circuit breaker

which protects the motor when the wipers are blocked.
The resulting high current will open the circuit breaker
which will reset upon cooling.
A-50 WINDSHIELD WIPERS AND WASHERS

PULSE

WHT (93) wire between wiper
motor connector C188 and fuse
block.
Test lamp lights.
GO to step 2.
Wiper motor runs.

(150) wire between pulse wiper
module connector C207 and
ground G200.
Wiper motor does not run.
REPLACE wiper motor.
Place ignition in RUN or ACC and

wipers to HI. Connect a fused
jumper from PPL (92) wire at
pulse wiper module connector
C207 to ground.
Connect a fused jumper from PPL

(92) wire at pulse wiper switch
ACTION
LOCATE and REPAIR open in PPL

(92) wire between wiper motor
connector C188 and pulse wiper
module connector C207. If no
open is found, REPLACE wiper
motor.
Wiper motor runs.
GO to step 2.

switch connector C204 and pulse
wiper module connector C207. If
no open is found, REPLACE pulse
wiper control module.
Wiper motor runs.
REPLACE wiper, washer switch.
WIPERS DO NOT OPERATE IN LO OR DE LAY
1.
2.
CHECK condition of WIPER fuse. If fuse is in good
condition, use the following diagnostic procedure.
RESULT
TEST
DIAGNOSIS WINDSHIELD WIPERS AND

WASHERS (PULSE)
PRELIMINARY CHECKS:
Connect a fused jumper from BLK

(150) wire at pulse wiper module
TEST
1.
When the Washer Switch is depressed, voltage is

applied to the Solid-State Control Board. The Control
Board supplies a ground to the washer motor through
the PNK (94) wire. It also starts the wiper cycle through
the low speed brushes of the Wiper Motor. The washer
continues to run as long as the switch is held down.
The Solid-State Control Board keeps the wipers on for
approximately six seconds after the washer goes off. If
the washer is switched on during the PULSE operation,
the wipers run in low speed for six seconds. The wash
cycle is completed before the wipers return to the
delayed pulse operation.

turn wipers to HI. Connect a test
lamp from WHT (93) wire at wiper
motor connector C188 to ground.
ACTION
WIPERS DO NOT OPERATE IN HI
WASHER
HIGH SPEED
RESULT

wipers to LO. Connect a fused
jumper from GRA (91) wire at
pulse wiper module connector
C207 to ground.
Connect a fused jumper from GRA

(91) wire at wiper switch
RESULT
ACTION
LOCATE and REPAIR open in GRA

open is found, REPLACE wiper
motor.
Wiper motor runs.
GO to step 2.

switch connector C204 and pulse
wiper module connector C207. If
no open is found, REPLACE pulse
wiper control module.
Wiper motor runs.
REPLACE pulse wiper/washer

switch.
WASHER MOTOR DOES NOT OPERATE

TEST
1.
2.
3.
4.
5.
ACTION
RESULT

WHT (93) wire between washer
pump connector C187 and fuse
block.
Test lamp lights.
GO to step 2.
Connect a test lamp from WHT

(93) wire to PNK (94) wire at
washer pump connector C187.
Test lamp lights.
REPLACE washer pump.
GO to step 3.
Connect a fused jumper from PNK

(94) wire at pulse wiper control
module connector C207 to
ground.
Washer motor does not pump.
LOCATE and REPAIR open in PNK

(94) wire between washer pump
control module connector C207.
Washer motor pumps.
GO to step 4.

control module connector C207
and pulse wiper switch connector
C204.
Washer motor pumps.
GO to step 5.
REPLACE wiper switch.
Washer motor pumps.

(150) wire between wiper switch
connector switch and ground
G200.
Place ignition to RUN or ACC and

pulse wiper/washer switch to
WASH. Connect a test lamp from
WHT (93) wire at washer pump
Connect fusible jumper from PNK

Connect a fusible jumper from

BLK (150) wire at wiper switch
WASHER MOTOR DOES NOT SHUT OFF

TEST
1.
2.
RESULT
ACTION

wiper switch to WASH.
Disconnect wiper switch connector
C204.
Washer motor stops pumping.
REPLACE wiper switch.
Washer motor pumps.
GO to step 2.
Disconnect wiper control module

connector C207.
REPLACE pulse wiper control

module.
Washer motor pumps.

LOCATE and REPAIR short to
ground in PNK (94) wire between
pulse wiper control module
connector C207 and washer pump
connector C187.
WINDSHIELD WIPERS AND WASHERS A-51

PULSE
HOT IN ACCY OR RUN
193-.8 WHT I
WIPER
25 AMP
193-.S WHT I
WINDSHIELD
WIPER
MOTOR
C188
8917544
PULSE WIPER
CONTROL MODULE
C189
8917548
WINDSHIELD
WASHER
PUMP
l/P
A-52 WINDSHIELD WIPERS AND WASHERS

PULSE
: 94
29
15
39
14
33
12
93
11
: 18
120
: 24
30
919 I1n
420 440
439 806
39
_J
m
o
g
S201
(SEE PAGE 17)
PULSE WIPER,
WASHER SWITCH
(COLUMN MOUNTED)
CIRCUIT OPERATION
DIAGNOSIS - START AND CHARGE

PRELIMINARY CHECKS:
START
When the Ignition Switch is moved to the START
position, battery voltage is applied to the Starter
Solenoid. Both solenoid windings are energized. The
circuit through the Pull-In Winding is completed to
ground through the Starter Motor. The windings work
together magnetically to pull in and hold in the Plunger.
The Plunger moves the Shift Lever. This action causes
the Starter Drive Assembly to rotate as it engages the
Flywheel ring gear on the engine. At the same time, the
Plunger also closes the solenoid switch contacts in the
Starter Solenoid. Full battery voltage is applied directly
to the Starter Motor and it cranks the engine.
Drive Assembly to disengage and Solenoid Switch

contacts to open simultaneously. As soon as the
contacts open, the starter circuit is turned off.
As soon as the Solenoid Switch contacts close,

voltage is no longer applied through the Pull-In Winding,
since battery voltage is applied to both ends of the
windings. The Hold-ln Winding remains energized, and
its magnetic field is strong enough to hold the Plunger,
Shift Lever, and Drive Assembly Solenoid Switch
contacts in place to continue cranking the engine.
This Generators regulator uses digital techniques to

supply the Rotor current and thereby control the output
voltage. The Rotor current is proportional to the width of
the electrical pulses supplied to it by the Regulator.
When the Ignition Switch is placed in RUN, narrow width
pulses are supplied to the Rotor, creating a weak
magnetic field.
When the engine is started, the
Regulator senses Generator rotation by detecting AC
voltage at the Stator through an internal wire. Once the
engine is running the Regulator varies the field current
by controlling the pulse width. This regulates the
Generator output voltage for proper battery charging and
electrical system operation.
When the Ignition Switch is released from the START

position, battery voltage is removed from the PPL (6) wire
and the junction of the two windings. Voltage is applied
from the Motor contacts through both windings to
ground at the end of the Hold-ln Winding. However, the
voltage applied to the Pull-In Windings is now opposing
the voltage applied when the winding was first energized.
The magnetic fields of the Pull-In and Hold-ln Windings
now oppose one another. This action of the windings,
with the help of the Return Spring, causes the Starter
Turn headlamps and dome lamps ON and place

ignition in START. If lamps go dim or go out, check
battery for correct charge.
If battery charge is
CHARGE
The Generator provides voltage to operate the
vehicles electrical system and to charge its Battery. A
magnetic field is created when current flows through the
Rotor. This field rotates as the Rotor is driven by the
engine, creating an AC voltage in the Stator windings.
The AC voltage is converted to DC by the rectified bridge
and is supplied to the electrical system at the Battery
terminal.
insufficient, refer to Section 6D of the 1991 R/V,P Light

Truck Service Manual. If battery has sufficient charge,
use the following procedures.
ENGINE DOES NOT CRANK AND STARTER SOLENOID DOES NOT CLICK
TEST
1.
RESULT
ACTION
Place transmission in PARK (auto)

or depress clutch pedal for man.
trans. Connect a voltmeter from
PPL (6) wire at starter solenoid to
ground. Turn ignition switch to
START position.
Battery voltage.
GO to step 2.
No voltage.
GO to step 3 for man. trans. GO

to step 5 for auto, trans.
Connect a voltmeter from PPL (6)

wire to starter mounting bolts.
Battery voltage.
REPLACE starter solenoid
Less than battery voltage.
CLEAN starter motor mounting

bolts, starter motor, and mounting
surface.
Disconnect clutch start switch

connector C237. Connect
voltmeter from YEL (5) wire at
clutch start switch connector C237
to ground. Ignition switch must
be in START position.
Battery voltage.
GO to step 4.
No voltage.

(5) wire between the clutch start
switch and the ignition switch. If
wire is in good condition, GO to
step 5.
Depress clutch and put

transmission in neutral. Apply
parking brake. Connect a fused
jumper from YEL (5) to PPL (6) at
clutch start switch connector
C237. Turn ignition switch to
START position.
Engine cranks.
REPLACE clutch start switch.
Engine does not crank.

(6) wire from clutch start switch to
starter solenoid.
5. With ignition switch OFF, connect

a voltmeter from RED (2) wire at
ignition switch connector C209 to
ground. Repeat step except
connect from RED (3) wire at
ignition switch connector C210 to
ground.
Battery voltage.
REPLACE ignition switch.
No voltage.
REPLACE and REPAIR open in

RED (2) wires and fusible link at
junction block.
2.
3.
4.
START AND CHARGE A-53
STARTER SOLENOID CL CKS, ENGINE DOES NOT CRANK OR CRANKS SLOWLY
1.
2.
3.
ACTION
RESULT
TEST
Remove CRANK and ECM 1 fuses.
Connect a voltmeter to positive
and negative battery terminals.
Turn ignition switch to
START.
Voltage reading greater than 9.6

volts after 15 seconds cranking.
GO to step 2.
Voltage less than 9.6 volts after 15

seconds cranking.
PERFORM a Battery Load Test.

Refer to Section 6D in 1991 R/V, P
Light Truck Service Manual.
Connect a voltmeter from negative

battery terminal to engine block.
Less than .5 volts.
GO to step 3.
More than .5 volts.
REPLACE negative battery cable.
Less than .5 volts.
REPAIR starter motor.
More than .5 volts.
REPLACE positive battery cable.
Connect a voltmeter from positive

battery terminal to starter solenoid
terminal at BLK (2) wire.
B A T T E R Y IS U N D ER C H A R G E D O R O V ER C H A R G E D
RESULT
TEST
1.
2.
Connect voltmeter from RED (2)

wire at generator to ground.
Reconnect generator connector

C106 and terminal. Have all
accessories turned off and engine
running at fast idle. Connect
voltmeter from battery terminal on
generator to ground.
ACTION
Battery voltage.
GO to step 2.
No voltage.

(2) wire and fusible link from
generator to junction block.
Reading of 13-16 volts.
PERFORM Generator Bench Test.

Refer to Section 6D in the 1991
R/V, P Light Truck Service Manual.
Reading of less than or greater

than 13-16 volts.
REPAIR generator.
A-54 START AND CHARGE
RPO CODES
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, ViN K
M20 - MAN TRANS, 4-SPD
C203
12066261
2-8.0 BLK/RED
START AND CHARGE A-55

GASOLINE ENGINE
RPO CODES
LH 6. 6.2L (378 CU. IN.) V8 DIESEL ENGINE VIN C
LL4 - 6.2L (378 CU. IN.) V8 DIESEL ENGINE VIN J
M20 - MANUAL 4-SPEED TRANSMISSION
MT1 - AUTOMATIC 3-SPEED TRANSMISSION
E D fp E I
OS] QT)
firiU j 4i91
H r iQ O
I 25-.8 BRN |
-f~
s is
J O O
ODnCD
m llD D
LH
BATTERY
C203
12066261
STARTER MOTOR
o
o
l/P CLUSTER
CONNECTOR
(SEE PAGE 103)
l/p
ID
94
29
15
39
14
33
12
93
11
18
24
30
5 }
3
1
39
L
3]
r
820
4 )
508
25
50
35
||
93
97
439
91
92
V
12020184
C100
12045896
C106
START
r----- N
*
'!
i-----
SHEET
RIGHT BANK
LEFT BANK
METAL
GLOW PLUGS GLOW PLUGS
GROUND
GROUND
GROUND
G111
G114
G113
>j
/f
* ' !
-m
a -i
Q:
GLOW PLUGS
CONTROLLER
(SEE PAGE 84)
vS= -< )
2-3.0 BLU
(FUSIBLE LINK)
I 2-.8 BLK/RED I
| 2-.8 RED
eT c)
CLUTCH
CLUTCI
START
SWITCH
(MAN TRANS ONLY)
A-56 START AND CHARGE

DIESEL ENGINE
RPO CODES
NA4 - EMISSION SYSTEM, ABOVE 8500 GVW
CIRCUIT WIRE
SIZE
NO.
COLOR
CAVITY
DESCRIPTION
465
.8
DK G R N /W H T
435
.8
GRA
A1
A2
A3
A4
419
439
*4 2 2
.8
.8
.8
B R N /W H T
PNK/BLK
TAN/BLK
A5
A6
A7
452
450
.8
.8
BLK
BLK/W HT
A11
A12
FUEL P U M P RELAY DRIVE

N O T USED
N O T USED
EGR S O LEN O ID (L 0 5 )
EVRV (L 0 5 W ITH NA4, L 0 5
CAN ADIAN A N D L19)
SYSTEM C H E C K LAMP
12V IG N ITIO N FUSED
T O R Q U E C O N V E R TE R C LU TC H
(M D8)
SER IA L DATA
A SSEM BLY LINE D IA G N O S TIC LINK
SPEED S EN SO R (L 0 5 , L19
W IT H O U T RW AL)
DRAC M O D U LE (L 0 5 , L19
W ITH RW AL)
5V R E TU R N B
SYSTEM R ETURN
440
120
453
.8
.8
.8
ORN
TA N /W H T
BLK/RED
430
.8
PPL/W HT
485
59
.8
.8
BLK
DK G RN
*4 3 4
.5
O RN /B LK
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
12V BATTERY FUSED

ELEC FUEL PU M P FUSED FEED
DIS TR IB U TO R REF LOW
N O T USED
DIS TR IB U TO R REF H IG H
N O T USED
SPA RK RETARD C O N TR O L
AIR C O N D ITIO N
N O T USED
PARK /N EU TR A L S W ITC H
N O T USED
N O T USED
461
451
437
.8
.8
.8
ORN
W H T/B LK
BRN
A8
A9
A10
*A U T O TRA NS ONLY
ELEC TR O N IC C O N TR O L M O DULE C O N N E C T O R
CIRCUIT WIRE
SIZE
NO.
COLOR
CAVITY
G R N /B LK
G R N /W H T
B L U /W H T
BLU/BLK
BLU
C1
C2
C3
C4
C5
C6
C7
444
443
441
4 42
*4 46
.8
.8
.8
.8
.8
LT
LT
LT
LT
LT
806
410
432
.8
.8
.8
PPL7WHT
YEL
LT G RN
417
416
.8
.8
DK BLU
GRA
440
.8
O RN
551
455
.8
.8
TA N /W H T
PPL
423
4 24
413
412
.8
.8
.8
.8
WHT
TA N /B L K
TAN
PPL
468
.8
DK GRN
DESCRIPTION
C8
C9
C 10
C11
C 12
C 13
C 14
C 15
C 16
N O T USED
N O T USED
S TEPPER C O IL B LO W
S TEPPER C O IL B H IG H
S TEPPER C O IL A H IG H
S TEPPER C O IL A LO W
A /C C O N T R O L (4TH GEAR
D IS C R E TE (L05 W IT H M D 8)
N O T USED
C R A N K SIG N A L (FU SED)
C O O L A N T TE M P E R A TU R E
M AP S E N S O R
N O T USED
TP S E N S O R
5V S E N S O R R E FE R E N C E
N O T USED
12V BATTERY FUSED
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
SYSTEM G R O U N D
5V R E TU R N A
N O T USED
HEI S PA R K T IM IN G
HEI BYPASS
OXYG EN S E N S O R LO W (G R O U N D )
OXYG EN S E N S O R HIG H
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
IN JE C TO R B (2) DRIVE
N O T USED
IN JE C TO R A (1) DRIVE
467
.8
DK BLU
*A U T O TR A NS O NLY
E LE C TR O N IC C O N T R O L M O D U LE C O N N E C T O R
ELECTRONIC CONTROL MODULE PINOUTS A-57

GASOLINE ENGINE
43S-.8 PNK/BLKI
ECM B
10 AMP
A-58
ELECTRONIC CONTROL MODULE (ECM)

INPUTS - GASOLINE ENGINE
RPO CODES
439-.8 PNK/BLK
L19 - ENGINE 7.4L (454 CID) V8 GAS ENGINE, VIN N
I419-.8 BRN/WHT I
SERVICE
ENGINE
SOON
LAMP
(SEE PAGE 104)
ECM
CONNECTORS
CRANK SIGNAL
(FUSED)
(SEE PAGE 55)
ALDL
C206
12020043
ENGINE
GROUND
G110
ELECTRONIC CONTROL MODULE (ECM) A-59

v A A W A A /W W f
<
HOT AT ALL TIMES <
J,W W V W V W V S
422-. 8 TAN/BLK I
439-.S PNK/BLK .
ECM B
10 AMP
EVRV
(L19)
ENGINE
GROUND
G115
A-60

OUTPUTS - GASOLINE ENGINE
RPO CODES
119 - ENGINE, 7.4L (454 CID) V8 GAS ENGINE, VIN N
444-.S LT GRN/BLK |
| 439-.S PNK/BLK
I 440-.8 ORN
820-.8 PPL/WHT
HANDLING MODULE
12064770
E
w m '
j i
^ 4 1 9 |4 5 0 | 451 | 4 3 7 |4 6 l]
SERVICE ENGINE
|434|822] 821|696| 33
J
12064769
SOON LAMP
(SEE PAGE 105)
A 422-.S TAN/BLK

A-61
C O LO R
CAVITY
D E S C R IP T IO N
A1
A2
A3
A4
A5
A6
M AP S E N S O R
TP S E N S O R
C O O L A N T T E M P E R A T U R E S W ITC H
N O T USED
N O T USED
A S S EM B LY LINE D IA G N O S T IC LINK
CONNECTOR
N O T USED
E N G IN E SPE E D S E N S O R
V SS FR O M D R A C M O D U L E
A S S EM B LY LINE D IA G N O S T IC LIN K
CONNECTOR
N O T USED
TP S E N S O R A N D M AP S N E S O R
5V R E FE R E N C E
C IR C U IT
NO.
W IR E
SIZE
4 32
4 17
4 10
.8
.8
.8
LT G RN
D K BLU
YEL
451
.8
W H T/B LK
121
4 37
4 88
.8
.8
.8
W HT
BRN
LT G RN
A7
A8
A9
A 10
4 16
.8
G RA
A11
A 12
B1
B2
B3
B4
B5
B6
B7
B8
B9
B 10
B11
B12
NOT
NOT
NOT
NOT
NOT
NOT
NOT
NOT
NOT
NOT
NOT
NOT
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
E LE C TR O N IC C O N T R O L M O D U L E C O N N E C T O R
CIRCUIT WIRE
SIZE
NO.
COLOR
452
150
.8
.8
BLK
BLK
*4 2 2
421
.8
.8
T A N /B L K
D K B LU /W H T
435
697
538
.5
.8
.8
GRA
LT BLU
D K G RN
439
.8
P N K /B LK
440
.8
ORN
CAVITY
DESCRIPTION
C7
C8
C9
C 10
C11
C12
C 13
C 14
C 15
C 16
SYSTEM G RO UND
SYSTEM G RO UND
NOT USED
NOT USED
TO RQ UE CO N VER TER C LU TC H
COLD ADV A N C E /G LO W PLUG
TIM ER IN H IB IT RELAY
NOT USED
NOT USED
NOT USED
EGR DIAG NO STIC C O N N E C T O R
EGR DUM P S O LEN O ID
EPR VALVE SO LEN O ID
NOT USED
12V IG NITIO N FUSED
NOT USED
12V BATTERY FUSED
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
NOT
NOT
NOT
NOT
NOT
NOT
NOT
NO T
NOT
NOT
NOT
NOT
NOT
NOT
NOT
NOT
C1
C2
C3
C4
C5
C6
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
USED
*A U T O TR A NS O NLY
E LE C T R O N IC C O N T R O L M O D U L E C O N N E C TO R
A-62 ELECTRONIC CONTROL MODULE PINOUTS

DIESEL ENGINE
GAGE/IDLE
20 AMP
39-.8 PNK/BLK
531-.8 LT GRN/BLK |
COLD
ADVANCE
CONTROL
1531
A
531-.8 LT GRN/BLK
S121
LL
C167
2977253
538-.5 DK GRN I
421-.8 DK BLU/WHT
1397-.8 LT BLU
I
)7 -.8 LT BLU I
------------------------ 1 -
150-.8 BLK I
150-1.0 BLK
j q
C193
S122
150-. 8 BLK ;
(SEE PAGE 18)

I 531-.8LT GRN/BLK V
697 .8 LT BLU I
------------------------------i -
EGR DUMP
39-.s p n k /b lk
m m r
435-.8 GRA
EGR VALVE
J H T
j^ m
39-.S PNK/BLK
* i^ r
v
?
z
Q.
CO
C194
ERR VALVE
39
/ T \
12015?Z6
a
39-.8 p n k /b lk
mht
jm m
53S-.8 DK GRN
i =
CD
CD
CD
S?
CL
CD
i'>
CL
CO
03
vj
J |r
39-.S PNK/BLK
a.
CO
538-.8 DK GRN
V^/
WATER
IN FUEL
SENSOR
538 )
(SEE PAGE 87)
S109
k
_____
m aw
39-.s p n k /b lk
COLD ADVANCE
FAST IDLE
TEMPERATURE SWITCH
(SEE PAGE 87)
531-.8LT GRN/BLK
ENGINE
GROUND
A-64 ELECTRONIC CONTROL MODULE (ECM)

OUTPUTS DIESEL ENGINE
GLOW PLUG
CONTROLLER
150-.8 BLK
, l
439-.S PNK/BLK
439-.S PNK/BLK I
ELECTRONIC CONTROL MODULE (ECM) A-65

OUTPUTS DIESEL ENGINES
CIRCUIT WIRE
SIZE
NO.
COLOR
CIRCUIT WIRE
NO.
SIZE
COLOR
CAVITY
GRA
PPL
FU E L P U M P RELAY D RIVE
S O LE N O ID B D R IV E R
S O LE N O ID A D R IV E R
T C C D RIVER
N O T USED
N O T USED
S YS TE M C H E C K LAM P
N O T USED
N O T USED
N O T US E D
EVR V S O LE N O ID
BRAKE S IG N A L
439
450
551
4 16
417
441
442
4 44
443
432
461
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
P N K /B LK
B LK /W H T
T A N /W H T
G RA
D K BLU
LT B LU /W H T
LT B LU/BLK
LT G R N /B L K
LT G R N /W H T
LT G RN
ORN
RED
D K BLU
PNK
LT BLU
D K G R N /Y EL
LT B LU /W H T
B LK /R ED
D K B LU /W H T
G R A /R E D
BRN
D K G RN
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B 12
N O T USED
P R E S S U R E S W ITC H M A N IF O L D C
P R E SS U R E S W ITC H M A N IF O L D B
P R E SS U R E S W IT C H M A N IF O LD A
O U T P U T S P E E D H IG H
O U T P U T S P E E D LO W
FO R C E M O T O R LO W
FO R C E M O T O R H IG H
IN P U T S PE E D H IG H
IN P U T S PE E D LO W
V SS (W /O RW AL) D R A C (W / RW AL)
AIR C O N D IT IO N IN G
413
412
468
467
.8
.8
.8
.8
TAN
PPL
D K G RN
D K BLU
440
455
452
474
4 96
451
1 20
.8
.8
.8
.8
.8
.8
.8
ORN
PPL
BLK
GRA
D K BLU
W H T/B LK
T A N /W H T
D2
D3
D4
D5
D6
D7
WHT
TA N /B LK
BLK/RED
P P L /W H T
BLK/YEL
YEL
D8
D9
D 10
D11
D 12
D 13
D 14
D 15
D 16
.8
.8
.8
.8
D K G R N /W H T
YEL/B LK
LT G R N
T A N /B L K
419
.8
B R N /W H T
435
4 20
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
DESCRIPTION
A1
A2
A3
A4
A5
A6
A7
A8
A9
A 10
A11
A 12
4 65
1223
1222
422
1226
1225
1224
1232
1233
1229
1228
1230
1231
4 37
59
CAVITY
P O W E R TR A IN C O N T R O L M O D U L E C O N N E C T O R
423
424
4 53
4 30
1 22 7
410
.8
.8
.8
.8
.8
.8
C1
C2
C3
C4
C5
C6
C7
C8
C9
C 10
C11
C 12
C13
C14
C15
C16
D1
DESCRIPTION
12V IG N ITIO N FUSED
SYSTEM G R O U N D
SYSTEM G R O U N D
5V SEN SO R R E FE R E N C E
TPS
STEPPER C O IL A H IG H
STEPPER C O IL A LO W
STEPPER C O IL B LO W
STEPPER C O IL B H IG H
MAP
SERIAL DATA
N O T USED
OXYGEN SEN SO R G R O U N D
OXYGEN SEN SO R
INJEC TO R B DRIVER
INJEC TO R A DRIVER
12V BATTERY FUSED
S ENSO R G R O U N D
SEN SO R G R O U N D
5V SEN SO R RE FE R E N C E
K N O C K SIGNAL
ALDL
ELECTRIC FUEL P U M P FEED
FUSED
N O T USED
NO T USED
NO T USED
HEI SPA RK T IM IN G
HEI BYPASS
DISTRIBUTO R R E FE R E N C E LO W
DISTRIBUTO R R E FE R E N C E H IG H
TR A N SM IS S IO N TE M P E R A TU R E
CO O LANT TE M P E R A TU R E
P O W E R TR A IN C O N T R O L M O D U LE C O N N E C TO R
A-66 POWERTRAIN CONTROL MODULE PINOUTS
CIRCUIT WIRE
SIZE
NO.
COLOR
1 224
1 225
1 226
1 223
1 22 2
451
.8
.8
.8
.8
.8
.8
PNK
DK BLU
RED
YEL/BLK
LT G R N
W H T/B LK
440
.8
O RN
59
4 20
4 22
488
1 23 3
1232
.8
.8
.8
.8
.8
.8
DK G R N
PPL/BLK
TA N /B LK
LT G R N
DK G R N /Y E L
LT BLU
CAVITY
DESCRIPTION
A1
A2
A3
A4
A5
A6
A7
A8
A9
A 10
A11
A 12
N O T USED
N O T USED
P R E SS U R E S W ITC H M A N IF O LD A
P R E SS U R E S W ITC H M A N IF O LD B
P R E SS U R E S W ITC H M A N IF O LD C
S O LE N O ID B D R IV E R
S O LE N O ID A DR IVER
ALDL
N O T USED
N O T USED
N O T USED
12V BATTERY FUSED
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
N O T USED
N O T USED
A IR C O N D IT IO N IN G
BRAKE S IG N A L
TCC
N O T USED
N O T USED
N O T USED
N O T USED
SER IA L DATA
O U TP U T SPE E D S E N S O R LO W
O U TP U T SPE E D S E N S O R H IG H
CIRCUIT WIRE
SIZE
NO.
150
150
4 52
4 16
.8
.8
.8
.8
COLOR
BLK
BLK
BLK
G RA
CAVITY
C1
C2
C3
C4
C5
C6
1 22 8
439
.8
.8
R E D /B LK
P N K /B LK
4 37
1231
1232
.8
.8
.8
BRN
DK B LU /W H T
LT BLU
121
452
4 17
.8
.8
.8
WHT
BLK
D K BLU
1 227
4 32
.8
.8
BLK/YEL
LT G RN
1229
.8
LT B LU /W H T
TR A N S M IS S IO N C O N T R O L M O D U L E C O N N E C T O R
DESCRIPTION
C7
C8
C9
C 10
C11
C 12
C 13
C 14
C 15
C 16
SYSTEM G R O U N D
SYSTEM G R O U N D
SENSOR GROUND
5V S E N S O R R E FE R E N C E
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
N O T USED
F O R C E M O T O R H IG H
12V IG N IT IO N FUSED
D1
D2
D3
D4
D5
D6
D7
D8
D9
D 10
D11
D12
D13
D14
D 15
D 16
N O T USED
VSS
IN P U T S PE E D LO W
IN P U T SPE E D H IG H
N O T USED
E N G IN E SPEED
SENSOR GROUND
TP S E N S O R
N O T USED
N O T USED
N O T USED
T R A N S M IS S IO N TE M P E R A TU R E
M AP S E N S O R
N O T USED
N O T USED
FO R C E M O T O R H IG H
T R A N S M IS S IO N C O N T R O L M O D U LE C O N N E C T O R
TRANSMISSION CONTROL MODULE (TCM) A-67

DIESEL ENGINES
WSAAAW^WWVW
W W W W W W \yf
S
HOT AT ALL TIMES <
HOT IN START OR RUN ^
W w w vvw s
ECM B
10 AMP
COOLANT
TEMPERATURE
SENSOR
OXYGEN
SENSOR
OUTPUT
SPEED
SENSOR
(4WD ONLY)
INPUT
SPEED
SENSOR
A-68 POWERTRAIN CONTROL MODULE (PCM)

INPUTS - GASOLINE ENGINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
G110
ENGINE
GROUND
TRANSMISSION
ENGINE
GROUND
G115
iv -
jm
^
* r
m m r m m ar ^m w
m tm '
jm m r
jm m r M m m r
450-.8 b lk / w h t '
551 -.8 t a n / w h t
mmmr
m m r i
A/C
(SEE PAGE 94)
POWERTRAIN CONTROL MODULE (PCM) A-69

INPUTS - GASOLINE ENGINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
439-.8 PNK/BLX I
ECM B
10 AMP
EVRV
ELECTRONIC
SPARK
TIMING
INJ-2
INJ-1
FUEL PUMP
OIL PRESS
SWITCH
FUEL
PUMP
RELAY
C100
12020183
I 440-1.0 ORN
A-70 POWERTRAIN CONTROL MODULE (PCM)

OUTPUTS GASOLINE ENGINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
k /W V W W W 'M
<
k /W W W W W
HOT AT ALL TIMES <
I a A/WWWWVn
ECM B
10 AMP
, WvVVWWVVWVW
HOT IN START >
W W V W W V ' ECM 1 CRANK

3 AMP
S HOT IN START OR RUN <
Ir
'W V W W V W V V n
439-.8 PNK/BLK
439-.8 PNK/BLK I
1440*1.0 ORN I
TP SENSOR
r439*.8 PNK/BLK
r.
1223-.8 YEL/BLK
1440*1.0 ORN
439-.8 PNK/BLK |
_ c
11226-.8 RED I
11225-.8 DK BLU
-452
417
1 1224- 8 P N K H
1452-.S BLK I
1 2 1 -.8 W H T H I
I417-.8 DK BLU
1452-.8 BLK I
1416-.8 GRA I
416
| 420-.8 PPL/BLK m
C134
12052843
422-.S TAN/BLK r
I 417-.8 DK B L U M
1229-.8 LT BLU/WHT I
^ 1233-.8 DK GRN/YEL I
11232-.8 LT BLU I
11222-.8 LT GRN I
I 416-.8 GRA I
I 452- 8 BLK I
S122
(SEE PAGE 18)
| 150-.8 BLK |
1230
I 150-.8 BLK I
'
1227-.8 BLK/YEL
-1231
M230-.8 DK BLU/WHT i
C173
12078084
INPUT
SPEED
SENSOR
1230-.8 GRA/RED M
1231-.8 DK BLU/WHT F
11231-.8 GRA/REDBT
r
452
1228-.8 RED/BLK
A
I452-.8 BLK I
0
121
1121-.8 W H Tl
LU
C175
12015792
ENGINE
SPEED
SENSOR
3
m
H
-j
5
O
*
Q
CO
j I
1233
11233-.8 DK GRN/YEL
-1232
OUTPUT
SPEED
SENSOR
C172
12084690
11232-.8 LT BLU I
TRANSMISSION
CONNECTOR
12084435
A-72 TRANSMISSION CONTROL MODULE (TCM)

DIESEL ENGINE
439-.S PNK/BLK
| i-139 h r
Ul
I 92 I 91 I
C100
12020183
ENGINE
GROUND
G110
W sM AW M VW Vf
RPO CODES
S HOT IN START OR RUN Z
"w w v w v w w v v a *
GAGE/IDLE
20 AMP
GT101
12064740
422-.8 TAN/BLK
446-.S LT BLU
i
B
01
A
1 14651
D 1 2
14531 3
1------ 1 4
|430l 5
L
1 6
f4 8 5 l 7
S O 8
1
1 9
[434110
BRAKE
SWITCH
1'" 1
|___ |
P35l
14191
14 39 1
[4 2 2 *
f46T1
f4 5 fl
|4 3 7|
(M D 8 ONLY)
z
CL
I
I 11 I452I
I___ | 12 [450J
ECM
CONNECTORS
______i________ i
(SEE PAGE 116)
139-.8 PNK/BLK
S202
(SEE PAGE 27)
RWAL
DIODE ARRAY
MODULE
I -
01
CN to
*
ILJ
C215
G
C203
12020043
(
I
ALDL
: 18
120
: 24
30
9 I
19 |
140
2
39
31
3>
r
50
436
93
97
91
92
35
120
2
422 V
6
o
o
A-74 TRANSMISSION CONVERTER CLUTCH (TCC) DETENT SOLENOID

5.7L V8 GASOLINE ENGINE
I 422-.S TAN/BLK I
O
to
*
<D
(*)
*
12045575
(SEE PAGE 116)
420 440
439 806
YAAAWVW
C216
12047946
hot in run <

(SEE PAGE 103)
Tw w vw *
HTR A/C
25 AMP
(11/629)
RPO CODES
I/P CLUSTER
CONNECTOR
ECM
CONNECTOR
I 440 l
[ ISO 1
1 1 4651
2 n n
1453 1 3 n
4 14351
I 50-2.0 BRN |
DRAC
[430'1 5 1 419<
E 14391
50-2.0 BRN I
50-2.0 BRN I
HTR A/C SELECTOR

CONTROL SWITCH
(SEE PAGE 94)
RWAL MODULE
(SEE PAGE 116)
DEncm
1485 1 7 14221
[ 59 1 B 1 4611
[ = 9 1451 1
f<34l 10 1 4371
1 1 U t452l
t = n 12 1 4S0l
n H
( 419/489/1234
<
<
1592]ui z371
0
s
"69
Ui
HDnCim
d Ud d
H
D
.
5
c
t-
_i
IX
<z
2_.
z
z
UI
8
CO f
0
Ui
0
Ui
Q.
Q.
(/)
a.
Q 4
UJ Q
LU O
(0
Ui
Ui
UI
Ui
O
Z
5 w
Ui
ui
0
I 50-1.0 BRN I
VSS
UJ
>
S211
Ui
>
O
AC
0
Ui
>
IT
*
C289
12066130
822-.8 LT GRN/BLK I
A 821-.8 PPL/WHT
SDH
GT101
12064740
I 437-.S BRN
RWAL CONTROLLER
(SEE PAGE 116)
I 696*.8 WHT H i
i (L05 WITH M20)

C200
CRUISE CONTROL
(SEE PAGE 124)
[
150-.8 BLK (LL4 ONLY)
fc
S215 (SEE PAGE 17)
I ______
CD
422
696 461
S122
(SEE PAGE 116)
436 j c
____ 436
150-.8 BLK
____ 451
ALDL CONNECTOR
C206
12020043
CD
C100
12020183
ENGINE
GROUND
G110
450/151)
^ (450/151
mgr ^450-.8
45o-.seBLK/WHT *
\
FUEL PUMP
CYCLE RELAY
(SEE PAGE 79)
ENGINE
GROUND
G115
DIGITAL RATIO ADAPTER CONTROLLER (DRAC) MODULE A-75
RPO CODES
yvwwwwwvv/
<
GAGE/IDLE
20 AMP
^w w w vw w w
HOT IN START OR RUN <
m w v v w v v v w ^ ECM 1
S HOT IN START OR RUN ^
^MVVNAVWWVÂ
10 AMP
I 439-.S PNK/BLK
439-.8 PNK/BLK I
f 39-.S PNK/BLK
o |
423-.8 WHT I
430-.8 PPL/WHTI
424-.S TAN/WHT
453-.B PPL/WHT
C133
GT101
424-.8 TAN/WHT
12064740
121-.8 WHT
3-3.0 PNK
TACHOMETER ?
139-.8 PNK/BLK
EVRV SOLENOID (L19)

IGNITION
SWITCH
(SEE PAGE 11)
(SEE PAGE 60)

AIR SWITCH SOLENOID
(UTILITY ONLY)
(SEE PAGE 60)
EGR SOLENOID
(L05 ONLY)
(SEE PAGE 60)
439-.Q PNK/BLK
439-.B PNK/BLK I
A-76 IGNITION
GASOLINE ENGINE
HYBRID FUNCTION ESC

(SEE PAGE 58)
I 439-.8 PNK/BLK I
ECM 1
10 AMP
ECM
CONNECTORS
THROTTLE BODY INJECTOR A-77

GASOLINE ENGINE
RPO CODES
440-1.0 ORN I
vAW AM AM M
<

HOT AT ALL TIMES <

. HOT IN START O R RUN
>VVVW\AMMN
39-.8 PNK/BLK*
ECM
CONNECTOR
ECM B
10 AMP
GAGE/IDLE
20 AMP
iv n v r
FUEL PUMP
CYCLE RELAY
(HOT FUEL HANDLING
MODULE)
A
1465 Ip
r f l2 0 l 2 1------ 1
14531 3 L Z 3
4 [435]
[4301 5 14191
6 1439]
f4 8 5 l 7 E H ]
1 59 1 8 J461 |
[~ 1 9 I 451J
[434110 14371
IDLER AIR
CONTROL
FRAME
(LI 9)
IGNmON SW
FUEL PUMP FUSED
GROUND
ito G E l C Z 3 e
| cQ D
b C D i | g
450
AI 12 I i
I 11 i 452J
I___ I 12 I 450 h
120-.8 GRA (SUBURBAN ONLY)

120-1.0 TAN/WHT
JM
Ih
C194
12045688
C161
12078082
ALDL
(SEE PAGE 59)
J 450*.8 BLK/WHT.
I 440-.8 ORN I
I 465-.8 DK GRN/WHT ,
S215
(SEE PAGE 79)
120-.8 GRA I
IDLE AIR
CONTROL
ACTUATOR
441-.8 LT BLU/WHT |
441-.8 LT BLU/WHT I
443-.8 LT GRN/WHT"
443-.S LT GRN/WHT
442-.8 LT BLU/BLK A
442-.8 LT BLU/BLK
444-.S LT GRN/BLK I
444-.8 LT GRN/BLK .
0-05)
STEPPER
MOTOR
DRAC
(SEE PAGE 75)
* 450-.8 BLK/WHT
551-.8 TAN/WHT
441
ENGINE
GT100
12064740
442
fYYY^
I..
413-.8 TAN I
443
444
: 94
29
15
39
14
33
12
806 | 439
120
140 I
93
C161
12015796
436
FUEL PUMP
OIL PRESSURE
SWITCH
422
11
J
(
50
: 18
120
: 24
30
97 1 93 |
I 420 440
439 806
9I
19 |
39
140
120
31
50
436
3rJ
35
93
97
422
91
92
GE3
*S139
C100
12020183
440-.8 ORN I
1120-1.0 G R A i
C100
12020184
ECM
CONNECTOR
FUEL GAGE
120-1.0 GRA I
C115
12065401
(SEE PAGE 108)
440-1.0 ORNI
FUEL
PUMP
PRIME
120-1.0 TAN/WH1 I
C409
12059473
RWAL
(SEEPAGE 116)
C160
2977253
ELECTRIC FUEL PUMP

FUEL GAGE SENDING UNIT
S140 .
120-1.0 TAN/WHT
30-.8 PNK I
450-.8 BLK/WHT I
C101
12020099
FUEL
PUMP
RELAY
450-.8 BLK/WHT
I v
^Jl
C148
12052287
A-78 FUEL CONTROL AND IDLE AIR CONTROL

GASOLINE ENGINE
ENGINE
GROUND O
G110
^
ENGINE
GROUND
G115
BLU OR PPL^
OR LT GRN
FRAME
GROUND
G409
3Q-.8 PNK/BLK
39-. 8 PNK/BLK
(FUEL PUMP CYCLE

RELAY HOT FUEL
HANDLING MODULE)
GAGE/IDLE
20 AMP
a
=!
________I
GROUND.-
450
IGNITION SWITCH - 4 39
FUEL PUMP FUSED - 120
GT
101
S117
(SEE PAGE 17)
o o
12064740
r ---------------------------------
I
bCZI
CI3
cziH
S T r - ' M
I O f T <~ r
l----- 1 I----- 1SI
v:
pm
^
|
^
|
------------------------------------
S139
i r
450-.8 BLK/WHT
FUEL PUMP OIL

PRESS SWITCH
(SEE PAGE 60)
l ______
C200
tar TBt
jir
c
r
_ L
12064770
120-1.0 GRA
||
120-1 .O G R A M B ^ -
l _____________
12047886
1450-.8 BLK/WHT I
r450-.8 BLK/WHT V .
I
w ------------ I -
12045688
rm
120-.8 G RAI
-t-, I
FUEL PUMP
RELAY
(SEE PAGE 60)
B
A
14401 1 14651
2I
[4531 3 C D
I
I 4 [4351
[430l 5 E H }
H \
I
I
ECM
CONNECTOR
(SEE PAGE 27)
m m
^ 1 4 5 0 - 8 BLK/WHT
\ r
(SEE PAGE 59)
?*
r- m
DRAC
^45 0 -.8 BLK/WHT i
(SEE PAGE 75)
I450-.8 BLK/WHT I
n
mO
I 11 [4521
I 12 [ 450)1
l/P
^ 4 5 0 - . 8 BLK/WHT
ALDL
I 6 [Ml
f~59~l 8 [4611
I
I 9 IW l
[4341 10 14371
_____________
^m
S215 ^ ^
CO
ELECTRIC FUEL PUMP

PARK/NEUTRAL
SWITCH
(SEE PAGE 59)
ENGINE
IS 1
i -
13
[LiJ
i T
112
1 (
i
39
1120
I3
306 | 439
140 |
35j
"1
1 6
92 | 91 |
C100
12020183
G110
ENGINE
GROUND
15
39
14
(50/130>
97 | 9 3 1
29
9
: 93
y))}DE
8g-p / 5 0 /2 5 ]
N
m
94
33
II
1 |422
Cl
31 |
| 436 | 50 |
I2
440 | 420 |
: 18
24
420 440
439 806
140
J
31
T (3 >I50
r 9735
120
93
12
11
19
91
92
450-.8 BLK/WHT
2
39
120
jm
w m
jm
39-.s p n k /b lk
3
39-.S PNK/BLK
436
_______ ___ i
FRAME
GROUND
G409
2
422
CO
v = i
120-1.0 TAN/WHT
120-.8 TAN/WHT
______________________________________________
120-.8 GRA(SUBURBAN ONLY)
\
120-.8 GRA (SUBURBAN ONLY)
WIRE COLOR
CAN BE BLU,
C100
12020184
PPL OR LT GRN
A 120-1.0 TAN/WHT d
18
24
120
30
9
19
I 30-.8 PNK I
C101
12020094
30-.5 PNK I
FUEL GAGE
(SEE PAGE 108)
I 30-.8 PNK I
HOT FUEL HANDLING A-79

GASOLINE ENGINES
39-.8 PNK/BLK
ENGINE
$___ I
GAGE/IDLE
20 AMP
o I 4S0~1 (
IG NITIO N SW
FUEL PUM P FUSED
GROUND
C I
450
B[
FUEL
PUMP
RELAY
Ie
39
39-.8 PNK/BLK
I I
)0
| H
V -------------------
39-.S PNK/BLK
39-,8 PNK/BLK
94
5*
Dk
Ml
15
14
39
33
12
93
11
420
440
439
806
39
140
120
31
m
, r
50
436
35
93
97
422
91
92
S202
(SEE PAGE 27)
l/P
I r
[/
(HOT FUEL HANDLING

MODULE)
ELECTRIC
FUEL PUMP
ASSEMBLY
(AUXILIARY
RIGHT SIDE)
30-.8 PNK *
120-1.0 TAN/WHT
120-1.0 TAN/WHT
FUEL TANK
SELECTOR
VALVE
AND METER
SWITCH
C304
FUEL GAGE
(SEE PAGE 108)
FUEL TANK
SELECTOR
SWITCH
9 2 1 -1 .0 G R A
921-1.0 GRA
921-1.0 GRA
920-1.0 TAN
920-1.0 TAN
S329
I 921-1.0 GRA IM
*| LEF
cT
rJ
p ? i
920-1.0 TAN H
930-.8 PNK/WHT
120-1.0 TAN/WHT
8
12010973
BUS
BAR
GROUND
G201
to
L*
12015792
w m m 30-. 8 PNK
VALVE
931-.8 PNK/BLK
RIGHT
C305
12020089
ELECTRIC
FUEL PUMP
(PRODUCTION
LEFT SIDE)
WIRE CAN BE
BLU, PPL OR
C203A
8911256
A-80 AUXILIARY FUEL TANK AND FUEL TANK SELECTOR SWITCH

GASOLINE ENGINE
C302
C409
12059473
FRAME
GROUND
G409
DK GRN COLOR
FRAME
GROUND
G410
15
FUEL GAGE
(SEE PAGE 108)
G201
BUS
BAR
GROUND
G410
FRAME
GROUND
r\
(Q)
(Q)
="
G409
FRAME
GROUND
AUXILIARY FUEL TANK AND FUEL TANK SELECTOR SWITCH A-81

DIESEL ENGINE
WAIT INDICATOR DOES NOT FLASH OR FLASHES FOR THE INCORRECT AMOUNT OF TIME WHEN
ENGINE IS BELOW NORMAL OPERATING TEMPERATURE
CIRCUIT OPERATION
The heating of the Glow Plugs is controlled by the
Glow Plug Relay in the Glow Plug Controller. Battery
voltage is applied to the relay contacts through the RED
wire from the Junction Block. The relay is operated by
a Solid-State Controller. The Controller responds to
engine temperature and also to an Ignition Switch Start
input.
After the initial time period the relay will de-energized for
five seconds then will cycle ON/OFF for approximately 10
seconds.
When the Ignition Switch is turned to RUN, battery

voltage is applied to the Enable Input of the Controller.
The Glow Plug Relay within the Controller will be
energized for approximately five seconds during which it
applies voltage to the Glow Plugs and WAIT Indicator.
After approximately 25 seconds the Controller will

open the Glow Plug Relay and the heating of the plugs
stops. If the engine is restarted while the engine is at
normal operating temperature, the ECM will keep the
relay contacts open so that no plug heating takes place.
TEST
NOTE: For 6.2L V8 diesel
engines, ground DK BLU/WHT
(421) wire at cold advance glow
plug inhibit relay connector C108.
RESULT
Test lamp lights.
GO to step 2.
1. Place ignition switch in RUN

position. Connect test lamp from
RED (2) wire at glow plug
controller to ground.

(2) wire and fusible link from glow
plug controller to junction block.
2.
Test lamp lights.
GO to step 5.
GO to step 3 for 6.2L engines.
When the Glow Plug Controller receives the Start

Input, the Glow Plugs and WAIT Indicator will cycle
ON/OFF after the Ignition Switch is returned to RUN.
DIAGNOSIS - GLOW PLUGS
Connect a test lamp from LT

GRN/BLK (531) wire for 6.2L or
PNK (3) wire for 6.2L HD engines
at glow plug controller connector
C168 to ground.
For 6.2L HD engines, LOCATE and

REPAIR open in PNK (3) wire from
glow plug controller to ignition
switch.
PRELIMINARY CHECKS:
A check of the glow plug system should be
performed before diagnostic procedures.
With engine below normal operating temperature, turn
ignition switch to RUN. The WAIT indicator should light.
After approximately 10 seconds, the WAIT indicator must
begin to flash for an additional 10 seconds and then go
out.
Turn ignition switch to OFF and then momentarily to

START and return to RUN position. The WAIT indicator
should flash for approximately 25 seconds and then go
out.
3.
With engine at normal temperature, turn ignition

switch to RUN. The WAIT indicator should not flash for
an 6.2L engine, but should flash for an 6.2L HD engine.
4.
5.
A-82 GLOW PLUGS
ACTION
Connect a test lamp from each

PNK/BLK (39) wire at cold
advance glow plug inhibit relay
Connect a 10 amp fused jumper

from DK BLU/WHT (421) wire at
cold advance glow plug inhibit
relay connector C167 to ground.
Connect test lamp from LT
GRN/BLK (531) wire at inhibit relay

GRN/BLK (531) wire for 6.2L
engines or PNK (3) wire for 6.2L
HD engines to BLK (150) wire at
glow plug controller connector
C168.
Test lamp lights.
GO to step 4.
CHECK condition of GAGE/IDLE

fuse. If fuse is good, LOCATE and
REPAIR open in PNK/BLK (39) wire
from inhibit relay to fuse block.
Test lamp lights.
CHECK for open in DK BLU/WHT

(421) wire from inhibit relay to
ECM. If wire is good, problem is
with ECM. Refer to Section 6E in
the 1991 R/V, P Light Truck
Service Manual.
CHECK for open in LT GRN/BLK

(531) wire. If good, REPLACE cold
advance glow plug inhibit relay.
Test lamp lights.
GO to step 6.

(150) wire from glow plug
controller to ground terminal G110.
WAIT INDICATOR STAYS ON OR FLASHES WHEN ENGINE IS AT NORMAL OPERATING

TEMPERATURE AND IGNITION SWITCH IN RUN POSITION (6.2 L DIESEL ENGINE ONLY)
TEST
RESULT
ACTION
______________
TEST
6.
7.
8.
9.
ACTION
RESULT
Connect test lamp from PPL/WHT

(806) wire at glow plug controller
connector C168 to ground. Move
ignition switch to START position.
Test lamp lights.
GO to step 7.

PPL/WHT (806) wire from glow
plug controller to starter motor.
Place ignition switch to OFF

ORN (503) wires at glow plug
controller to ground.
Test lamp lights.
REPLACE glow plug controller.
GO to step 8.
Disconnect glow plug controller

connector C168. Using a positive
polarity ohmmeter, check
continuity between ORN (503) or
(509) wires and BLK (150) wires.
Reading of 2 ohms or less.
GO step 9.
Reading greater than 2 ohms.

(503)and (509) wires from glow
plug controller connector C117 to
glow plug harness splices S198
and S199.
Connect glow plug controller

connector. Connect test lamp from
ORN (503) wires at glow plug
controller to connector C168 to
ground. Turn ignition switch
momentarily to START and then
release to RUN position.
Test lamp cycles on and off for

approximately 25 seconds then
goes off.
GO to step 11.
Test lamp does not light or cycles

for the incorrect time.
Test lamp lights for all glow plugs.

(503) or ORN/BLK (509) wires and
fusible links from glow plug to
controller.
Test lamp does not light for one or

more glow plugs.
REPLACE glow plug(s) where test

lamp did not light.
10. Remove all connectors from glow

plugs. Connect one lead of test
lamp to battery voltage and other
lead to each glow plug.
1. Connect test lamp from each

PNK/BLK (39) wire at cold
Test lamp lights.
GO to step 2.
CHECK condition of GAGE/IDLE

REPAIR open from inhibit relay to
fuse block.
2.
Test lamp lights.
CHECK for open in DK BLU/WHT

(421) wire from inhibit relay to
ECM. If wire is good, problem is
with ECM. Refer to Section 6E in
1991 R/V, P Light Truck Service
Manual.
REPLACE cold advance glow plug

inhibit relay.
Connect a fused jumper from DK

BLU/WHT (421) wire at cold
Connect test lamp from LT
GRN/BLK (531) wire at inhibit relay
GLOW PLUGS A-83
3108
11-32.0 BLK I
906-1.0 P P Li
I 2-.Q BLK/RED
2- 8 BLK/RED I
RIGHT BANK GLOW PLUGS
3-3.0 PNK I
RH BATTERY
FUEL SHUTOFF
SOLENOID
LH BATTERY
FUSIBLE LINKS
S198
509-5.0 ORN/BLKI
509-2.0 GRA m
(FUSIBLE UNK)
i 503-2.0 GRA
^ S199
FUSIBLE UNK)
FUSIBLE UNKS
S103
S197
503-1.0 ORN I
503-1.0 ORN I
LEFT BANK GLOW PLUGS

LEFT BANK SHEET
GLOW PLUGS METAL
GROUND
GROUND
G113
G111
RIGHT BANK
GLOW PLUGS
GROUND
G114
6-3.0 PPL I
2-3.0 RED

S106
A-84 GLOW PLUGS
12-3.0 RED 1
RPO CODES
LH6 ENGINE, 6.2L (378 CID) V8 DIESEL ENGINE, VIN C
M20 MAN TRANS, 4 SPD.
1806-1.0 PPL/WHTl
COLD ADVANCE GLOW PLUG
531-.8 LT GRN/BLX
" TIMER INHIBIT RELAY

(LH6) (SEE PAGE 64)
COLD ADVANCE CONTROL
(LH6) (SEE PAGE 64)
CLUTCH START SWITCH

(M20 ONLY)
(SEE PAGE 56)
ENGINE GROUND
G110
i/P
GROUND (0 1
G200
^
GLOW PLUGS A-85
DIAGNOSIS DIESEL ENGINE FUEL CONTROLS
CIRCUIT OPERATION
The Diesel Fuel Filter System combines five functions
into a single package:
the fuel. When the switch is closed, battery voltage is

applied to the heater form the GAGE/IDLE Fuse.
1. Heats diesel fuel to prevent wax-plugging of the filter.

2. Combines very small droplets of water in the fuel into
larger drops and separates the water from the fuel.
3. Filters the diesel fuel.
4. Detects the presence of excess water in the fuel and
5. Provides a means to drain the water it has separated.
The fuel then passes through the Primary and

Secondary filters. Next the fuel flows through the water
coalescer. Here the droplets of water in the fuel are
combined into larger drops, the drops fall to the water
reservoir in the filter. When the fuel flows from the Fuel
Filter Assembly to the injection pump, it is clean and free
of water.
The Fuel Filter Assembly consists of the Fuel Heater,

the Water In Fuel Sensor and a Filter. The Filter contains
the "coalescer" (the device that combines small droplets
of water into larger ones) and the filter/separator.
An electric fuel pump delivers diesel fuel from the tank
to the fuel filter. As fuel enters the filter, it passes first
through the Fuel Heater.
The heater contains a
thermostatic switch. The switch opens or closes, to turn
the heater off or on, depending on the temperature of
The Solid-State Water In Fuel Sensor applies voltage

to a Probe. When the Probe touches water, the Module
closes a switch. This completes a circuit to ground to
light the SERVICE FUEL FILTER indicator.
A time delay circuit in the Water In Fuel Module
grounds the indicator bulb briefly to test the bulb each
time the system is turned on.
PRELIMINARY CHECKS:
CHECK condition of GAGE/IDLE fuse. If fuse is
If fuse is in good condition, use the following
blown, LOCATE and REPAIR source of overload, then diagnostic procedures.
REPLACE fuse.
FUEL HEATER DOES NOT OPERATE
TEST
1.
Disconnect fuel heater connector

C196. Place ignition switch to
RUN position. Connect a
voltmeter from PNK/BLK (39)
wire at fuel heater connector
C196 to ground.
2. Connect a voltmeter from

PNK/BLK (39) wire to BLK (150)
C196.
RESULT
ACTION
Battery voltage.
GO to step 2.
No voltage.

PNK/BLK (39) wire from fuel heater
to fuse block.
Battery voltage.
REPLACE fuel filter.
No voltage.

(150) wire from fuel sensor to
ground terminal G110.
SERVICE FUEL FILTER INDICATOR DOES NOT LIGHT BRIEFLY WITH IGNITION SWITCH TURNED TO RUN
TEST
1.
RESULT
ACTION
Disconnect water in fuel sensor

connector C197 and place ignition
switch in RUN. Connect a
wire at fuel sensor connector
C197 to ground.
Battery voltage.
GO to step 2.
No voltage reading.

PNK/BLK (39) wire from fuel'sensor
to fuse block.

PNK/BLK (39) to BLK (150) wire at
water in fuel sensor connector
C197.
Battery voltage.
GO to step 3.
No voltage.

(150) wire from fuel sensor to
3.
Battery voltage.
No voltage.
CHECK Service Fuel Filter lamp. If

lamp is good, LOCATE and
REPAIR open in YEL (508) wire.
Connect a voltmeter from YEL

(508) wire at water in fuel sensor
SERVICE FUEL FILTER INDICATOR LIGHTS WITH NO WATER IN FUEL

TEST
position. Disconnect water in fuel
sensor connector C197.
A-86 DIESEL ENGINE FUEL CONTROLS
RESULT
ACTION
SERVICE FUEL FILTER indicator

stays on.

ground in YEL (508) wire.
SERVICE FUEL FILTER indicator

goes out.
yvw w w w vw /
<
HOT IN START OR RUN ?
m w vvvw w w ^
39
/ .
GAGE/IDLE
20 AMP
COLD
ADVANCE
FAST IDLE
TEMPERATURE
SWITCH
534
#1
C102A
a 2977373
534-.S DK GRN I
39-. 8 PNK/BLK
FAST IDLE
SOLENOID
EGR DUMP VALVE

(SEE PAGE 64)
C100A
EGRVALVE
(SEE PAGE 6 4 )'
39-.8 PNK/BLK r
M
COLD ADVANCE TIMER
EPR VALVE
(SEE PAGE 64) '
39- 8 p n k /b lk jm
39" 8 PNKyBLKWr S
' b
|
a
^
39-.s p n k /b lk
39 e PNK/BLK ^
I RELAY (SEE PAGE 64)

|
GENERATOR
(SEE PAGE 12)
i I
S I 22
(SEE PAGE 18)
I U
I
CD
CD
WATER
IN FUEL
SENSOR
S202
(SEE PAGE 27)
n o
39- 8 PNK/BLK V
I 150-.8 BLK
139-.8 PNK/BLK
FUEL
HEATER
94
29
15
39
14
33
12
93
11
18
120
24
30
420
9
Inr
19 ||
508
50
35
97
150
1508-.8 YEL
1
WATER IN FUEL
LAMP (SEE PAGE 105)
I 3-3.0 PNK I
FUEL SHUTOFF
SOLENOID
C199
12020274
(q\
^
ENGINE
GROUND
G110
C100
12020183
DIESEL ENGINE FUEL CONTROLS A-87

6.2L V8 DIESEL ENGINE
, HOT IN START OR RUN
GAGE/IDLE
20 AMP
I _______
COLD
ADVANCE
CONTROL
FAST IDLE
SOLENOID
GENERATOR
(SEE PAGE 12)
COLD
ADVANCE
FAST IDLE
TEMPERATURE
SWITCH
(OPENS AS
TEMPERATURE
INCREASES)
A n
C198
2977373
C171
12004267
I 936-.8 LT GRN i
936-.0 LT GRN
S109
I 39-.8 PNK/BLK I
39
5 0 8 )
39-.S PNK/BLK I
\
|
[
WATER
IN FUEL
SENSOR
m m
39-.8 p n k /b lk h f
^m m
^ m
^m m
*m m
^m
39-.e p n k /b lk
S202
(SEE PAGE 27)
I
i
FUEL
HEATER
RWAL
(SEE PAGE 116)
39-.8 PNK/BLK
C196
12020397
39-.8 PNK/BLK ' m W
m m w ^
Q )
I 3-3.0 PNK
I2
503
31]
| 420
140
39
| 508
440
I3
I
I2
25
| 439
97
93 |
II 6
92
91 |
GLOW PLUG
CONTROLLER
50
ENGINE
GROUND
G110
DM
FUEL SHUTOFF SOLENOID
3-3.0 PNK
68
35
= U (t
12020183
12020274
A-88 DIESEL ENGINE FUEL CONTROLS

6.2L HD V8 DIESEL ENGINE
F
jI
Ui L
1
III
C100
F\
*
94
n
29
* dl
15 I
39
14 p i
33
12
: 93
11
18
120
: 24
30
503
13931 140
L 440
68
9 I
191
2
820
:
WATER IN FUEL
508
25
3
50
r
93
35
97
439
91
92
LAMP
(SEE PAGE 105)
IGNITION
V 3 . 0 PNK
S207
(SEE PAGE 13)
; SWITCH
(SEE PAGE 13)
COOLING FAN RUNS CONTINUOUSLY
CIRCUIT OPERATION
TEST
Battery voltage is applied to the Auxiliary Cooling Fan
Relay at all times by the RED (2) wire and by the
PNK/BLK (39) wire through the GAGE/IDLE fuse, when
the Ignition Switch is in RUN or START. When the
Auxiliary Cooling Fan Temperature Switch closes at
107C (225F), the DK GRN (935) wire is grounded and

the Auxiliary Cooling Fan Relay energizes.
Battery
voltage is applied across the Auxiliary Cooling Fan Motor
and the Auxiliary Cooling Fan runs.
DIAGNOSIS - AUXILIARY COOLING FAN

COOLING FAN DOES NOT RUN
TEST
ACTION
RESULT
Disconnect auxiliary cooling fan

temperature switch connector
C170. Connect a fused jumper
from DK GRN (535) wire at
auxiliary cooling fan temperature
Auxiliary cooling fan does not run.
GO to step 2.
Auxiliary cooling fan runs.
REPLACE auxiliary cooling fan

temperature switch.

relay connector C190. Connect
test lamp from PNK/BLK (39) wire
at auxiliary cooling fan relay
Test lamp lights.
GO to step 3.

(GAGE/IDLE) and/or LOCATE and
REPAIR open in PNK/BLK (39) wire
from auxiliary cooling fan relay to
fuse block.
Connect fused jumper from DK

GRN (535) wire at auxiliary cooling
fan temperature switch connector
C170 to ground. Connect a test
lamp from PNK/BLK (39) wire to
DK GRN (935) wire at auxiliary
cooling fan relay connector C190.
Test lamp lights.
GO to step 4.

GRN (535) wire.
Test lamp lights.
GO to step 5.

(2) wire and fusible link.
5. Connect a 30 amp fused jumper

from RED (2) wire to BLK/RED
(702) wire at auxiliary cooling fan
relay connector C190.
GO to step 6.

relay.
6.
Leave 30 amp fused jumper

connector. Disconnect auxiliary
cooling fan connector C191.
BLK/RED (702) at auxiliary cooling
fan connector C191 to ground.
Test lamp lights.
GO to step 7.

BLK/RED (702) wires from auxiliary
cooling fan to auxiliary cooling fan
relay.
7. Connect a test lamp from

BLK/RED (702) to BLK (151) wires
at auxiliary cooling fan connector
C191.
Test lamp lights.
REPLACE auxiliary cooling fan.

(151) wire from auxiliary cooling
fan to ground terminal G106.
1.
2.
3.
4.
Connect a test lamp from RED (2)

wire at auxiliary cooling fan relay
RESULT
ACTION

position and with engine
coolant temperature below
107C (225F), disconnect
auxiliary cooling fan
C170.
GO to step 2.
Auxiliary cooling fan does no

run.

temperature switch.
I.
Test lamp lights.
CHECK for short in DK GRN (535)

wire from fan relay to
auxiliary cooling fan
temperature switch.

relay.
Disconnect auxiliary cooling

fan relay connector C190.
PNK/BLK (39) to DK GRN (535)
wires at auxiliary cooling fan
relay connector C190.
AUXILIARY COOLING FAN A-89

.H O T IN S T A R T O R RUN
GAGE/IDLE
20 AMP
TEMPERATURE SWITCH
(CLOSES WHEN COOLANT
TEMPERATURE EXCEEDS
2 2 5 F (107C)
I 2-.8 RST (FUSIBLE U NK)I
S116
C193
a
UJ
CC
BATTERY JUNCTION
BLOCK
I 2*2.0 RED I
C192
12065171
935
S202
(SEE PAGE 27)
12065172
I 935-.8 DK GRN I
AUXILIARY
COOLING
FAN
RELAY
mmr
l l 15
702-2.0 b lk / r e d v
s o -.e p n k /b lk '
jm
r mmw
jm m
ss-.sp n k/b lk
___
r
29 1 94 1
12 | 33 |
11 ] 93 |
\
C190
12065169
IP P
jl 14^ 39 1 9 1
C102
12020100
'
l/P
GO
(5 0/1 30 )
|4 2 0 440 f 2
439 8 0 6 / 39
L
L
AUXILIARY
COOLING
FAN
jtm m
im m r
a 702
702-2.0
-2.0
b
BLK/RED
lk / r e d ,
151-2.0 BLK I
_93_ _M
S 111
(SEE PAGE 16)
TT
19
35
97
422
91
92
V
151-3.0 BLK
SHEET
METAL
GROUND
G106
A-90 AUXILIARY COOLING FAN

C100
12020184
FRAME
GROUND
G107
3
436
93
18
jm m
120
DIAGNOSIS - AIR CONDITIONING
CIRCUIT OPERATION
BLOWER CONTROLS
COMPRESSOR CONTROLS
Battery voltage is applied at all times to the HI Blower

Relay, through the RED (2) wire. When the Blower
Switch is in the OFF, LO or MED positions, the HI Blower
Relay is de-energized.
The Compressor for the A/C System is driven by the

engine by means of a belt drive and the A/C Compressor
Clutch.
The Clutch allows the Compressor to be
disengaged when the A/C is not required.
With the Ignition Switch is in the RUN and ACC

position, voltage is supplied to the Selector Control by
way of the BRN (50) wire through the HTR A/C Fuse.
This voltage is supplied, through the Selector Control,
and then through the BRN/WHT (64) wire to the Blower
Switch and Resistor Block. At the Resistor Block, voltage
is dropped through three resistors. This reduced voltage
flows through the DK BLU (101) wire to the de-energized,
HI blower relay. Since the Hi blower relay is de
energized, circuits 101 and 65 are connected through
the relay. This reduced voltage flows through the PPL
(65) wire to the Blower Motor and the Blower Motor will
run at a slow speed.
Operation of the Compressor depends on the

particular A/C Mode selected at the Heater and A/C
Controller. With A/C ON selected, battery voltage flows
through the Selector Control to the Evaporator Pressure
Control Switch by way of the LT GRN (66) wire. Voltage
flows through the normally closed contacts of the
Evaporator Pressure Control Switch to the A/C
Compressor Clutch. The coil is energized and the A/C
Compressor Clutch engages.
When the Blower Switch is turned to LO, voltage flows

through the Blower Switch, to the Resistor Block, through
the TAN (63) wire. Voltage flows through two resistors,
through the DK BLU (101) wire, through the contacts of
the de-energized HI Blower Relay to the Blower Motor by
way of the PPL (65) wire.
When the Blower Switch is turned to MED, voltage
flows through the Blower Switch, to the Resistor Block,
through the LT BLU (72) wire. Voltage flows through one
resistor, through the DK BLU (101) wire, through the
contacts of the de-energized HI Blower Relay to the
Blower Motor by way of the PPL (65) wire.
When the Blower is turn to HI, voltage flows through
the Blower Switch, to the HI Blower Relay, through the
ORN (52) wire. This voltage flows through the coil of the
HI Blower Relay. With the HI Blower Relay energized,
battery voltage flows through the RED (2) wire, through
the contacts of the energized HI Blower Relay to the
Blower Motor by way of the PPL (65) wire. This allows
battery voltage to power the Blower Motor.
If the refrigerant pressure drops to a point which may

cause icing of the evaporator, the Evaporator Pressure
Control Switch opens, de-energizing the A/C Compressor
Clutch. When the refrigerant pressure rises to a point
where cooling is required again, the Evaporator Pressure
Control Switch closes to re-energize the A/C Compressor
Clutch.
The A/C Compressor Clutch Diode is connected
across the terminals of the A/C Compressor Clutch.
Whenever the clutch is de-energized, the magnetic field
around it collapses, generating an induced voltage in the
clutch coil. The Diode provides a path for the current
resulting from the induced voltage so that other circuit
components are not damaged by it.
PRELIMINARY CHECKS:
Outside temperature must be above 16C (60F) in order to properly diagnose system.
A /C C O M P R E S SO R C LU TC H DO ES N O T ENGAGE
TEST
1.
2.
3.
4.
RESULT
ACTION
Place ignition switch in RUN,

selector control in MAX.
Connect voltmeter from BRN
(50) wire at selector control
Battery voltage.
GO to step 2.
No voltage.

(50) wire from selector
control to fuse block. CHECK
HTR/AC fuse.
Disconnect A/C compressor

control switch connector C178
and place selector control to
MAX. Connect a fused jumper
between LT GRN (66) wire and DK
GRN (59) wire at A/C
compressor control switch
connector C178.
A/C clutch engages.
GO to step 4.
A/C clutch does not engage.
CHECK for open A/C compressor

control switch. If A/C
compressor control switch is
open and refrigerant pressure
is normal, REPLACE A/C
compressor control switch.
Connect voltmeter from DK GRN

(59) wire at compressor clutch
Battery voltage.
GO to step 5.
No voltage.

GRN (59) wire from A/C
compressor clutch to A/C
compressor control switch.
Connect voltmeter from DK GRN

(59) wire to BLK (150) wire at
A/C compressor clutch
connector C165.
Battery voltage.
REPLACE A/C compressor clutch.
No voltage.

(150) wire from A/C compressor
clutch to ground terminal
G110.
REAR BLOWER CONTROL

Battery voltage is supplied to the Blower Switch
through the AUX HTR A/C Fuse and the BRN (50) wire.
When the Blower Switch is turned to LO, voltage flows
through the Blower Switch to the Resistors by way of the
YEL (51) wire. Voltage flows through two resistors,
through the ORN (52) wire to the Rear Blower Motor.
When the Blower Switch is turned to HI, voltage flows
through the Blower Switch directly to the Rear Blower
Motor through the ORN (52) wire.
AIR CONDITIONING A-91
BLOWER MOTOR DOES NOT OPERATE IN ANY MODE

ACTION
RESULT
TEST
BLOWER MOTOR DOES NOT OPERATE IN HI
1. Place ignition switch to RUN,

selector control to VENT and
blower switch to HI. Disconnect
blower motor connector C180.
Connect voltmeter from PPL (65)
wire at blower connector C180 to
Battery voltage.
REPLACE blower motor.
No voltage.
GO to step 2.
2. Connect voltmeter from BRN (50)

wire at selector control connector
C233 to ground.
Battery voltage.
GO to step 3.
No voltage.
CHECK condition of HTB/AC fuse.

If fuse is good, LOCATE and
REPAIR open in BRN (50) wire
from selector control connector
C233 to fuse block.
3.
4.
5.
Connect voltmeter from BRN/WHT

(64) wire at blower switch
Connect voltmeter from ORN (52)

wire at HI blower relay connector
C177 to ground.
Disconnect HI blower relay

voltmeter from ORN (52) wire at HI
blower relay connector C177 to
BLK (150) wire.
6. Connect HI blower relay connector

C177. Connect voltmeter from PPL
(65) wire at HI blower relay
connector to ground.
1.
2.
Battery voltage.
GO to step 4.
No voltage.

BRN/WHT (64) wire between
blower switch connector C234 and
selector switch connector C233. If
no open is found, REPLACE
selector control.
Battery voltage.
GO to step 5.
No voltage.

(52) wire between HI blower relay
connector C177 and blower switch
connector C234. If no open is
found, REPLACE blower switch.
Battery voltage.
GO to step 6.
No voltage.

connector C177 and ground
terminal G115.
Battery voltage.
No voltage.
A-92 AIR CONDITIONING
TEST

connector C177 and blower motor
connector C180.
REPLACE HI blower relay.
3.
RESULT
Place ignition switch to RUN,

selector control to VENT and
blower switch to HI. Connect
voltmeter from ORN (52) wire
at HI blower relay connector
C177 to ground.
Connect voltmeter to RED (2)
wire at HI blower relay
Connect voltmeter to RED (2)
wire at HI blower relay
connector C177 to BLK (150)
wire.
ACTION
Battery voltage.
GO to step 2.
No voltage.

(52) wire from HI blower relay
to blower switch.
Battery voltage.
GO to step 3.
No voltage.

(2) wire or fusible link.
Battery voltage.
REPLACE HI blower relay.
No voltage.

(150) wire to ground G115.
BLOWER MOTOR DOES NOT OPERATE IN MED

TEST
1.
2.
RESULT
ACTION
Place blower switch to MED.

Connect voltmeter to LT BLU
Battery voltage.
GO to step 2.
No voltage.
REPLACE blower switch.
Connect voltmeter to LT BLU

(72) wire at blower resistor
Battery voltage.
REPLACE blower resistor.
No voltage.

BLU (72) wire between blower
resistor and blower switch.
BLOWER MOTOR DOES NOT OPERATE IN LO

RESULT
TEST
1.
2.
ACTION
Place blower switch to LO.

Connect voltmeter to TAN (63)
wire at blower switch
Battery voltage.
GO to step 2.
No voltage.
Connect voltmeter to TAN (63)

wire at blower resistor
Battery voltage.
No voltage.

(63) wire between blower
resistor and blower switch.
DIAGNOSIS CHART - AIR CONDITIONING, REAR
BLOWER MOTOR DOES NOT OPERATE IN LO BUT ONLY IN HI
PRELIMINARY CHECKS:
TEST
CHECK condition of AUX HTR A/C fuse. If fuse is

blown, LOCATE and REPAIR source of overload, then
REPLACE fuse.
If fuse is in good condition, use
following diagnostic procedures.
1.
BLOWER MOTOR DOES NOT OPERATE AT ALL

TEST
1.
2.
3.
4.
ACTION
RESULT
Disconnect blower motor

ignition switch in RUN
position. Connect a test lamp
from PPL (52) wire at blower
motor connector C410 to
ground.
Test lamp lights.
GO to step 2.
GO to step 3.
Connect a test lamp from PPL

Test lamp lights.

ground BLK (2) wire between
blower motor and ground
terminal G411.

Test lamp lights.
GO to step 4.

switch connector C281 and fuse
block connector C283. If no
open is found, CHECK AUX HTR
A/C fuse.
Place blower switch in LO or

HI. Connect a test lamp from
blower switch connector C281
at wire that applies to
position of switch to ground.
LO is YEL (51) wire and HI is
ORN (52) wire.
Test lamp lights.
LOCATE and REPAIR open in wires

to blower motor.
2.
3.
Place blower switch in LO

from YEL (51) LO wire at blower
motor switch connector C281 to
ground.
RESULT
ACTION
Test lamp lights.
GO to step 2.
Connect a test lamp from YEL

(51) LO wire at blower
resistor connector C181 to
ground.
Test lamp lights.
GO to step 3.

(51) wire from blower resistor
to blower switch.

(52) wire at blower resistor
Test lamp lights.

resistor connector C181 and
splice S220. If no open is
found, REPLACE resistor.
BLOWER MOTOR DOES NOT OPERATE IN HI BUT ONLY IN LO

TEST
1.

RESULT
ACTION
Test lamp lights.

switch connector C281 and
splice S220.
AIR CONDITIONING
A-93
50-5.0 BRN
f OFF
LO Q i
O |
<>
U)
BLOWER
SWITCH
<N
IO
If)
C281
12004101
52-2.0 ORN m m m 52
S220
2977253
RESISTOR
C282
8900420
2977518
eggm----
GT103
8911215
REAR BLOWER
MOTOR
o
o
\Q)
=
SHEET
METAL
GROUND
G405
AIR CONDITIONING A-95

REAR
BLOWER MOTOR DOES NOT OPERATE IN LO AND/OR MED BUT ONLY IN HI
CIRCUIT OPERATION
TEST
FRONT HEATER
AUXILIARY HEATER
The blower motor delivers air to the interior of the

vehicle. Its speed is controlled by the Blower Switch and
Blower Resistors. When the Ignition Switch is placed in
RUN, battery voltage is applied to the Blower Switch
through the HTR A/C Fuse. With the Blower Switch in
LO, voltage is applied across both resistors to the Blower
Motor. With the Blower Switch in MED, voltage is applied
across one resistor to the Blower Motor, and the Blower
runs faster. When the Blower Switch is in HI, battery
voltage is applied directly to the Blower Motor and
Blower operates at its fastest speed.
The Auxiliary Blower Motor delivers heated air to the

rear of the vehicle. Its speed is controlled by a rear
Blower Switch and Blower Resistors. When the Ignition
Switch is placed in RUN, battery voltage is applied to the
rear Blower Motor through the AUX HTR A/C Fuse. With
the rear Blower Switch in LO, a ground path through two
resistors allows the voltage at the rear Blower Switch
Motor to flow to ground. With the rear Blower in HI, a
ground path allows full voltage at the rear Blower Motor
to flow to ground.
1.
2.
RESULT
Place blower switch in position

where blower motor does not
work. Connect a test lamp from
either YEL (51) LO wire or LT BLU
(72) MED wire (depending on
switch position) at blower motor
Connect a test lamp from either
YEL (51) LO wire or LT BLU (72)
MED wire (depending on switch
position) at resistor blower
ACTION
Test lamp lights.
GO to step 2.
Test lamp lights.

wire(s) (51 or 72) from blower
resistor connector C183 to blower
switch connector C234.
DIAGNOSIS - FRONT HEATER

BLOWER MOTOR DOES NOT OPERATE AT ALL
TEST
1.
2.
3.
4.
Check condition of HTR A/C fuse.
Place ignition switch in RUN and

blower switch in HI. Disconnect
(52) wire at blower motor
connector C 180 to ground.
(50) wire at heater blower switch
Place blower switch to LO, MED,

or HI. Connect a test lamp from
heater blower switch connector
C234 at wire that applies to
position of switch to ground. LO is
YEL (51) wire, MED is LT BLU (72)
wire, and HI is ORN (52) wire.
RESULT
Fuse is not blown.
GO to step 2.
Fuse is blown.

Test lamp lights.
CHECK blower motor screws for a

good ground. If ok, REPLACE
blower motor.
AUXILIARY HEATER BLOWER MOTOR DOES NOT OPERATE AT ALL
GO to step 3.
Test lamp lights.
GO to step 4.

(50) wire between heater blower
switch connector C234 and fuse
block.
Test lamp lights.

wires to blower motor between
heater blower switch connector
C234 and blower resistor
connector C183.
RESULT
ACTION
1. Connect a test lamp from ORN

Test lamp lights.
GO to step 2.
2.

(52) wire from blower resistor
connector C183 to blower switch
connector C234.

(52) wire at resistor connector
C183 to ground.
A-96 HEATER
TEST
1. Check condition of AUX HTR A/C
fuse.
2.
BLOWER MOTOR DOES NOT OPERATE IN HI BUT ONLY IN LO AND/OR MED

TEST
DIAGNOSIS - AUXILIARY HEATER
ACTION
3.
4.

blower switch in HI. Disconnect
Connect blower motor connector
C425. Connect a test lamp from
BRN (50) wire at blower motor to
DK GRN (952) wire.
from DK GRN (952) wire at blower
switch connector C234 to BLK
(150) wire.
RESULT
ACTION
Fuse is not blown.
GO to step 2.
Fuse is blown.

Test lamp lights.
GO to step 3.

(50) wire between blower motor
connector C425 and fuse block
connector C285.
Test lamp lights.
GO to step 4.
Test lamp lights.

GRN (952) wire between blower
switch connector C284 and blower
motor connector C425.

(150) wire between blower switch
connector C284 and bus bar
ground connector C296. If no
open is found, REPLACE blower
switch.
AUXILIARY HEATER BLOWER MOTOR DOES NOT OPERATE IN LO

TEST
1.
2.
RESULT
ACTION
Connect a self-powered test

lamp from YEL (51) wire at
blower resistor connector
C426 to ground.
Test lamp lights.
GO to step 2.
Connect a self-powered test

lamp from YEL (51) wire at
blower resistor connector
C426 to BLK (150) wire.
Test lamp lights.

resistor connector C426 and
blower switch connector C284.
HEATER A-97
RPO CODES
L05 - ENGINE, 5.7L (350 CIO) V8 GAS ENGINE, VIN K

L19 - ENGINE, 7.4L (454 CIO) V8 GAS ENGINE, VIN N
HOT IN RUN '
HTR A/C
25 AMP
I 50-2.0 BRN
I 50-2.0 BRN
T
I
X
t
05 a
5
T fi
ss
DRAC
(SEE PAGE 75)
RESISTOR
BLOWER
MOTOR
CQ <3>
C183
El
2965010
r O hi
52
OMEDO0FF
C180
HEATER
BLOWER
SWITCH
QLOT
I ?
2977976
GT104
8811217
52-2.0 ORN
51-2.0_YEL_| |
51-2.0 YEL
52-2.0 ORN
52-2.0 ORN
72-2.0 LT BLU
72-2.0 LT BLU
50-2.0 BRN
C235
12015952
A-98 HEATER
FRONT
12015987
si
S3
53203
C311
51-2.0 YEL I
GT402
6268585
12015956
952-2.0 DK GRN
1 (M l
(A
0)
C312
50-2.0 BRN
I 50-2.0 BRN I
50
| q>[
1 50
L -
12004727
C425
2973781
BUS
BAR
GROUND
G201
EC
BLOWER
MOTOR
AUXILIARY HEATER A-99
DIAGNOSIS - INSTRUMENT PANEL: GAGES AND INDICATORS
CIRCUIT OPERATION
FUEL GAGE
The pointer of the Fuel Gage is moved by the
magnetic fields of two coils. The coils are at right angles
to each other. Battery voltage is applied to the E-coil
and the circuit divides at the opposite end of the coil.
One path continues to ground through the F-coil.
Another goes to ground through the variable resistor of
the Fuel Gage Sender.
directly and the other is grounded through the

Temperature Sender. This has 55 ohms resistance at
128C (260F) (hot coolant) and its resistance becomes
greater at low temperatures. It is approximately 1400
ohms at 38C (100F). This causes the current through
the Sender and one coil to increase as the coolant
temperature increases. This moves the pointer.
PRELIMINARY CHECKS
Check condition of GAGE/IDLE fuse. If fuse is blown,
locate and repair source of overload, then replace fuse.
If fuse is in good condition, use the following diagnostic
procedures.
FUEL G AG E IN D IC A TE S FU LL OR BEYOND AT A LL TIM E S
When the tank is low, the resistance of the Sender is

low. A large flow of current passes through the E-coil
and the Fuel Gage Sender resistor. This moves the
pointer toward E on the scale. When the tank is full, the
Sender resistance is high. More current now flows
through the F-coil, moving the pointer toward F on the
scale.
With two coils operating the pointer, the Gage is not
affected by changes in the systems battery voltage.
OIL PRESSURE GAGE

The engine oil pressure is displayed by the Oil
Pressure Gage. The pointer of the Gage is moved by
two coils, and its operation is similar to that of the Fuel
Gage.
The Oil Pressure Sender is connected to the junction
of the two coils. It has low resistance when the oil
pressure is low, and 90 ohms resistance when the oil
pressure is high. This changing resistance changes the
current flow through the coils. The magnetic fields of the
coils move the pointer from low to high.
TEMPERATURE GAGE
The Temperature Gage is also operated by two coils.
Battery voltage is applied to both coils. One is grounded
A-100
INSTRUMENT PANEL
GAGES AND INDICATORS
TEST
VOLTMETER
The Voltmeter measures the electrical systems
voltage with the Ignition Switch in RUN or START. With
the engine stopped, the Voltmeter indicates Battery
condition.
With the engine running, the Voltmeter
indicates Charging System operation.
1.
LOW COOLANT INDICATOR

The Low Coolant Indicator comes on to warn the
driver when a low level of coolant exists in the radiator.
Battery voltage is applied to the Low Coolant Module.
When a low coolant condition exists, a signal is sent to
the Low Coolant Module from the Low Coolant Sensor.
The Low Coolant Module will provide a ground to the
Low Coolant Indicator.
The Low Coolant Sensor is not a switch that opens
and closes. It has a very high resistance to ground, more
than 50,000 ohms, when the engine coolant level is low.
This causes the Low Coolant Module to light the Low
Coolant Indicator. With more of the Sensor covered by
coolant, its resistance decreases. When the fluid level is
good, the resistance will be less than 10,000 ohms. With
the Sensor resistance between 10,000 and 50,000 ohms,
the Sensor is partly covered and the fluid is not low
enough to cause the warning to be displayed.
RESULT
Disconnect fuel sender

connector C409 and place
ignition switch to RUN.
Connect a fused jumper from
PNK (30) wire at fuel tank
sender connector C409 to
ground.
ACTION
Fuel gage indicates full.
LOCATE and REPAIR a short in

PNK (30) wire. If no short is
found, REPLACE fuel gage.
Fuel gage indicates empty.
CHECK fuel gage ground. If

ground is good, REPAIR/REPLACE
fuel gage sender.
FUEL GAGE INDICATES EMPTY WHEN THERE IS FUEL IN THE TANK

TEST
1.
RESULT
Disconnect fuel tank sender

switch to RUN.
ACTION
CHECK fuse gage ground. If

ground is good, REPAIR/REPLACE
fuel gage sender.

PNK (30) wire. If no short is found,
REPLACE fuel gage.
FU EL G AG E IS INACCURATE
TEST
1.
Disconnect fuel tank sender

connector C409. Connect one
RED lead of Tester J 33431-B to
PNK (30) wire and other to
ground. Set resistance dials
to 0 ohms and then to 90 ohms.
Fuel gage should indicate
empty and then full. (Allow
time for gage to reach full due
to anti-slosh device.)
RESULT
ACTION
Gage responds correctly.
CHECK fuel tank ground wire for

high resistance. If ground is
good, REPAIR/REPLACE fuel gage
sender.
Gage does not respond

correctly.
CHECK for high resistance in

PNK (30) wire. If wire is good,
REPLACE fuel gage.
TEMPERATURE GAGE INDICATES HOT WITH ENGINE COOLANT

BELOW OPERATING TEMPERATURE AND IGNITION SWITCH IN RUN
RESULT
TEST
Disconnect temperature sender
switch to RUN.
OIL PRESSURE GAGE INDICATES HIGH PRESSURE AT ALL TIMES
Temperature gage indicates cold.
REPLACE temperature sender.
Temperature gage does not

indicate cold.

DK GRN (35) wire. If no short is
found, PERFORM diagnostic
procedures under symptom
Temperature Gage Is Not
Accurate.
1.
ACTION
RESULT
TEST
ACTION
Disconnect oil pressure

sender connector C115
(Gasoline) or C116 (Diesel)
and place ignition switch to
RUN. Connect a fused jumper
from TAN (31) wire at oil
pressure sender connector
C115 (Gasoline) or C116
(Diesel) to ground.
Oil pressure gage indicates

low pressure.
REPLACE oil pressure sender.

high pressure.

(31) wire. If wire is good,
REPLACE oil pressure gage.
TEMPERATURE GAGE INDICATES COLD ALL THE TIME

RESULT
TEST
1.

connector C107. Ground the DK
GRN (35) wire at temperature
sender connector C107.
Temperature gage indicates

hot.
indicate hot.

connector C107. Connect red lead
from J 33431 -B tester to DK GRN
(35) wire and other lead to ground.
Adjust resistance dials to 1400
ohms and then to 55 ohms.
Temperature gage should indicate
cold then hot.
RESULT
TEST

GRN (35) wire. If wire is good,
REPLACE temperature gage.
TEMPERATURE GAGE IS NOT ACCURATE

TEST
OIL PRESSURE GAGE IS NOT ACCURATE
ACTION
ACTION
Gage indicates correctly.
Gage is not correct.

1.

(Gasoline) or C116 (Diesel).
Connect one RED lead of
J33431-B tester to TAN (31)
wire at oil pressure sender
connector C115 (Gasoline) or
C116 (Diesel) and other lead
to ground. Set resistance
dials to 0 ohms and then to 90
ohms. The oil pressure gage
should indicate low pressure
and then high pressure.
OIL PRESSURE GAGE INDICATES LOW PRESSURE WHEN 0 L PRESSURE IS GOOD
1.

(Gasoline) or C116 (Diesel)
and place ignition switch to
RUN.
ACTION

correctly.
Oil pressure gage does not

indicate correctly.

VOLTMETER IS NOT ACCURATE

TEST
TEST
RESULT
RESULT
ACTION

high pressure.
Oil pressure gage indicates no

or low pressure.
LOCATE and REPAIR short TAN

Place ignition switch to RUN

position. Connect a voltmeter
between positive and negative
terminals of the battery.
RESULT
ACTION
Voltage reading is same as

vehicles voltmeter.
Voltmeter is good.
Voltage reading is different from

vehicles voltmeter.

PNK/BLK (39) wire and BLK (150)
wire at instrument cluster. If wires
are good, REPLACE voltmeter.
INSTRUMENT PANEL A-101

SPEEDOMETER IS INOPERATIVE OR INACCURATE

RESULT
TEST
1.
2.
ACTION
Disconnect instrument cluster

connector C203 and place
Connect voltmeter from LT
BLU/BLK (824) wire at
instrument cluster connector
C203 to ground.
Battery voltage.
GO to step 2.
No voltage.
CHECK condition of HTR A/C

fuse. If fuse is good, LOCATE
and REPAIR open in LT BLU/BLK
(824) wire.
Connect voltmeter from LT

BLU/BLK (824) wire to BLK
(150) wire at instrument
cluster connector C203.
Battery voltage.
REFER to speed sensor in

Emissions Manual (Gasoline) or
Service Manual (Diesel) for
further diagnosing.
No voltage.

(150) wire from instrument
cluster to ground.
LOW COOLANT INDICATOR DOES NOT LIGHT WITH COOLANT LEVEL LOW (DIESEL ONLY)
TEST
1 . Disconnect low coolant probe
RESULT
ACTION
Low coolant indicator lights.
REPLACE low coolant probe.
Low coolant indicator does not

light.
GO to step 2.
2. Disconnect low coolant module

voltmeter from PNK/BLK (39) wire
at low coolant module connector
C225 to ground.
Battery voltage.
GO to step 3.
No voltage.

PNK/BLK (39) wire.
3. Connect voltmeter from PNK/BLK

(39) wire to BLK (150) wire at low
coolant module connector C225.
Battery voltage.
GO to step 4.
No voltage.

(150) wire.
4. Connect voltmeter from GRA (69)

wire at low coolant module
Battery voltage.
GO to step 5.
No voltage.
LOCATE and REPAIR open or

short to ground in GRA (69) wire
going from low coolant module to
low coolant indicator lamp.
5. Connect voltmeter from PNK/BLK

(39) wire to YEL/BLK (68) wire at
low coolant module connector
C225.
Battery voltage.

ground in YEL/BLK (68) wire from
low coolant module to low coolant
probe.
No voltage.
REPLACE low coolant module.

switch to RUN. Observe low
coolant indicator light.
LOW COOLANT INDICATOR IS LIT WHEN COOLANT LEVEL IS GOOD

TEST
Connect a fused jumper from low
coolant probe connector C186 to
ground. Place ignition switch to
RUN and observe low coolant
indicator light.
RESULT
Low coolant indicator goes out.
Low coolant indicator stays lit.

YEL/BLK (68) wire. If wire is good,
follow diagnostic procedures listed
under symptom Low Coolant
Indicator Does Not Light With
Coolant Level Low.
A-102 INSTRUMENT PANEL

ACTION
ILLUM
ILLUM
ILLUM
ILLUM
ILLUM
<0
L05 - ENGINE, 5.7L (350 CIO) V8 GAS ENGINE, VIN K

FIBER OPTIC
CABLE
ASHTRAY
ILLUMINATION
CANADIAN
DAYTIME
RUNNING
INSTRUMENT CLUSTER A-103
GLOW PLUG RELAY

AND CONTROLLER
(LL4, LH6)
(SEE PAGE 04)
LOW COOLANT
SENSOR (LL4)
(SEE PAGE 106)
I 33-.5 TAN/WHT 4
A-104 INDICATOR LAMPS

SUBURBAN/UTILITY
419-.0 BRN/WHTl
I 33-. 5 TAN/WHT |
A-106 INDICATOR LAMPS

FLEETSIDE, WIDESIDE, CREW-BONUS CAB
RPO CODES
wvwwwwww/
MT1 - AUTO TRANS, HD 4-SPD., WfTH OVERDRIVE
S HOT IN START OR RUN <
Ivw w w W V W V ^ A
GAGE/IDLE
20 AMP
12064770
135- 8 DKGRN
COOLANT
TEMPERATURE
SENDER
C107
12015306
120
31
FUEL PUMP
OIL PRESSURE
SWITCH
31-.8 TAN
440
(L05, L19)
31-.5 TAN (LL4 WITH MT1)
OIL PRESSURE
SENDER
C116
2977935
(LH6, LL4)
FUEL TANK
SENDER
(LH6, LL4)
I30-.BPNK
BUS BAR
GROUND
G200
FRAME
GROUND
G409
A-108 INSTRUMENT PANEL GAGES

SUBURBAN/UTILITY
RPO CODES
VAAMiWvM/WVW
<

HOT IN START OR RUN ?
W vw w vw w ^
GAGE/IDLE
20 AMP
39-.8 PNK/BLK T
S202
(SEE PAGE 27)
I
3 9-5 PNK/BLK V
DRAC
(SEE PAGE 75)
35-.8 DK GRN
COOLANT
TEMPERATURE
SENDER
C183
12052644
l/P CLUSTER
CONNECTOR
(SEE PAGE 103)
31-.5 T A N i
31-.8 TAN
FUEL PUMP
OIL PRESSURE
SWITCH
(L05, L19)
131-.8 TAN
31-.5 TAN (LL4 WITH MT1)
OIL PRESSURE
SENDER
S201
(SEE PAGES 17, 19)
C185
2977935
(LH6, LL4)
35-5 DK GRN1
ECM/PCM
(SEE PAGE 60)
C 30
20-1.0 TAN/WHT1
120-1.0 TAN/WHT
S139
(SEE PAGE i
ELECTRIC FUEL PUMP

(L05, L19)
FUEL TANK
SENDER
(LH6, LL4)
30-.8 PNK I
130-.8 PNK I
m tm t 30-.8 PNK w M
I 30-.5 PNK
FRAME
GROUND ( Q
G409
-= r
BUS BAR
GROUND
G200
INSTRUMENT PANEL GAGES A-109

FLEETSIDE
INSTR LPS
5 AMP
HEATER A/C
CONTROL ASSEMBLY
LAMP
l/P CLUSTER
CONNECTOR
RADIO
C203
12026261
GROUND
G200
A-110 INSTRUMENT PANEL LAMPS
T H E S A F E T Y BELT W A R N IN G B U ZZER DO ES N O T O P ER A TE
CIRCUIT OPERATION
TEST
SAFETY BELT WARNING BUZZER
1.

applied through the GAGE/IDLE Fuse to the Audio Alarm
at the Convenience Center. With the drivers safety belt
not buckled, terminal 39 of the Audio Alarm is grounded
through the Safety Belt Switch. The Fasten Belts
Indicators always goes on for about five seconds when
the Ignition Switch is turned to RUN or START.
IGNITION KEY WARNING BUZZER

Whenever the key is in the ignition switch, the ignition
switch is in LOCK, OFF, or ACC and the drivers door is
open, terminal 80 or the audio alarm is grounded. This
sounds the buzzer.
LAM PS-ON WARNING BUZZER
panel dimmer switch is not in the dimmest setting,

voltage is applied through the INSTR LPS fuse to the
audio alarm module through the GRA (8) wire. With the
panel dimmer switch at its dimmest setting the voltage
may not be enough to activate the alarm. When the
ignition switch is in RUN or START, voltage is applied
through the GAGE/IDLE fuse and the PNK/BLK (39) wire.
These two voltage are sensed and the alarm is not
sounded.
The alarm is activated when the ignition switch is
turned to LOCK, OFF, or ACC, the GAGE/IDLE fuse loses
voltage. The audio alarm module senses this loss of
voltage and activates the alarm.
If voltage is still
available from the INSTR LPS fuse. Voltage from the
STOP HAZ fuse is applied to sound the alarm. The
alarm can be turned off by turning off the light switch.
When the light switch is in HEAD or PARK and the
2.
GO to step 2.
CHECK STOP/HAZ fuse. If fuse is

good, REPAIR open in ORN (140)
wire. Install audio alarm module.
2.

form LT GRN (80) at convenience
center to ground.
Test lamp lights.
REPLACE audio alarm module.
GO to step 3.

from LT GRN (80) wire at turn
signal switch connector C205 to
ground.
Test lamp lights.

GRN (80) wire from turn signal
convenience center. Install audio
alarm module.

from TAN (159) wire at turn signal
5. Connect a self-powered test lamp

from TAN (159) wire at LH jamb
CHECK condition of the

GAGE/IDLE fuse. If fuse is not
blown, LOCATE and REPAIR open
in PNK/BLK (39) wire from
convenience center to fuse block.
Connect test lamp from WHT (238)

wire and BLK (150) wire at
convenience center.
Test lamp lights.
GO to step 3.

(150) wire from convenience
center to bus bar ground.
Test lamplights.
GO to step 4.

WHT (238) wire from safety belt
retractor switch to convenience
center.
Test lamp lights.

(150) wire from safety belt retractor
switch to bus bar ground.
REPLACE safety belt retractor

switch.
TEST
ACTION
Test lamp lights.
4.
GO to step 2.
TH E S A F E T Y B E LT W A R N IN G B UZZER O P E R A TE S W H EN S A FE T Y BELT IS BUC KLED
1. Turn ignition switch OFF. Leave

key in ignition switch. Open left
door. Remove audio alarm
module. Connect a voltmeter from
ORN (140) wire at convenience
center to ground.
3.
Test lamplights.
4. Buckle safety belt. Connect test

lamp from BLK (150) wire at safety
belt retractor switch connector
C306 to ground.
KEY-IN WARNING ALARM DOES NOT OPE RATE

RESULT
ACTION
Connect test lamp from PNK/BLK

(39) wire at convenience center to
ground.
3. Connect test lamp from WHT (238)

wire at safety belt retractor switch
DIAGNOSIS -- AUDIO ALARMS

TEST
RESULT
GO to step 4.
Test lamp lights.
REPLACE turn signal switch,

INSTALL audio alarm module.
Test does not light
GO to step 5.
Test lamp lights.

(159) wire between LH door jamb
switch connector C208 and turn
signal switch connector C205.
REPLACE LH door jamb switch.

RESULT
Disconnect safety belt retractor

ACTION
Safety belt buzzer stops.
REPLACE safety belt retractor

switch.
Safety belt buzzer continues.
CHECK for a short from WHT (238)

wire to ground. REPAIR as
required.
LAMPS-0 J WARNING ALARM DOES NOT OPERATE

TEST
1.
2.
3.
RESULT
ACTION
Remove audio alarm module.

Turn ignition switch to RUN.
Turn lamps switch ON. Connect
wire at convenience center to
ground.
Battery voltage.
GO to step 2.
No voltage.
CHECK GAGE/IDLE fuse. If fuse

is good, LOCATE and REPAIR open
in PNK/BLK (29) wire.
Connect voltmeter from GRA (8)

wire at convenience center to
ground.
Battery voltage.
GO to step 3.
No voltage.

(8) wire.
Connect ohmmeter from BLK

(150) wire at convenience
center to ground.
Low resistance.
REPLACE audio alarm module.
High resistance.
LOCATE and REPAIR cause of high

resistance in BLK (150) wire.
AUDIO ALARM A-111
RPO COOES
CONVENIENCE
CENTER
GAGE/IDLE
20 AMP
SAFETY BELT
RETRACTOR
SWITCH
(OPEN WHEN
SEAT BELT
ENGAGED)
150
T
8911773
i/p
U39-,8 PNK/BLK
I 39-.8 PNK/BLK I
CLUSTER
CONNECTOR
(SEE PAGE 105)
r
39-.8 PNK/BLK
I 39-.8 PNK/BLK |
^ r
S202
39-.8 PNK/BLK
'/fils
WATER IN FUEL
FILTER LAMP ..
(SEE PAGE 105)
(RPO LH6, LL4)
LOW
COOLANT
WARNING
MODULE
39-.8 PNK/BLK
} 39-.8 PNK/BLK I
I 39- 8 PNK/BLK |
If
39*.8 PNK/BLK I
(SEE PAGE 104)
39-.8 PNK/BLK I
BUS
BAR
GROUND
G200
A-112 SAFETY BELT WARNING BUZZER
|5
co
JJ
T
238
t
5
5
CD
]
C306
8911772
RPO CODES
yvw w w w w f
S
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TVWWWVWV'A
INSTR LPS
5 AMP
STOP HA2
15 AMP

S HOT IN START OH RUN ^
HOT AT ALL TIMES <
GAGE/IDLE
20 AMP
HORN/DM
20 AMP
240-1.0 ORN
L
140-.8 ORN I
HORN RELAY
S210
140-.8 ORN I
CONVENIENCE
CENTER
SAFETY BELT SW
-2 3 8
GROUND
-150
FASTEN BELTS
-2 3 7
IGNITION
- 39
IGN KEY SW
-8 0
BATTERY
-1 4 0
LIGHTS ON SW
I 140-.8 ORN
I 80-.5 LT GRN I
m
140
80
238
150
237
14O-.0 ORN I
RWAL MODULE
(SEE PAGE 116)
I 39-.8 PNK/BLK I
39
S202
(SEE PAGE 27)
-2 7
-1 4 0
r a
HAZARD FLASH
o
2
HZ/F
HORN
RELAY
AUDIO ALARM
FRONT
<3
in
cb
I
z
cc
O
3
CD
l/P CLUSTER
CONNECTOR
(SEE PAGE 105)
237-.8 Y E L I
240-1.0 ORN I
I 8-.5 GRA I
S201
(SEE PAGES 17, 19)
S209
y -f
17
19
16
------- .8 YEL ------- .8 PPL -
27
------- .8 BRN -
15
.8 DK BLU
18
RADIO
3
cn
o
S
I S-.5 GRA I
-------.8 WHT ---- 8 DKGRN
-.8LTBLU
l/P CLUSTER
CONNECTOR
(SEE PAGE 105)
HEATER, A/C
CONTROL ASSEMBLY
LAMPS (SEE PAGE 110)
28
l 8 .5 GRA i
159
159-.8 TAN
8-.5 GRA I
BUS BAR
GROUND
G200
LH DOOR
JAMB
SWITCH
(SEE PAGE 118
TURN
SIGNAL
SWITCH
KEY-IN AND LIGHTS-ON WARNING BUZZER A-113
CIRCUIT OPERATION
BRAKE INDICATOR DOES NOT LIGHT DURING A WARNING CONDITION

OR DURING THE ANTILOCK SYSTEM CHECK
Battery voltage is applied to the Brake Indicator when

the Ignition Switch is in RUN or START. Two switches
are connected to the Brake Indicator. When either of
these two switches close, ground is provided and the
indicator lights. The Brake Indicator is also connected to
the Electronic Rear Wheel Brake Control Module.
Indicator when there is low brake fluid pressure in one of

the two hydraulic brake systems. This could be caused
by a leak in one of the brake lines. Refer to Section 5 in
the 1991 R/V,P Light Truck Service Manual for Switch
reset procedures. This can only be accomplished after
the faulty system has been repaired.
1.
The Park Brake Warning Switch provides a ground

when the Parking Brake is applied. The Park Brake
Indicator lights to alert the driver.
The Electronic Rear Wheel Brake Control Module

grounds the Brake Indicator when the module senses a
fault in the Antilock Brake System. For Electronic Rear
Wheel Brake Control Diagnosis, refer to Section 5A in the
1991 R/V,P Light Truck Service Manual.
2.
The Brake Pressure Switch closes to light the Brake
TEST
DIAGNOSIS - BRAKE SYSTEMS

BRAKE INDICATOR REMAINS ON WITH IGNITION SWITCH IN RUN AND PARK BRAKE OFF
RESULT
TEST
1.
2.
Disconnect park brake switch

connector C293.
Disconnect brake pressure

warning switch connector C104.
ACTION
Brake indictor lamp does not go

out.
GO to step 2.
Brake indicator lamp goes out.
CHECK adjustment of park brake

switch. If adjustment cannot be
corrected, REPLACE brake switch.
Brake indicator lamp does not go

out.
GO to step 3 if not equipped with

Electronic Rear Wheel Brake
Control.
GO to step 4 is equipped with
Electronic Rear Wheel Brake
Control.
Brake indictor lamp goes out.

3.
4.
CHECK for a possible leak or loss

of fluid in the brake system.

from TAN/WHT (33) wire at park
brake warning switch C293 to
ground.
Test lamp lights.
LOCATE and REPAIR short in

TAN/WHT (33) wire.
CHECK instrument cluster and

indicator lamp.
Disconnect Electronic Rear Wheel

Brake Control module connector
C103.

out.
CHECK wiring between instrument

cluster and each switch and
module for a short to ground. If
wiring is good, the problem is in
the instrument cluster.
CHECK for an inoperative antilock

brake system. Refer to Section 5A
of the 1991 R/V, P Light Truck
Service Manual for a diagnostic
circuit check.
A-114 BRAKE WARNING SYSTEM
3.
RESULT
ACTION

connector C293. Connect a
fused jumper from park brake
ground.
Brake indicator lamp does

light.

warning switch connector
from TAN/WHT (33) wire at
brake pressure warning switch
connector C 104 to ground.
Brake indicator lamp does not

light.
GO to step 3.
Brake indicator lamp lights.
REPLACE brake pressure warning

switch.
Disconnect electronic rear

wheel brake control module
connector C103. Connect a
fused jumper from TAN/WHT (33)
wire at antilock module
Brake indicator lamp does not

light.
CHECK wiring and in-line diode

(if equipped) between
instrument cluster and each
switch and module for an open.
If wiring is good, the problem
is in the instrument cluster.
CHECK for an inoperative

antilock brake system. Refer
to Section 5A of the 1991 R/V,
P Light Truck Service Manual
for a diagnostic circuit
check.
GO to step 2.
switch. If adjustment cannot
be corrected, REPLACE brake
switch.
[ 300 } A
[ BL_g_J f j [~36l p c
133-. 5 TAN/WHT |
oldD
33-.5 TAN/WHT |
C210
6294641
IGNITION SWITCH
S219
l\
l/P
Z
<
ID
I1
L i
.m
115 !291941
1141391 9 I
\ l l r t 2 l3 3 |
111 193 il
II
I3 3 -.5 TAN/WHT I
: 94
29
39
33
12
93
11
18
: 24
15
14
120
30
19
420
440
439
806
39
140
120
31
50
436
35
93
97
422
91
92
C102
12020100
I 33-.S TAN/WHT I
PARK BRAKE
WARNING SWITCH
BRAKE SET
C
BRAKE
PRESSURE
WARNING
= SWITCH
(CLOSED WITH
PARK BRAKE
APPLIED)
I 33-.5 TAN/WHT I
C293
12004267
BRAKE WARNING SYSTEM A-115

WITH RWAL
VsMMA/WV/WW yw vw w w w w
S
HOT AT ALL TIMES <
> HOT IN ACCY OR RUN <
>VVV\VVVVVW'i
^W vvw vw w w vA
ECM 1
10 AMP
RWAL
CONTROLLER
ANTILOCK
BRAKE VALVE
(Q )
A-116 REAR WHEEL ANTILOCK BRAKES
ENGINE
GROUND
G110
CIRCUIT OPERATION
DOME LAMP DOES NOT WORK OR STAYS ON ALL THE TIME

TEST
COURTESY
DOME,
COMPARTMENT BOX,
UNDERHOOD LAMPS
CARGO LAMP
VANITY,
l/P
CARGO AND
Voltage is applied at all times from the T/L CTSY Fuse

to the Courtesy Lamp, Dome Lamp, l/P Compartment
Box Lamp and Vanity Lamps. The Courtesy and Dome
Lamps turn on when a ground path is provided by the
Panel Dimmer Switch or one of the Door Jamb Switches.
The l/P Compartment Box and Vanity Lamps have
their own switches that provide ground paths when their
switches close.
1.
Voltage is applied at all times through the HORN/DM

Fuse to the Cargo Lamp Switch. When the Cargo Lamp
Switch is turned on, voltage flows through the switch to
the Lamp. On models with a tailgate, a ground path is
provided when the tailgate is opened.
2.
UNDERHOOD LAMP
Voltage is applied at all times to the Underhood Lamp
from the Junction Block, through an in-line fuse. When
the switch is closed a ground path is provided.
3.
DIAGNOSIS - INTERIOR LAMPS

PRELIMINARY CHECKS:
Checks condition of T/L CTSY fuse. If fuse is good,
refer to appropriate diagnostic procedure.
TEST
1.
2.
c o u RTESY LA M P S D O N O T OPERA1rE
RESULT
4.
ACTION

wire at courtesy lamp connector
C218 to ground. Check at each
courtesy lamp.
Test lamp lights.
GO to step 2.

ORN (40) wire.
Open right door. Connect test lamp

from ORN (40) wire to WHT (156)
wire at courtesy lamp connector
C218.
Test lamp lights.
REPLACE bulb.
CHECK to make sure jamb switch

is closing. If switch closes,
WHT (156) wire and BLK (150)
wire.
CARGO LAMP DOES NOT WORK

TEST
RESULT
ACTION
1. Turn cargo switch on. Connect a

test lamp from ORN (140) wire at
cargo lamp connector C436 to
ground.
Test lamp lights.
GO to step 2.
GO to step 3.
2.
Test lamp lights.
REPLACE bulb.

WHT (156) wire from cargo lamp to
light switch.

(140) wire to WHT (156) wire at
cargo lamp connector C436.

(40) wire at cargo lamp switch
(140) wire at cargo lamp switch
Test lamp lights.
GO to step 4.

(40) wire.
Test lamp lights.

ORN/WHT (140) wire from cargo
lamp switch to cargo lamp.
REPLACE cargo lamp switch.
A-118 DOME LAMPS, l/P COMPARTMENT LAMP, CARGO LAMP, UNDER

HOOD LAMP AND LIGHTED VANITY MIRROR
RESULT
ACTION

(40) wire at both dome lamps to
ground.
Test lamp lights.
GO to step 2.

(40) wire.
Open both doors and turn panel

lamp switch to ON. Connect a
test lamp from ORN (40) wire to
WHT (156) wire at dome lamp.
Test lamp lights.
REPLACE bulb if dome lamp did

not work. If dome lamp stayed ON
all the time, GO to step 3.
Test lamp does not light
GO to step 3.
Disconnect jamb switch

connectors. Connect an
ohmmeter from WHT (156)
terminal to BLK (150) terminal at
jamb switch. Take a reading with
door open and a reading with
door closed. With door open
reading must be 0 ohms and door
closed, infinite ohms.
Correct readings.
GO to step 4.
Incorrect readings.
REPLACE jamb switch(es) that

have incorrect reading.
Disconnect light switch connector

C202. Connect an ohmmeter from
WHT (156) terminal to BLK (150)
terminal at light switch. Turn light
switch to ON and the OFF and
take a reading in each position.
When ON, reading must be 0
ohms and when OFF, reading
must be infinite ohms.
Correct readings.
LOCATE and REPAIR open or

short in WHT (156) wire and BLK
(150) wire.
Incorrect readings.
l/P COMPARTMENT BOX LAMP DOES NOT WORK

RESULT
TEST
ACTION
1. Open l/P compartment box door.

wire l/P compartment box lamp
Test lamp lights.
GO to step 2.

ORN (40) wire.
2. Connect test lamp from ORN (40)

wire to BLK (150) wire at l/P
compartment box lamp connector
C230.
Test lamp lights.
REPLACE l/P compartment box

lamp assembly.

(150) wire from l/P compartment
box lamp to ground terminal G202.
UNDERHOOD LAMP DOES NOT WORK

TEST
RESULT
ACTION

underhood lamp connector C101 A.
Test lamp lights.
REPLACE underhood lamp bulb.
GO to step 2.
2. Connect test lamp to RED (2) wire

at in-line fuse connector C100A to
ground.
Test lamp lights.
REPLACE in-line fuse.

RED (2) wire or fusible link.
C219
12004886
RH DOOR
JAMB SWITCH
(CLOSED WITH
DOOR OPEN)
IREAR
|C] |C] 0
^BATJ
ig m E
S HOT AT ALL TIMES C
i n M A m [] i
WOO
RH REAR
DOORJAMB
jcuj8
*N
1
n w/-\!Vfw dqqp
OPE
)
SWITCH
8911287
yvw w w vw /
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[w] g] [d]
i ] H] I
GT602
i (i
[i
(SUBURBAN ONLY)
156
(i i
C438
6288872
ACC LPS
SHUNT
I . I h J h
SHUNT
_ _ _ ^ s jp g p i p i
INSTR LPS
153
B d
HORN/DM
1GN
lS
AUX HTR A/C
p H
& G
GAGE/IDLE HTR A/C

30
A
TURNB/U PWRWDO
DS Gd
DRL
FRONT
W E
FRONT DOME LAMP
REAR DOME LAMP

(SUBURBAN/UTILITY)
(SUBURBAN/UTILITY)
t 0
frfl EkB
D
S 0 0
CRANK__________
i IT fl-A p '
[fc-H
W E
D d
ECM 1
Ip w
l/P
COMPARTMENT
BOX LAMP
AND SWITCH
o S
^ Q Q Q Q S lri )
O S ^ J i
FUSE BLOCK
12103404
C218
I156-.8W HT
I 156-.8 WHT
I40-.8 ORN
94
29
15
39
14
33
12
93
11
18
120
420 440
439 806
140
3r1
S413
2
39
120
31
50
436
35
93
97
422
91
92
S412
GENERATOR
AND BATTERY
(SEE PAGE 10)
156-.8 W H T I
REAR PANEL
DOOR/END GATE
HARNESS EXTENSION
(SUBURBAN ONLY)
(SEE PAGE)
44
40-.8 ORN
C323
12047682
12047683
LIGHTED
VANITY
MIRROR
159-.8 TAN I
150DOME
2
GT502
CARGO LAMPS
(SUBURBAN ONLY)
(SEE PAGE 120)
12015958
CIRCUIT
BREAKER
25 AMP
PARK
156-.8 WHT
LH DOOR
JAMB SWITCH
HEAD
OFF
(CLOSED WITH
DOOR OPEN)
'PARK
LIGHT SWITCH
SHEET
METAL
GROUND / q )
G200
^
KEY-IN
WARNING
BUZZER
(SEEPAGE 113)
C208
12047682
12047683
C437
6288872
LEFT REAR (CLOSED WITH

DOORJAMB DOOROPEN>
SWITCH
DOME LAMPS, l/P COMPARTMENT LAMP, AND LIGHTED

VANITY MIRROR
A-119
RPO CODES
E63 - FLEETSIDE BODY
JPCAO
HTR
fc] (c] S
i m
^B A T J
[U 0
[U
11
WDO
m 0
M GNJ
m
"
m
Tf VTTTi
yvvw w vw vw
>
HOT AT ALL TIMES ?
Ta w
11111 ii A11111
w w smv^
* I) (1 1 ID II (1 I
o<
ACC LPS PWR
| r 4 1 v ^
Dd K l
D d
K l
T/L CTSY GAGE/IDLE HTR A/C

n n
I
30
A
LÛ
ECM B
TURN B/U PWR WDO
D 3
nun
DRADIO
d
I kS
[ k&h
DWIPER
3
I !*fi I k f i
EJ D3
ECM 1
Ik s IpS p i
X H T R A /C STOP HA2
CD
DRL
D3 D
CRANK
I kS
CARGO
LAMP
SWITCH
FLEETSIDE
MODELS
(E63)
C431
2962793
\ HORN/DM
20 AMP
I kH
S'S S'S
o)
B^B I
FRONT
CARGO
LAMP
FUSE BLOCK
12103404
FLEETSIDE
MODELS
(63)
COURTESY LAMP
AND FRONT DOOR
JAMB SWITCHES
(SEE PAGE 119)
I 40-.8 ORN
C219
12004886
C433
12015987
C455
2977253
JI156-.8 WHT w
156*.8 WHT
40-.8 ORN I
C442
12015952
REAR GATE
SWITCH
^ jh 5 6 ^ J
C456
12004333
6288544
(UTILITY ONLY)
I
DOME
. LAMPS
(SEE PAGE 112)
A-120 CARGO LAMP
BATTERY
JUNCTION BLOCK
C100A
12033769
S142
z
(L
o
UNDERHOOD
LAMP
SHEET METAL
GROUND
=
G118
UNDERHOOD LAMP A-121
CRUISE CONTROL DOES NOT OPERATE
CIRCUIT OPERATION
The Cruise Control System operates a mechanical
linkage to the throttle by means of a Vacuum Motor.
This is a diaphragm moved by a vacuum applied to one
side. A solenoid operated valve connects the Vacuum
Motor to a Vacuum Tank. Another solenoid valve vents
the vacuum to reduce the suction. The Cruise Control
Module controls the vacuum motor and the throttle by
pulsing these solenoid valves on and off.
One input to the module is the vehicle speed. This
input comes from the DRAC. If the actual speed signal
is different from the speed that was sent into and
remembered by the module, the module generates
pulses to change the vacuum and return the vehicle to
the set speed. Other inputs to the module are from the
Cruise Switch and the Set Switch. A disconnect input to

the module comes from a switch on the brake pedal and
on vehicles equipped with a manual transmission, from
the Clutch Switch. A separate vacuum shut-down of the
Cruise Control comes from the Brake/Clutch Cruise
Release Valve on the brake pedal.
The two outputs of the Cruise Control Module operate
the coils of the Vacuum Valve and the Vent Valve. Both
valves are located in the Cruise Control Servo. These
valves move the throttle by means of the Vacuum Motor.
The Servo Position Sensor coil senses the position and
motion of the Vacuum Motor. It feeds this information
back to the module to provide smooth acceleration while
the vehicle is in Cruise Control.
DIAGNOSIS - CRUISE CONTROL

CRUISE CONTROL DOES NOT DISENGAGE WHEN CLUTCH OR BRAKE PEDAL IS DEPRESSED
TEST
and cruise control switch to
ON. Connect a test lamp from
GRA (397) wire at brake switch
RESULT
GO to step 2, (man trans).

GO to step 5 (auto trans).

(397) wire between brake
switch and cruise control
switch.
2. Connect a test lamp from BRN

(86) wire at brake switch
connector C253 to ground. Do
not depress brake pedal.
Test lamp lights.
GO to step 3.
CHECK adjustment of brake

switch. If brake switch cannot
be adjusted, REPLACE brake
switch.

(86) wire at clutch switch
Test lamp lights.
GO to step 4.

(86) wire between brake switch
and clutch switch.

GRA/BLK (87) wire at clutch
ground. Do not depress clutch
pedal.
Test lamp lights.
REFER to "Cruise Control Does

Not Operate" procedure.

GRA/BLK (87) wire at brake
ground. Do not depress brake
pedal.
A-122 CRUISE CONTROL
CHECK adjustment of clutch

be corrected, REPLACE clutch
switch.
Test lamp lights.
REFER to "Cruise Control Does

Not Operate" symptom.

be made, REPLACE brake switch.
ACTION

and cruise control switch to
ON. Connect a test lamp from
GRA (397) wire at cruise
control switch connector C252
to ground.
Test lamp lights.
GO to step 2.

PNK/BLK (139) wire between
cruise control switch and fuse
block. If wire is in good
condition, REPLACE cruise
control switch.
2. Connect a test lamp from DK BLU

(84) wire at cruise control
ground.
Test lamp lights.
REPLACE cruise control switch.
GO to step 3.
3.
Test lamp lights.
GO to step 4.

BLU (84) wire between cruise
control switch and cruise
control module. If wire is in
good condition, REPLACE cruise
control switch.
4. Depress and hold RESUME/

ACCELERATE switch. Connect a
test lamp from DK GRN (83) wire
at cruise control module
Test lamp lights.
GO to step 5.

GRN (83) wire. If wire is in
good condition, REPLACE cruise
control switch.
5. Connect a test lamp from GRA

ground.
Test lamp lights.
GO to step 6.

(397) wire between cruise
control module and brake
switch and/or brake switch and
cruise control switch.
6. Connect a test lamp from BLK

(150) wire to GRA (397) wire at
cruise control module
connector C252.
Test lamp lights.
GO to step 7.

control module and bus bar
ground.
7. Place ignition switch to OFF.

Disconnect cruise control
servo connector C184. Using
four jumper leads, connect
cavities A, B, D and E to
ground. Using a digital
ohmmeter, check for
continuity in DK BLU/WHT
(403), TAN (398), LT BLU/BLK
(399) and LT GRN (402) wires at
cruise control module
No continuity in any or all

wires.

wire(s) that show no
continuity.
Continuity.
GO to step 8.
Depress SET/COAST switch.

Connect a test lamp from DK BLU
ground.
ACTION
Test lamp lights.
RESULT
TEST
CRUISE CONTROL DOES NOT OPERATE (CONTINUED)

RESULT
TEST
8.
Connect a digital ohmmeter at

BLK (150) cavity in cruise
control servo connector C184
and check for continuity to
ground.
ACTION
No continuity.

control servo and bus bar
ground.
Continuity.
Problem is not related to the

cruise control system wiring
or switches, replace cruise
control module and test drive.
If still inoperative, replace
cruise control servo.
CRUISE CONTROL A-123
RPO CODES

-1
i
(LH6, LL4 ONLY)
CRUISE
CONTROL
MODULE
C255
12034117
8911256
A-124 CRUISE CONTROL
FOUR-WHEEL DRIVE ENGAGES BUT 4WD INDICATOR LAMP DOES NOT LIGHT (V100, V200)
CIRCUIT OPERATION
When the Ignition Switch is in RUN and the FourWheel Drive Control (4WD) Lever is engaged, the
Transfer Case Switch closes and battery voltage is
applied across the Front Axle Actuator. The Front Axle
Actuator energizes and the four-wheel drive gears are
meshed. This meshing action of the four-wheel drive
gears closes the Front Axle Switch, and battery voltage
is applied through the WHT (156) wire across the fourwheel drive indicator lighting the bulb in Utility and
Suburban models.
On Fleetside, Wideside and
Crew/Bonus Cab models, the closing of the switch
provides a ground for the indicator lamp. Battery voltage
is also applied through the front axle switch contacts and
the PPL (420) wires to the Electronic Rear Wheel Brake
Control Module in the Utility and Suburban models. This
will keep the antilock braking system disabled in 4WD
mode. The In-Line Resistor (automatic transmission only)
prevents the TCC Solenoid from engaging when the
Front Axle Switch is closed.
TEST
GO to step 2.
CHECK RADIO fuse. If fuse is

good, LOCATE and REPAIR open
in BRN (141) wire between transfer
case switch connector C309 and
fuse block connector C288.
Connect transfer case connector

C309. Connect a test lamp to the
WHT (156) wire at the back of the
transfer case connector C309 to
ground. Place the transfer case in
four-wheel drive.
Test lamp lights.
GO to step 3.
REPLACE transfer case switch.
3. With ignition switch in RUN and

transfer case in four-wheel drive,
disconnect 4WD indictor lamp
connector C246. Connect a test
lamp between WHT (156) wire and
ground.
Test lamp lights.
GO to step 4.

WHT (156) wire between transfer
case switch connector C309. and
four-wheel drive indicator lamp
connector C246.
4.
Test lamp lights.
REPLACE bulb.

2.
PRELIMINARY CHECKS:
While performing the following diagnostic procedures,
the Ignition Switch must be in RUN, and the 4WD Control
Lever must be in the 4WD ENGAGED position.
To determine whether the vehicle is in Two-Wheel

Drive or Four-Wheel Drive, it must be lifted up so the
wheels can spin freely.
FOUR-W HEEL D R IV E IN D IC A T O R LAM P W IL L N O T TU R N O FF

TEST
Disconnect transfer case switch
connector C309.
RESULT
4WD indicator lamp goes off.
ACTION
Test lamp lights.
1.
DIAGNOSIS - FOUR-WHEEL DRIVE INDICATOR LAMP

Make sure all mechanical components are operative
before diagnosing the electrical portion of the four-wheel
drive system.
RESULT
Place ignition switch in RUN.

Remove transfer case connector
BRN (141) wire to ground.
Connect a test lamp between

WHT (156) wire and BLK (150)
wire at four-wheel drive indicator
lamp connector C246.
ACTION
FO U R -W H E E L D R IV E EN G A G ES B U T 4W D IN D IC A TO R LA M P DO ES N O T L IG H T (V 300)
TEST
1.
2.
3.
4.
RESULT
ACTION
Disconnect 4WD indicator lamp

connector C246. Connect test
lamp to BRN/WHT (141) wire to
ground.
Test lamp lights.
GO to step 2.
CHECK RADIO fuse, if fuse is

in BRN/WHT (141) wire.
Connect test lamp to connector

C246 to BRN/WHT (141) to WHT
(156) wire. Engage four-wheel
drive.
Test lamp lights.
REPLACE 4WD indicator lamp.
GO to step 3.

to WHT (156) wire at transfer case

WHT (156) wire.
Test lamp lights.
GO to step 4.
Test lamp lights.


between WHT (156) wire and BLK
(150) wire at transfer case switch
connector C246. Make sure fourwheel drive is engaged.
FOUR-WHEEL DRIVE A-125
C288
12004887
43*.8 YEL
0 0 0 0
L iG N ^f
SHUNT
SHUNT
ACC LPS
El
INSTR LPS
K l
KIGN l AUXKHTR lA/C
k f i HMl
3 3
IK K l
kQ I kQ I k
HORN/DM

30
A
ECM B
TURN B/U PWR WDO
to t
I kB I kH
IK
KECM 1l
DDRLd
B 'f l
DC
FRONT
B^S
o )
REAR
FUSE BLOCK
12103404
I 141-.8 BRN/WHT
FOUR-WHEEL
DRIVE
INDICATOR
LAMP
n
E
IF
ill
(ft)
If ^T1
TRANSFER
CASE
SWITCH
(CLOSED
INFOURWHEEL DRIVE)
TRANSFER
CASE
SWITCH
FOUR-WHEEL DRIVE
INDICATOR W/RWAL
A-126 FOUR-WHEEL DRIVE
(CLOSED
IN FOURWHEEL DRIVE)
13
FOUR-WHEEL DRIVE INDICATORS W/O RWAL
BUS
BAR
GROUND
G200
DIAGNOSIS POWER MIRRORS
CIRCUIT OPERATION
PRELIMINARY CHECKS:
POWER MIRRORS
Voltage is applied at all times to the Power Outside
Rearview Mirror Switch, through the HORN/DM Fuse and
an In-Line Auto Fuse.
The mirror assemblies contain two motors. One
motor positions the mirror up and down, the other motor
positions the mirror to the left or right. By reversing the
polarity of the motors, the motors will move the mirrors
either up/down or left/right.
POWER DOOR LOCKS

When a Door Lock Switch is operated, all of the doors
will unlock or lock. Each lock can also be operated
manually. The locks are operated by reversible motors
that receive voltage from the PWR/ACC Circuit Breaker.
The Door Lock Switches operate to turn the Motors on
by applying battery voltage to one of the terminals and
ground to the other terminal.
When either Door Lock Switch is moved to the LOCK
position, it completes the circuit to the Motors. Voltage

is applied to the GRA (295) wire and to the Door Lock
Motors, which are grounded by the TAN (294) wire from
the other terminal of the Motor through the other switch
contact to ground. The Motor in each door runs to
operate the Door Locks. When the Door Lock Switch is
released, the circuit is opened and the Motors turn off.
A similar action occurs with either of the Door Lock
Switches closing to the UNLOCK position. Now the TAN
(294) wires to the Motors supply battery voltage and the
GRA (295) wires are grounded. The polarity of the
voltage to the Motors has reversed. The Motors run in
the opposite direction to unlock the doors.
The Door Lock Switches are usually closed for just a
moment. If the Door Lock Switches are held closed, a
circuit breaker in each Motor will open to protect against
damage. The circuit breakers close automatically when
they cool off.
1. Check to see that the HORN/DM, PWR ACC and

in-line (C266) fuses are not blown. If blown, locate
and repair source of the overload, then replace fuse.
2. Refer to Section 8 of the 1991 R/V,P Light Truck

Service Manual for diagnosis and repair of all nonelectrical system components.
NEITHER MIRROR IS OPERATIONAL

TEST
RESULT
1.

wire at mirror switch connector
C505 to ground.
2.

wire to BLK (150) wire at mirror
Test lajrnp does not light.
Test lamp lights.

Test lamplights.
ACTION
(40) wire between mirror switch
connector C505 and fuse block.
GO to step 2.
(150) wire between mirror switch
connector C505 and bus bar ground.
REPLACE mirror switch.
LH MIRROR WILL NOT ADJUST UP AND DOWN

TEST
RESULT
Disconnect in-line fuse connector

C266 and connector C504 at LH
mirror motor. Place ohmmeter on
Rx1 scale and connect leads to
YEL (88) and LT BLU (82) wires at
LH mirror motor connector C504.
While holding mirror adjustment
switch in the UP and DOWN
positions, measure for continuity.
ACTION
Continuity.
REPLACE LH mirror motor.
No continuity.

(88) or LT BLU (82) wires between
mirror switch connector C505 and
If none if found, REPLACE switch.
LH MIRROR WILL NOT ADJUST LEFT AND RIGHT

TEST
RESULT

C266 and connector C504 at LH
WHT (81) and LT BLU (82) wires at
While holding mirror adjustment
switch in the LEFT and RIGHT
positions, measure for continuity.
Continuity.
No continuity.
ACTION
REPLACE LH mirror motor.
WHT (81) or LT BLU (82) wires
between mirror switch connector
C505 and LH mirror motor
connector C504. If none is found,
REPLACE switch.
POWER MIRROR AND POWER DOOR LOCKS A-127
RH MIRROR WILL NOT ADJUST UP AND DOWN

C266 and connector C600 at RH
YEL/BLK (888) and LT BLU/BLK
(82) wires at RH mirror motor
connector C600. While holding
mirror adjustment switch in the UP
and DOWN positions, measure for
continuity.
REPLACE RH mirror motor.
Continuity.
No continuity.
TEST
ACTION
RESULT
TEST
ONE DOOR LOCK MOTOR DOES NOT LOCK OR UNLOCK FROM A PARTICULAR SWITCH

YEL/BLK (888) and LT BLU (82)
wires between mirror switch
connector C505 and RH mirror
motor connector C600. If none is
found, REPLACE switch.

ORN/BLK (60) wire at
inoperative switch connector
to ground.
2.
RH MIRROR WILL NOT ADJUST LEFT AND RIGHT

C266 and C600 at RH mirror
motor. Place ohmmeter on Rx1
scale and connect leads to
WHT/BLK (881) and LT BLU/BLK
(82) wires at RH mirror motor
connector C600. While holding
mirror adjustment switch in the
LEFT and RIGHT positions,
measure for continuity.
REPLACE RH mirror motor.
Continuity.
No continuity.
3.

WHT/BLK (881) and LT BLU/BLK
(82) wires between mirror switch
connector C505 and RH mirror
motor connector C600. If none is
found, REPLACE switch.
1.
NONE OF THE DOOR LOCK MOTORS LOCK OR UNLOCK

Connect test lamp from ORN/BLK
(60) wire at door lock relay
ACTION
RESULT
Test lamp lights.

ORN/BLK (60) wire between switch
and splice S259.
Test lamp lights.
If door lock will not lock, go to step

2. If door lock will not unlock, go
to step 3.
Door lock motor runs.
REPLACE door lock switch.
Door lock motor does not run.

BLU (195) wire between
inoperative switch connector and
door lock relay connector C264.
Door lock motor runs.
REPLACE door lock switch.
Door lock motor does not run.

BLK/WHT (194) wire between
inoperative switch connector and
door lock relay connector C264.
ONE DOOR LOCK MOTOR DOES NOT OPERATE FROM ANY SWITCH
TEST
DIAGNOSIS POWER DOOR LOCKS

TEST

ORN/BLK (60) wire to BLK/WHT
(194) wire at inoperative switch
connector.
LOCATE and REPAIR open in ORN/

BLK (60) wire between door lock
relay connector C264 and fuse
block. Inspect splice S259 for
open wire. If no open is found,
REPLACE PWR ACC circuit breaker.
INSPECT door lock relay for poor
ground condition or REPLACE
door lock relay.
A-128 POWER MIRRORS AND POWER DOOR LOCKS
ACTION
ACTION
RESULT
TEST

ORN/BLK (60) wire to LT BLU
(195) wire at inoperative switch
connector.
RESULT
2.
Connect test lamp from TAN (294)

wire to GRA (295) wire at
inoperative motor and momentarily
place door lock switch in lock or
unlock position while observing
test lamp.
Connect test lamp from TAN (294)
wire at inoperative motor to ground
and momentarily place door lock
switch to unlock position while
observing test lamp.
RESULT
ACTION
Test lamp lights.
REPLACE door lock motor.
GO to step 2.
Test lamp lights.

GRA (295) wire between
inoperative motor connector and
spliceS258.

TAN (294) wire between
inoperative motor connector and
splice S257.
w v w w w w m
S
HOT AT ALL TIM ES <
Z'VM/VWVWWN
I 640-1.0 ORN
HORN/DM
20 AMP
f
0
* BATj^
0 /[c] 0
[cf
@
WDO
|c ]
[a )
[a ]
MGN^J
[D]
ACC LPS
SHUNT
SHUNT
D
H
5RN3
/bl4l
GAGE/IDLE HTR A/C
\S ] \
TURN B/U PWR WDO
ECM 1
K ]
DRL
Kl 0
FRONT
40-.5 ORN
150-.5 BLK
I 40-.5 ORN
LEFT/RIGHT
s = i '
C266
12010105
IN-LINE
3 AMP
AUTO FUSE
POWER WINDOWS
(SEE PAGE 139)
BUS
BAR
__ GROUND
TT]
31
G201
POWER OUTSIDE REARVIEW MIRRORS A-129
-----1l 2
'
LH
DOOR LOCK
MOTOR
A-130 POWER DOOR LOCKS

2-DOOR (WITHOUT POWER OUTSIDE REARVIEW MIRRORS)
[c] 0
@ 1] @ i B fcAR
m
m
0 0 1 0
t-B A T -*
WDO
M G N ^f
SHUNT
ACC
i
Gj]Ha
LPS
BS
B d
T /L CTSY
K
l
ECM B
PWR
|sHUNT [ 'sA* |
INSTR LPS
H O R N /D M
PW R A C C
K l K l K
IG N
A U X HTR A /C
G A G E /ID L E
STO P HA
I K
HTR A /C
BdDL
T U R N B /U
PW R W D O
KE C M l1
KDRL l
RADIO
nn
WIPER
Cd 0
FRONT
D OOR
LOCK
RELAY
-------------- l
X
T
' -------------------m m 5
LH
DOOR LOCK
MOTOR
POWER DOOR LOCKS A-131

2-DOOR (WITH POWER OUTSIDE REARVIEW MIRRORS)
RH FRONT DOOR
LOCK MOTOR
[c] (c) 0
T
M il
0 (W) 0 0
WDO
batj
HGN^
SHUNT
MM
0 0 0 0
SH UN T
ACC LPS
P iA ^ j
UE
INSTR LPS
HORN/DM
Kl Kl
kfi BkA
K l
Kl K
VE
Is T
IGN
AUX HTR A/C

30
kECM Bi
B d
I UE
I VE
TURN B/U PWR WDO
K
J KDHL]
ECM 1
B 'fl S'S
Kl 0
0 D 0/fi
CRANK
FRONT
60-2.0 GRN/BLK
ll
195-.8 LT
r
jm v
.m v
194 -. a b lk / w h t
.^ b v
j h
^m a r
> 12020398
12015344
LH DOOR
LOCK SWITCH
A B C
nn nn
0)
(O
Ik
U1 0 <0
UNLOCK
12020397
TT
LOCK
GT500
GT501
8911670
L =
12010247
194-.8 LT BLU H
i^ ^ ^ B H 1 9 4 - .8 L T B L U
60-2.0 ORN/BLK I
195-.8 BLK/WHT
^60-2.0 O R N /B LK iv
295-1.0 GRA
295-1.0 GRA I
294-1.0 TAN H H 1
294-1.0 TAN

A JI
îi95-.8 BL-K/WHT^*"^'
LH FRONT DOOR
LOCK MOTOR
GT800
12010366
I 295-1.0 GRA I
295-1.0 GRA
I 294-1.0 TAN
294-1.0 TAN
i
i 295
{
294
..
RH REAR
DOOR LOCK
MOTOR
C802
12004140
12015344
SIDE DOOR
CONTACT
BUTTONS
REAR
PANEL
DOOR LOCK
MOTOR
C402
I 295-1.0 GRA |
295-1.0 GRA
I 294-1.0 TAN I
294-1.0 TAN
295-1.0 GRA
294-1.0 TAN
C404
I 294-1.0 TAN I
12047676
12020397
| 295-1.0 GRA
1295-1.0 GRA I
CONTACTOR
I 195-.8 LT BLU I
1194-.8 BLK/WHT I
DOOR
LOCK
RELAY
I 295-1.0 GRA I
I 294-1.0 TAN I
I 294-1.0 TAN |
C264
2984378 I
I 294-1.0 TAN I
I 60-2.0 ORN/BLKI
1295-1.0 GRA I
I 195-.8 LT BLU I
I 194-.8 BLK/WHT I
I
A B C
12047675
C403
I 295-1.0 GRA
I 294-1.0 TAN
H
L_
295
294
r
LH REAR
DOOR LOCK
MOTOR
GT700
12020366

RH FRONT DOOR
LOCK MOTOR
LH FRONT DOOR
LOCK MOTOR

4-DOOR (WITHOUT POWER OUTSIDE REARVIEW MIRRORS)
GT800
12010366
1
295-1.0 GRA
(-1
294-1.0 TAN
295 c
294
L
fc =
I [*"'
CIRCUIT
. I
B R EA K E R
RH
DOOR LOCK
MOTOR
C602
12004140
SIDE DOOR
CONTACT
BUTTONS
REAR
PANEL
DOOR LOCK
MOTOR
295-1.0 GRA
294-1.0 TAN
C404
AAA A A t f i
294-1.0 TAN
12047676
12020397
295-1.0 GRA
DOOR
LOCK
RELAY
194-.8 BLK/WHT
295-1.0 GRA

294-1.0 TAN
Bl l
294-1.0 TAN
AA
294-1.0 TAN
I I
m<
194-.8 BLK/WHT
r nn nn
KJ
12020397
n5
GT700
C702
12004140
12020366
295-1.0 GRA
295-1.0 GRA
294-1.0 TAN
in
294-1.0 TAN
Fn
u
I"r
?94 r
LH REAR
DOOR LOCK
MOTOR

4-DOOR (WITHOUT POWER MIRRORS)
CIRCUIT OPERATION
A permanent magnet (PM) motor operates each of
the Power Windows. Each Motor raises or lowers the
window when voltage is supplied to it. The direction the
Motor turns depends on the polarity of the supply
voltage.
The Switches control the supply voltage
polarity.
DIAGNOSIS circuit breaker and the ORN/BLK (60) wire. When the
ignition switch is in RUN or ACC, battery voltage is
applied to the PWR WOO circuit breaker and the PNK
(76) wire to the front tailgate window switch.
WINDOW SWITCH OPERATION

The Master Door Lock/Power Window Switch
Assembly controls all of the Window Motors. Each
window also has its own control switch.
Each Motor is protected by a built-in circuit breaker.
If a Window Switch is held too long with the window
obstructed or after the window is fully up or down, the
circuit breaker opens the circuit. The circuit breaker
resets automatically.
When the Ignition Switch is in RUN or ACC, battery
voltage is applied to the Master Door Lock/Power
Window Switch Assembly, the PWR WDO Circuit Breaker,
and the PNK (76) wires.
When any of the UP Switches are operated, battery
voltage is applied to the Window Motor through the DK
BLU/WHT (166) wire. The Window Motor is grounded
through the DN contact. The Motor runs to drive the
window up. When any of the DN Switches are operated,
battery voltage is applied to the Window Motor in the
opposite direction through the BRN (65) wire. The
Window Motor is grounded through the UP contact. The
Motor runs to drive the window down.
Battery voltage is supplied to the key-operated
tailgate window switch at all times through the PWR ACC
A-136 POWER WINDOWS
When the Ignition Switch is in RUN or ACC, battery

voltage is applied to the Window Switch through the
PWR WOO Circuit Breaker and the PNK wires to terminal
76. When the UP Switch in the Window Switch is
operated, battery volt~ge is applied to the Window Motor
through the OK BLU/WHT (166) wire. The Motor is
grounded through the BRN (165) wire, the ON contact in
the Window Switch, the TAN (167) wire and the ON
contact in the Master Door Lock/Power Window Switch
Assembly. The Motor runs to drive the window up.
When the DN switch in the Window Switch is operated,
battery voltage is applied to the Window Motor in the
opposite direction through the BRN (165) wire. The
Motor is grounded through the OK BLU (164) wire, the
UP contact in the Window Switch, the OK BLU/WHT (166)
wire and the UP contact in the Master Door Lock/Power
Window Switch Assembly. The Motor runs to drive the
window down.
The tailgate window motor receives voltage from
either the front or key-operated tailgate switches through
the LT BLU (183) wire for down or the TAN/WHT (184) for
up operation. The tailgate window motor is grounded at
the tailgate.
POWER WINDOWS
PRELIMINARY CHECKS:
Check condition of PWR WDO circuit breaker. If
circuit breaker is in good condition, use the following
POWER WINDOWS DO NOT OPERATE OR ONLY GO IN ONE DIRECTION
TEST
RESULT
ACTION
1. Place ignition switch in RUN or

ACC position. Connect a test
lamp from PNK (76) wire at
affected window switch connector
C500, C601, C700 or C800 to
ground.
Test lamp lights.
GO to step 2.

(76) wire from affected window
switch to fuse block.
2. Connect a test lamp from PNK

C500, C601, C700 or C800.
Test lamp lights.
GO to step 3.

3. Move and hold affected window

switch to UP position. Connect a
test lamp from BRN (165,667, or
669) wire at affected window
switch connector C500, C601,
C700 or C800 to ground.
Test lamp lights.
GO to step 4.
REPLACE affected window switch.

(165, 667, or 669) wire to OK BLU
(164, 666, or 669) wire at affected
window switch connector C5 0 0,
C601, C700 or C800.
Test lamp lights.
GO to step 5.

window motor connector C503,
C604, C701 or C801 to ground.
Test lamp lights.
GO to step 6.

(165, 667 or 669) wire from
affected window motor to window
switch.

(165, 667, or 669) wire to OK BLU
C604, C701 or C801.
Test lamp lights.
REPLACE affected window motor.

BLU (164, 666 or 668) wire
between affected window motor
and window switch.
POWER WINDOWS ONLY OPERATE FROM DRIVERS SIDE WINDOW SWITCH

TEST
1. Place ignition switch in ACC
PNK (76) wire at affected window
switch connector C601, C700 or
C800 to ground.
2. Move affected window switch to
UP position. Connect test lamp
from BRN (667 or 669) wire at
3.
Move affected window switch to

DOWN position. Connect test lamp
from DK BLU (666 or 668) wire at
RESULT
8. Connect test lamp from PNK (76)

wire to DK BLU/WHT (166), DK
GRN (168) or LT GRN (170) wire
and then to TAN (167), PPL (169)
or PPL/WHT (171) wire at affected
window switch connector C601,
C700 or C800.
ACTION
Test lamp lights.
GO to step 2.

PNK (76) wire from affected
window switch to fuse block.
Test lamp lights.
GO to step 3.
1. Place ignition switch in ACC

position. Position and hold
affected window switch to UP
BRN (667 or 669) wire at affected
C701 or C801 to ground.
1.
1.
RESULT
ACTION
Test lamp lights.
GO to step 2.
GO to step 3.
REPLACE affected window motor.
GO to step 3.
3. Connect a test lamp from PNK

(76) wire at affected window
Test lamp lights.
GO to step 4.

PNK (76) wire from affected
window switch to fuse block.

wire to BLK (150) wire at affected
window switch connector C506.

wires (166,168,170,167,169 or
171) from affected window switch
to left window switch.
Tailgate should remain closed t hroughout the

diagnosis of the POWER REAR WrINDOW circuit.
TEST
Test lamp lights.

wire to DK BLU/WHT (166), DK
GRN (168) or LT GRN (170) wires
at affected window switch
connector C506.
Test lamp lights at only one wire or

not at all.
2.
CHECK condition of PWR WDO and PWR ACC

circuit breakers. If circuit breakers are in good
condition,
use the following diagnostic
procedures.
TAILGATE WINDOW DOES NOT OPERATE FROM FRONT TAILGATE WINDOW SWITCH
Connect test lamp from BRN (667

or 669) wire to DK BLU (666 or 668)
wire at affected window motor
connector C604, C701 or C801.
2.
PRELIMINARY CHECKS:
POWER WINDOWS DO NOT OPERATE FROM DRIVERS SIDE WINDOW SWITCH

TEST
Test lamp lights at all wires.
Test lamp lights.
GO to step 6.
GO to step 5.
Test lamp lights.


wire to TAN (167), PPL (169) or
PPL/WHT (171) wire at affected
Test lamp lights.
GO to step 8.
GO to step 7.

wire to BLK (150) wire at affected
Test lamp lights.

2.
3.
4.
5.
6.
RESULT
ACTION
Place ignition switch in RUN or

ACC position. Connect a test
lamp from PNK (76) wire at front
tailgate window switch connector
C274 to ground.
Test lamp lights.
GO to step 2.

(76) wire from front tailgate window
switch connector C274 to fuse
block.
Position and hold tailgate window

switch in the UP position.
TAN/WHT (184) wire at front
C274 to ground.
Test lamp lights.
GO to step 3.
REPLACE front tailgate window

switch.
Position and hold front tailgate

window switch in the DOWN
from LT BLU (183) wire at front
C274 to ground.
Test lamp lights.
GO to step 4.
REPLACE front tailgate window

switch.

(76) wire at the front tailgate
window switch connector C274 to
TAN/WHT (184) wire. Then
connect a test lamp from
TAN/WHT (184) wire at tailgate
window motor connector C905 to
ground.
Test lamp lights.
GO to step 5.

TAN/WHT (184) wire between
tailgate window motor connector
C905 and front tailgate window
switch.

(76) wire at the front tailgate
window switch connector C274 to
LT BLU (183) wire. Then connect
a test lamp from one LT BLU (183)
wire at cutout switch connector
C904 to ground. REPEAT for the
other LT BLU (183) wire.
Test lamp lights at both wires.
GO to step 6.
Test lamp does not light at one or

both wires.

BLU (183) wire from cutout switch
connector C904 to front tailgate
window switch connector C274. If
wire is in good condition,
REPLACE cutout switch.

(183) wire at tailgate window
motor connector C905 to ground.
Test lamp lights.
REPLACE tailgate window motor.

BLU (183) wire between tailgate
motor connector C905 and cutout
switch. If wire is in good condition,
REPLACE tailgate window motor.
POWER WINDOWS A-137
____________
RPO CODES____________________
76 -2.0 p n k
D48 - ELECTRIC REMOTE CONTROL OUTSIDE MIRROR
HTR
m
i
(g [c] 0
[wp
0 m
6ca r
WDO
@ @ 0 0 1 0
J
L-IG
ig N
n^
SHUNT
SHUNT
1 167-2.0 TAN
ACC LPS PWR
El
666-2.0 DK BLU
176-2.0 PNK
INSTR LPS PWR ACC
HORN/DM
1 166-2.0 DK BLU/WHT
KIGN] AUXKHTR]A/C H
STOP HA
667-2.0 BRN
GT601
Kl Kl Kl
Kl Kl

30
A
ECM B
TURN B/U PWR WDO
K Kl
E 00
ECM 1
DRL
CRANK '
12010247
CD^ t0 -
o \
/ C
u)i q
S'S S'S
0 S'S r
A
12015345_
FRONT
C262
c -o=
= = t
76
667
166
666
167
r * ___ t
RH WINDOW
SWITCH
150-2.0 blk
FUSE BLOCK
m
annni
n^^r,
in
îrsn
rr
RH WINDOW
MOTOR
12004267
G200
POWER WINDOWS A-139

________________ 2-DOOR___________
12004884
C259
DOWN
UP
RH REAR
MASTER
WINDOW SWITCH
n 64-2.0 DK BLU
LH FRONT
WINDOW MOTOR
A-140 POWER WINDOWS

4-DOOR
RPO CODES
D48 - ELECTRIC REMOTE CONTROL OUTSIDE MIRROR
0 f
r1 t-
170-2.0 LT GRN
J-JnnLJ
12047675
C402
12015344
DOWN -------------------------------------------------- ,
-------------------- -- IUP
^
I
k
S261 (D48 ONLY)
1150-3.0 BLKl
1150-.8 BLK I
76
i
669
170
668
76
669
170
668
i6 8
- o - - ..-...
.
4
171
RH REAR
WINDOW SWITCH
POWER OUTSIDE
REARVIEW MIRRORS
(SEE PAGE 127)
s
ffi
12047675
C403
12015344
GT700
FTVUFTl
1 76-2.0 PNK
76-2.0 PNK
1169-2.0 P P L M H
169-2.0 PPL
1 168-2.0 DK GRN I
168-2.0 DK GRN
DOWN
C D ^tO
up
169
LH REAR
WINDOW SWITCH
T
C257
12004267
BUS BAR
GROUND
G201
POWER WINDOWS A-141

(4-DOOR)
CUTOUT
SWITCH
183-3.0 LT BLU
183-3.0 LT BLU I
183
C904
12004480
(OPENS WHEN
WINDOW FULLY
UP OR DOWN)
(SUBURBAN ONLY)
183-3.0 LT BLU
TAIL GATE
WINDOW
MOTOR
184-3.0 TAN/WHT
183-3.0 LT BLU
184-3.0 TAN/WHT
(UTILITY ONLY)
TAIL GATE
WINDOW
SWITCH
(KEY OPERATED)
60-3.0 ORN/BLK
184-3.0 TAN/WHT
MOTOR
BRAKE
GROUND
G904
A-142 POWER REAR WINDOW
CIRCUIT OPERATION
PANEL LAMP DOES NOT COME ON

TEST
The RADIO Fuse provides main power to the Radio.

With Ignition Switch in ACC or RUN, voltage is applied
through the RADIO Fuse and the YEL wire to the On/Off
Switch in the Radio. The On/Off Switch is located in the
Radio. The circuit is grounded at Bus Bar Ground. With
the On/Off Switch closed, voltage is applied to the SolidState Radio circuits to ground. Two wires connect each
speaker to the Radio. The ETR Radio has two inputs
that other models do not have: Display Dim Signal and
Clock Power.
stations can be stored in the electronic memory. The

ETR model also provides a digital display of time or
station frequency. As in other models, the Panel Lamp
Switch controls panel lamp dimming. In the ETR model,
dimming is also controlled by the Radio itself by means
of the DIM Display Input Signal.
The ETR models Clock memory and Radio and
memory functions are supplied voltage at all times
through the HORN/DM Fuse. If voltage to the ETR
model is cut off - by disconnecting the Battery, for
example - the operator must reset the memory functions
when voltage is restored.
The ETR model is an AM/FM Radio that changes

stations electronically. The frequency of preselected
1.
RESULT
Disconnect radio connector C241.

Place light switch to PARK and
panel dimmer switch to HIGH.
Connect a voltmeter from GRA (8)
wire at radio connector C241 to
ground.
Battery voltage.
ACTION
REMOVE radio and send in for
service.
No voltage.
CHECK condition of INST LPS
REPAIR open in GRA (8) wire from
radio to fuse block.
DISPLAY DIMMING FUNCTION WILL NOT OPERATE

RESULT
TEST
1.
DIAGNOSIS -- RADIO

Place light switch to PARK.
Connect voltmeter from BRN (9)
wire at radio connector C204 to
ground.
ACTION
Battery voltage.

service.
No voltage.

(9) wire from radio at light switch.
RADIO DOES NOT APPEAR TO WORK (NO DISPLAY LIGHTS, NO SOUND)

TEST
RESULT
ACTION
NO SOUND OR DISTORTED SOUND FROM A SPEAKER
1.
2.
Disconnect radio connector C241

and place ignition switch to RUN
or ACC. Connect a voltmeter
from YEL (43) wire at radio
Battery voltage.
GO to step 2.
No voltage.
CHECK condition of RADIO fuse.

REPAIR open in YEL (43) wire.
Connect a voltmeter from YEL (43)

wire to BLK (150) wire at radio
connector C241.
Battery voltage.

service.
No voltage.
(150) wire from radio to bus bar
ground.
RESULT
TEST
1.
2.
ACTION
Disconnect suspected speaker

connector. Set analog ohmmeter
on RX1 scale. Connect an
ohmmeter across speaker
terminals.
Speaker pops.
GO to step 2.
No noise.
REPLACE speaker.
Place ignition switch to RUN or

ACC and turn radio ON. Tune
radio to a strong signal. Connect
a voltmeter across outputs for
suspect speaker.
Varying around 1 volt AC.
REPLACE speaker.
No voltage or greater than 1 volt

AC.
LOCATE and REPAIR speaker

wires between radio and speaker.
If wires are good, REMOVE radio
and send in for repairs.
CLOCK DOES NOT OPERATE

TEST
1.

Connect a voltmeter form ORN
(40) wire at radio connector C204
to ground.
RESULT
ACTION
Battery voltage.

service.
No voltage.
CHECK condition of HORN/DM

REPAIR open in ORN (40) wire.
RADIO A-143
RADIO RECEIVER
BUS
BAR
GROUND
G200
A-144 AM RADIO
MONAURAL
RPO COOES
HOT AT ALL TIMES
UM6 - RADIO, ETR AM/FM STEREO, CASSETTE
RH
REAR
SPEAKER
C440
12077787
C439
12077787
LIGHT
SWITCH
LH
REAR
SPEAKER
RADIO A-145
AM/FM STEREO
CIRCUIT OPERATION
DIAGNOSIS REAR DEFOGGER
With the Ignition Switch in RUN, voltage is applied to

the Rear Defogger Switch. When the Rear Defogger
Switch is moved to the ON position, voltage is then
applied to the Rear Defogger Timer-Relay. The contact
closes, which provides voltage to the ON Indicator and
the Rear Defogger. The rear window will become warm
to remove fog from the surface of the window.
The first time the Rear Defogger Switch is activated,

the Timer-Relay will allow the Rear Defogger to operate
for 10 minutes. Each time after the Rear Defogger
Switch is activated, the Timer-Relay will allow the Rear
Defogger to operate for a maximum of five minutes. The
Timer-Relay will reset to 10 minutes when the Ignition
Switch is turned OFF and then back to the RUN position.
The contact in the Rear Defogger Control will stay

closed until the Rear Defogger Control Switch is turned
off, or the timer cycle is complete.
The Timer also shuts off at any time the Rear

Defogger Control On-Off Switch is depressed to OFF.
REAR WINDOW DEFOGGER DOES NOT WORK AND ON INDICATOR DOES NOT LIGHT
TEST
RESULT
ACTION

from ORN/BLK (60) at timer relay
Test lamp lights.
GO to step 2.
CHECK condition of PWR ACC

circuit breaker. If circuit breaker is
in ORN/BLK (60) wire.
2.

PNK/BLK (39) wire at rear window
defogger switch connector C278
to ground.
Test lamp lights.
GO to step 3.
CHECK condition of IGN fuse. If

fuse is good, LOCATE and REPAIR
open in PNK/BLK (39) wire.

PNK/BLK (39) and BLK (150) wires
at rear window defogger switch
Test lamp lights.
GO to step 4.

(150) wire.
Place rear window defogger

switch on and hold. Connect a
test lamp from LT BLU (292) wire
at rear window defogger switch
Test lamp lights.
GO to step 5.
REPLACE rear window defogger

switch.
REPLACE timer relay.
3.
4.
5.
Place rear window defogger

switch ON and hold. Connect a
test lamp from PPL/WHT (293)
connector at timer relay to ground.
ON INDICATOR WORKS BUT REAR WINDOW DEFOGGER DOES NOT DEFROST

TEST
1.
2.
RESULT
ACTION

rear defogger switch ON.
(293) wire to ground (tailgate
models) or PPLVWHT (293) wire at
rear window defogger to ground
(panel door models).
Test lamp lights.
GO to step 2.

or PPL/WHT (293) wires.

(293) to ground wires at rear
window defogger (tailgate models)
or PPL/WHT (293) (panel door
models) to BLK (150) wires at rear
window defogger, ground G411.
Test lamp lights.
REPAIR rear defogger as required.

(150) wire.
REAR DEFOGGER PANEL LAMP DOES NOT WORK

TEST
Turn headlamps ON and position
dimmer control to BRIGHT.
Connect test lamp from GRA (8)
wire at rear window defogger
A-146 REAR DEFOGGER
RESULT
ACTION
Test lamp lights.
REPLACE panel light bulb.

GRA (8) wire.
C212
12059884
r
293-3.0 PPL/WHT
12059885
fc 9 3 j
293-3.0 PPL/WHT
293-3.0 PPL/WHT
293-.S PPL/WHT
________
RH DOOR
CONTACTOR
A V A V v W /M W
L -A V A W A W A W A
RH REAR
WINDOW
HEATER
REARDEFOGGER A-147
PANEL DOORS
293-.3 PPL I
293-3.0 PPL/WHT
C449
C103A
2977976
GT108
8911213
6288585
6288585
2977976
8917583
C912
89177378
I 0- 8 GRAl
FRONT
FUSE BLOCK
REAR
WINDOW
DEFOGGER
SWITCH
GROUND
JUMPER
293-3.0 PPL/WHT
C280
12004201
60-3.0 ORN/BLK
*
CD
BUS
BAR
GROUND
G201
TIMER
RELAY
1150-1.0 BLKI
P39-.8 PNK/BLK;
148 REAR DEFOGGER

TAILGATE
dm
CIRCUIT OPERATION
BACKUP LAMPS
PARK, TAIL, MARKER AND LICENSE LAMPS
With the Ignition Switch in RUN, or START, voltage is

applied through the TURN/BU Fuse to the Transmission
Position Switch or the Backup Lamp Switch. Whenever
the gear selector lever is shifted to REVERSE the
Transmission Position Switch or the Backup Lamp Switch
closes and voltage is applied to the Backup Lamps and
the Lamps turn on.
Voltage is applied through the T/L CTSY Fuse to the

Light Switch at all times. With the Light Switch in the
PARK or HEAD, voltage is applied to the Park, Tail,
Marker, and License Lamps.
TRAILER WIRING
Trailer wiring is a modification of the existing rear
body harness. The trailer lamps operate in the same
manner as the vehicle lamps. The trailer lamps are
grounded to the vehicle lamps.
DIAGNOSIS REAR EXTERIOR LAMPS
REAR TAIL, MA RKER AND LICENSE LAMPS DO NOT OPERATE

TEST

(9) wire between light switch
connector C202 and connector
C300.
Test lamp lights.
If only RH rear Tail/Marker lamps

and license lamps do not operate,
GO to step 2. If only LH rear
Tail/Marker lamps do not operate,
GO to step 3.
2.

(9) wire between connector C300
and RH tail or marker lamp
connector C411 or C414.
Test lamp lights.
GO to step 4.

(9) between LH tail or marker lamp
connector C412 or C413 and
connector C300.
Test lamp lights.
Go go step 5.

(150) between tail or marker lamp
connector C411, C412, C413 or
C414 and G403.
Test lamp lights.
If rear tail or marker lamp is

inoperative, REPLACE bulb. For
inoperative license lamps, GO to
step 6.
LOCATE and REPAIR open BRN

(9) wire between license lamp
connector and S300 and S404.
Test lamp lights.
Inspect ground connection at

license lamp socket. If satisfactory
REPLACE bulb.
ground terminals G402 and G403. If only one system is

not working, LOCATE and REPAIR an open in the wiring
and/or bulbs that pertain to that system.
3.
BACKUP LAMPS DO NOT OPERATE

TEST
1.
2.
3.
4.
RESULT
ACTION

transmission in reverse. Connect
a test lamp from LT GRN (24) wire
at backup lamp connector C428
or C429 to ground.
Test lamp lights.
GO to step 2.
GO to step 3.

backup lamp connector C428 or
C429.
Test lamp lights.
REPLACE bulb.

(150) wire from backup lamp to

(75) wire at backup lamp switch
connector C286 or C118 to
ground.
Test lamp lights.
GO to step 4.
CHECK condition of TURN/BU

fuse. If fuse is good LOCATE and
REPAIR open in DK BLU (75) wire
from backup lamp switch
backup lamps.

ground.
Test lamp lights.

GRN (24) wire from backup lamp
switch connector C286 or C118 to
fuse block.
Adjust backup lamp switch. If

backup lamp switch will not adjust
properly, REPLACE backup lamp
switch.
ACTION
Place light switch in HEAD or

PARK position. If only license
lamp does not operate, GO to
step 5. Connect a test lamp from
BRN (9) wire at connector C300 to
ground.
1.
PRELIMINARY CHECKS:
The rear lamp systems (taillamps, clearance lamps,
end gate lamps, and license plate lamps) all receive
voltage from same wire circuit BRN (9) and share same
RESULT
4.
5.
Connect a test lamp from BRN (9)

wire at RH tail or marker lamp
ground.

wire at inoperative LH tail or
marker lamp connector C412 or
C413 to ground.

wire and BLK (150) wire at
inoperative tail or marker lamp
connector C411, C412, C413 or
C414.

wire at license lamp connector
REAR LAMPS
A-149
RADIO/CLOCK
I 4 0 .8 ORN
LIGHT
SWITCH
RH SIDE
MARKER LAMP
(SEE PAGE 156)
T/L CTSY
20 AMP
ywwwwww
S
156
HOT A T A L L T M E S ?
mwwwwvs
C411
8911035
RH TAIL,
STOP AND
TURN LAMP
C ji
9-.8BRN
9-.8BRN
29
15
39
14
12
11
420 440
439 806
140
2
39
120
31
50
436
35
93
97
422
91
92
(m
5300
9-.8BRN
12015024
LH TAIL
STOP AND
TURN LAMP
I9 -.8 BRN I
LH SIDE
MARKER LAMP
(SEE PAGE 156)
I9 -.8 BRN I
A-150 TAILLAMPS
SUBURBAN/UTILITY
(Q )
____
SHEET
METAL
GROUND
G402
SHEET
METAL
GROUND
G403
(SUBURBAN)
m m
C412
8811035
b lk m m
RPO COOES
RADIO/CLOCK
T/L CTSY
20 AMP
RH SIDE
MARKER LAMP
(SEE PAGE 156)
156
RH TAIL,
STOP AND
TURN LAMP
LIGHT
SWITCH
I I 150-.8BLK
RH CLEARANCE
LAMPS (R05)
(SEE PAGE 156)
11 150-.8 BLK
1 1 9-.S BRN
Ll 9-.8 BRN
9- 8 BRN
C300
M 9-.8B R N M I
19-.8 BRN I
LH CLEARANCE
LAMPS (R05)
(SEE PAGE 156)
9-.8 BRN I
I 150-.8 BLK I
I 150-.8 BLK
C101
12020099
LH SIDE
MARKER LAMP
(SEE PAGE 156)
SHEET
METAL
GROUND
G403
SHEET
METAL
GROUND
G404
TAILLAMPS A-151
FLEETSIDE AND WIDESIDE
w w w vw w w *
S
HOT A T ALL TIMES <
S204
40-.8 ORN |
M B M
40-, 8 ORN
W W W W W 'T
T/L CTSY
20 AMP
44
RADIO/CLOCK

l/P CTSY LPS
|
40-.8 ORN
(SEE PAGE 118)
tr
150-
2-
DOME
RH TAIL,
STOP AND
TURN LAMP
CIRCUIT
BREAKER*
25 AM P
ll-HEAD
-1
OFF
' PARK
HEAD
LIGHT
SWITCH
C412
6288424
LH TAIL
STOP AND
TURN LAMP
LH TAIL, STOP,
AND TURN
LAMP GROUND
G406
A-152 TAILLAMPS
STEPSIDE
FRAME
GROUND
G405
RH TAIL, STOP,
AND TURN
LAMP GROUND
G407
75-.8 DK BLU I
WW WAM
<
wmm M
HOT IN RUN <
C286
2973407
24-.8 LT GRN
> w w vw *
e.
TURN/BU
15 AMP
175-.S DK BLU
BACKUP
LAMP SWITCH
(AUTO TRANS ONLY)
CLOSED WHEN TRANS
IN REVERSE
24
~>
Ui
z
S402
EA l
LL
REV
75
RH TAIL, STOP,
TURN AND SIDE
MARKER LAMPS
(SEE PAGE 150)
BACKUP
LAMP SWITCH
CJD
(MAN TRANS ONLY)

CLOSED WHEN TRANS
IN REVERSE
RH BACKUP
LAMP
24- 0 LT GRN
GT401
8911027 (UTILITY)
(SUBURBAN ONLY)
8911028 (SUBURBAN)
I 150-.8BLK
94
29
15
39
14
33
12
93
11
I 420 440
439 806
140
2
39
31
50
436
35
93
97
422
91
92
35
r
120
C428
8911027 (UnLTTY)
z
cc
(S
8811028 (SUBURBAN)
I 150-.8 BLK
C100
1202184
I 150-.8 BLK
24-,8 LT GRN
LH BACKUP
LAMP
I 24-.8LTGRN
LH TAIL, STOP,
TURN AND SIDE
MARKER LAMPS
(SEE PAGE 150)
l/P
GT400
(SUBURBAN ONLY)
120
19
30
18
I 24-.0 LT GRN I
12015798
SHEET
METAL
GROUND
G402
SHEET
METAL
GROUND
G403
BACKUP LAMPS A-153

SUBURBAN/UTILITY
RPO CODES
LL4 - ENGINE, 6.2L (378 CID) V8 HD DIESEL ENGINE VIN J
kAAWWWW
\
HOT IN START ?
>w w w w v^
TURN/BU
15 AMP
BACKUP
LAMP SWITCH
175-.S DK BLU I
BACKUP
LAMP SWITCH
C200
(MAN TRANS ONLY)

CLOSED WHEN TRANS
IN REVERSE
H D
24
i
I
i
R EV
O
UK
3U
L
Z
75
(AUTO TRANS ONLY)

CLOSED WHEN TRANS
IN REVERSE
(o )
I 24- 8 LT GRN
I75 -.8 DK BLU
RH TAIL, STOP,
TURN AND SIDE
MARKER LAMPS
150-.8 BLK
A
J
A
12064769
75-. 8 DK BLU
GT101 I
12064740
(SEE PAGE 151)
-rK
(LL4 ONLY)
I24-.8 LT GRN I
RH BACKUP
LAMP
24-.S LT GRN
l/P
150-.8 BLK
94
29
15
39
14
33
12
93
11
18
120
I 420 440
439 806
24-.8 LT GRN
120
31
50
75
35
93
97
24
91
92
y
9
140
2
39
C428
150-.8 BLK
I 24-.6 LT GRN I
SHEET
METAL
GROUND
G403
A-154 BACKUP LAMPS

LH BACKUP
LAMP
LH TAIL, STOP,
TURN AND SIDE
MARKER LAMPS
(SEE PAGE 151)
75-. 8 DK BLU I
yw w w w
V
HOT IN RUN C
24- 8 LT GRN M
C266
2973407
w vvw *
TURN/BU
15 AMP
BACKUP
LAMP SWITCH
(AUTO TRANS ONLY)
CLOSED WHEN TRANS
IN REVERSE
o
>
LL
\ID
UJ
z
24
PART OF
LAMP ASSEMBLY
>
_ Ul
CC
75
24-.8 LT GRN
C118
BACKUP
LAMP SWITCH
12015792
RH BACKUP
LAMP
(MAN TRANS ONLY)

CLOSED WHEN TRANS
IN REVERSE
CO
4;
24-.S LT GRN I
S410
2
o
CC
94
29
15
39
14
33
12
93
18
11
120
I 420
440
439
806
39
140
120
(J
9
31
50
436
35
93
97
422
91
92
12015798
\
PART OF
LAMP ASSEMBLY
l/P
I 24-.S LT GRN I
150-.8 BLK
LH TAIL, STOP,
AND TURN
LAMP GROUND
G406
150-.8 BLK M
Y
FRAME
GROUND
G405
2 4 -.8 L T G R N
I
RH TAIL, STOP,
AND TURN
LAMP GROUND
G407
LH BACKUP
LAMP
BACKUP LAMPS A-155

STEPSIDE
RADIO/CLOCK
RH SIDE
MARKER LAMP
LIGHT
SWITCH
0
C414
6294015
BACKUP LAMP
(SEE PAGE 153)
RH TAIL, STOP
ANDTURN LAMP
(SEE PAGE 150)
9- .8 BRN
9-.8BRN
GT 401
(SUBURBAN ONLY)
12015024
12015798
UCENSE LAMP
(SEE PAGE 158)
I 9-.S BRN I
29
15
39
14
12
11
I 420 440
439 806
2
39
140
120
31
50
436
35
93
97
422
91
92
(D
5
CD
co
S300
9*.8 BRN
g
9-.8 BRN
GT 400
(SUBURBAN ONLY)
*
|
BACKUP LAMP
150-.8 BLK |
(SEE PAGE 153)
S405
9-.8 BRN I
S403
i V
I
150-.8 BLK
150-.8 BLK H
LH TAIL STOP
AND TURN LAMP
(SEE PAGE 150)
C413
6294015
I9 -.8 BRN I
C101
12020099
A-156 REAR PARK AND MARKER LAMPS

SUBURABN/UTILITY
LH SIDE
MARKER LAMP
SHEET
METAL
GROUND
G402
SHEET
METAL
GROUND
G403
RRO CODES
40-.8 ORN
S204
0 M
RADIO/CLOCK
r 40-.8 ORN
WIDESIDE PICK-UP
(R05 ONLY)
T/L CTSY
20 AMP
RH FRONT
CLEARANCE
LAMP
RH REAR
CLEARANCE
LAMP
RH SIDE
MARKER LAMP
C414
6264015
BACKUP LAMP
(SEE PAGE 154)
RH TAIL STOP
AND TURN LAMP
(SEE PAGE 151)
LICENSE LAMP
(SEE PAGE 158)
94
29
15
39
14
33
12 J
11
93
18
24
120 9
30
I420 440
439 806
L 140
31
f
D j SO
r 9735
93
19 j
91
92
9-.BBRN
39
120
END GATE
IDENTIFICATION
LAMPS
(SEE PAGE 151)
3
436
2
422
6
LH TAIL, STOP
AND TURN LAMP
(SEE PAGE 151)
BACKUP LAMP
(SEEPAGE 154)
t/P
19-. 8 BRNI
LH FRONT
CLEARANCE
LAMP
WIDESIDE PICK-UP
(R05 ONLY)
LH REAR
CLEARANCE
LAMP
LH SIDE
MARKER LAMP
SHEET
METAL
GROUND
G403
REAR PARK AND MARKER LAMPS A-157

RADIO/CLOCK
40-.8 ORN
l/P CTSY LPS

(SEE PAGE 118)
LIGHT
SWITCH
RH SIDE
MARKER LAMP
|
(SEE PAGE 156) |
T/L CTSY
20 AMP
1150-.8 B L K M
yvwvwwwv/
S
H O TATALLTN ES <
C202
12004628
Ta w w w v w v n
150-
- 156
DOME
2I
C1RCUIT
BREAKER
2$ A M P
1 9-.8 BRN H
(SUBURBAN)
OFF
RH TAIL, STOP
AND TURN
LAMP
' PARK
I * HEAD
-10
(SEE PAGE 156)
OFF
40-
'P A R K
HEAD
9-.8 BRN I
RADIO/CLOCK
9-.8 BRN I
LICENSE
LAMP
VP
9-.8BRN
cc
.cl
I 420 440
439 806
140
31
50
436
30
2
39
120
35
93
97
422
91
92
9- 8 BRN
33
12020184
C100
LH TAIL, STOP
AND TURN
LAMP
(SEE PAGE 156)
19 -8 BRN I
150-.8 BLK m
(SUBURBAN)
I9-.8 BRN I
[I
L
120
19
30
18
24
LH SIDE
MARKER LAMP
(SEE PAGE 156)
I9 -.8 BRN I
C101
12020099
A-158 LICENSE LAMP

SUBURBAN/UTILITY
SHEET
SHEET
METAL
METAL
GROUND GROUND
G402
G403
LICENSE LAMP A-159

FLEETSIDE AND WIDESIDE __________
RPO CODES
TP2 - AUXILIARY BATTERY
BATTERY
JUNCTION
BLOCK
cc
0
*o
(W/OTP2)
TAIL, STOP
TURN SIG, MARKER
AND BACKUP LAMPS
X
o
(W/O TP2)
oj
cn
|J jtO ) ( 0 7
IN-LINE
FUSE
30 AMP
BATTERY
JUNCTION
BLOCK
Q D
C300
'S'C D
IN-LINE
FUSE
(30 AMP)
O
O
47-3.0 DK BLU- AUX
2-5.0 RED- POWER FEED
2-5.0 RED- POWER FEED
24-.8 LT GRN- BACKUP LAMP

9-.8 BRN- TAIL AND UCENSE LAMP
24-.A LT GRN- BACKUP LAMP
18-.8 YEL- LH STOP AND TURN SIG LAMP
S-.8 BRN- TAIL AND LICENSE LAMP
TRAILER
19-.8 DK GRN- RH STOP AND TURN SIG LAMP
18-.8 YEL- LH STOP AND TURN S/G LAMP

t0-.8 DK GRN- RH STOP ANO TURN S/G LAMP
IN-LINE
FUSE
30 AMP
BATTERY
JUNCTION
BLOCK
(W/TP2)
FRAME
GROUND
G403
REAR
LAMP
CONNECTOR
19-.8 DK GRN
REAR
LAMP
CONNECTOR
24-.S LT GRN
C101
12020099
18-.8 YEL
9-.8 BRN
CAMPER EQUIPMENT
A-160 CAMPER AND TRAILER WIRING
22-5.0 WHT- GROUND
IN-LINE
FUSE
(30 AMP)
BATTERY
JUNCTION
BLOCK
(W/TP2)
C101
12020099
FRAME
GROUND G403
19-.8 DK GRN
24-.S LT GRN
B-.8 BRN
18-.8 YEL
HEAVY DUTY TRAILER
TAIL, STOP
TURN SIG, MARKER
AND BACKUP LAMPS
DIAGNOSIS
Conditions most likely to cause vacuum system
problems include hoses that leak or become
disconnected. With the engine running, either condition
is easily detected from the hiss of air at the opening.
Other common vacuum problems are kinked or
obstructed hoses, hoses connected incorrectly or
binding components.
A vacuum pump can be used as a vacuum source to
operate components and test the system. The built-in
vacuum gage of the pump provides a means of checking

for a vacuum leak as well. Once vacuum is applied to
operate the component, the gage should hold steady
until the vacuum is purposely released.
On vacuum system that are controlled by electrical or
electronic switches, check for a blown fuse, wiring that is
cracked, frayed or burned, and high resistance in
connectors of the control circuits) before checking for a
suspected vacuum system problem.
DIAGNOSIS - AUXILIARY HEATER VACUUM CONTROL

PRELIMINARY CHECKS:
With the engine warmed up and running, verify that
the front heater can deliver a strong flow of heated air
from the floor outlets with the blower switch on HI," the
mode selector set for heater operation and the
temperature lever in the full "HOT" position. If the front
heater or A/C heating system is functioning correctly but

the auxiliary heater does not, the problem is in the
auxiliary heater system. The following procedure will
isolate the cause.
LITTLE OR NO HEAT FROM AUXILIARY HEATER

RESULT
TEST
1. With the engine running and the
auxiliary heater OFF,move the
auxiliary heater control rocker
switch to LO and then to
HI, pausing to listen for a
change in the force of the
airflow from the heater outlet
with the change.
No airflow (or improper airflow).
2. With the engine running and the

auxiliary heater switch in LO,
disconnect the vacuum hose at
the hot water valve and feel for
vacuum at the hose end.
No vacuum.
Vacuum.
3. Disconnect the hot water valve

vacuum hose at the auxiliary
heater control switch and feel
for vacuum at the open port of
the switch.
No vacuum.
4. Connect all vacuum hoses. With

the engine warmed up and
running, place the auxiliary
heater control switch in HI.
After at least a minute of
operation in this mode, carefully
feel the temperature of the
heater inlet pipe downstream
from the hot water valve.
Proper airflow in both control

switch positions.
ACTION
REFER to Auxiliary Heater
Diagnosis in this manaul.
GO to step 2.
IMPROPER AIR DISTRIBUTION FROM OUTLETS

TEST
1. Disconnect the vacuum hose at
the actuator for the inoperative
air valve (door). With the
engine idling and the mode
lever set in a position that will
apply vacuum to the actuator,
check for vacuum at the
disconnected hose.
RESULT
Vacuum at or near engine vacuum
at idle.
Little or no vacuum.
ACTION
REPAIR binding condition in air
valve or linkage. (If no binding is
found, REPLACE actuator.)
GO to step 2.
2. Disconnect the vacuum hose

harness at the rotary selector
valve on the A/C control
assembly. With the same test
conditions as in step 1, check
for vacuum at the rotary selector
valve port that feeds the
suspected vacuum hose.
Vacuum at or near engine vacuum

at idle.
REPAIR obstruction or vacuum

leak in hose to the affected
actuator.
GO to step 3.
3. With the vacuum supply hose

disconnected from the rotary
selector valve and with the
same test conditions as in step
2, check for vacuum at the open
end of the tan vacuum supply
hose.
Vacuum at or near engine vacuum.
REPLACE rotary selector valve.
REPAIR obstruction or vacuum

leak in vacuum supply hose.
DIAGNOSIS - CRUISE CONTROL VACUUM HARNESS

GO to step 3.
GO to step 4.
CRUISE CONTROL DOES NOT OPERATE

TEST
Vacuum.
Little or no heat.
Adequate heat.
REPAIR vacuum source line or

REPLACE auxiliary heater control
switch, as necessary.
REPAIR or REPLACE faulty hot
water valve vacuum hose.
REPAIR or REPLACE the hot
water valve, heater core or heater
hoses and pipes as necessary.
VERIFY complaint. Vacuum
system is OK.
DIAGNOSIS - FRONT MANUAL AIR CONDITIONING VACUUM CONTROL

PRELIMINARY CHECKS:
Use the charts in this section to verify that air is either
begin delivered from an outlet when it should not be, or
that air is not being delivered when it should be, during
operation in one or more modes.
After making checks of the vacuum system (listening
for the hiss of a vacuum leak, checking for proper

vacuum hose connections and kinked, pinched or
misrouted hoses), be sure the complaint is not caused
by a mechanical problem before making additional
vacuum system checks.
RESULT
ACTION
1. Disconnect vacuum hose

(smaller hose) at vacuum valve
inlet of servo unit. Connect a
vacuum gage to the
disconnected hose. Start engine
and allow it to idle. Measure
vacuum at vacuum hose.
Vacuum is less than normal engine

vacuum at idle.
Vacuum is same as normal

engine vacuum at idle.
REPAIR vacuum pump (diesel

engine) or air leak in hose or
connections between cruise
control servo and vacuum source
(inlet manifold vacuum fitting or
vacuum pump).
GO to step 2 (gas engine).
Verify complaint (diesel engine).
2. Momentarily accelerate engine

sharply while watching vacuum
gage.
Vacuum reduces noticeably as

engine accelerates.
Vacuum does not change.
REPLACE check valve in line from

vacuum source.
GO to step 3.
3. Stop engine. Disconnect

vacuum gage and connect
vacuum hose to servo unit.
Disconnect vent hose (larger
hose) from servo unit and
connect a vacuum pump with
built-in vacuum gage to the
disconnected hose. Operate
vacuum pump to obtain the
same vacuum as observed in
step 1. Stop pumping and
observe the vacuum reading.
Vacuum drops.
REPAIR air leak in hose or

connections, or ADJUST or
REPLACE vacuum release valve
on brake pedal bracket.
REFER to Cruise Control
Diagnosis in this manaul.
Vacuum does not change.
VACUUM SYSTEM A-161
CIRCUIT OPERATION
AIR DISTRIBUTION
VACUUM SYSTEMS
A vacuum-operated component uses the force of
normal air pressure working against the lower air
pressure of a partial vacuum to provide voltage that
operates the component. With a gasoline engine, the
vacuum created in the inlet manifold when the engine is
running is stored in a ball-shaped vacuum tank
suspended from the center of the hood inner panel. A
check valve in the line feeding vacuum to the tank keeps
the stored vacuum from weakening when inlet manifold
vacuum drops during high speed or high voltage
operation.
An engine-driven mechanical vacuum pump serves as
the source of vacuum with a diesel engine. A vacuum
tank is not required with a vacuum pump.
Vacuum is routed through hoses to a mechanical or
electric valve that provides a means of controlling the
vacuum-operated component. When the valve is open,
it allows vacuum to go to an actuator that actually
operates the component. When the component is to be
returned to its original position, the valve cuts off the
vacuum to the actuator hose and vents the hose to
normal air pressure.
A typical actuator is a metal shell with a movable
shaft that retracts and extends to mechanically operate
the component. A flexible diaphragm separates the
interior of the shell into two chambers - a sealed
chamber to which vacuum can be admitted, and an
open chamber exposed to normal air pressure. The
movable shaft is attached to the center of the diaphragm
and extends from the open chamber.
When vacuum is directed to the sealed chamber,
normal air pressure presses on the other side of the
diaphragm and causes it to retract the shaft. When the
vacuum is cut off, the sealed chamber is vented to
outside air to balance the air pressure on both sides of
the diaphragm and eliminate the force that retracted the
shaft.
A coiled spring within the sealed chamber
expands to push the diaphragm back to its original
position. This extends the shaft.
In addition to the two-position actuator described
above, a three-position actuator may be used for certain
applications. The three-position actuator has a vacuum
hose at each end of the shell. When vacuum is applied
to either end of the actuator and the opposite end is
vented, the shaft will move in the direction of the end
having the vacuum. When both ends of the actuator are
vented to normal air pressure, internal springs center the
shaft. This provides a center position as well as both
extremes for an actuator application that requires three
operating positions. The heater and air conditioning
actuator of the R/V truck front manual air conditioning
system is a three-position actuator.
A-162 VACUUM SYSTEM
The servo unit of the cruise control is a special type

of vacuum actuator with an internal control valve that can
apply varying amounts of vacuum to the diaphragm. The
varying vacuum provides a calibrated range of throttle
positions that can accurately control vehicle speed. The
function of the servo is explained more fully under
-CRUISE CONTROL VACUUM CONTROL" in this section.
AUXILIARY HEATER VACUUM SYSTEM
MODE
SELECTION
UPPER (l/P)
A/C OUTLETS
LOWER (FLOOR)
HEATER OUTLETS
DEFROSTER
OUTLETS
OFF
MAX A/C
NORM A/C
BI-LEVEL
V EN T
HEAT
DEF
NONE
HIGH
HIGH
MEDIUM
HIGH
NONE
NONE
NONE
NONE
NONE
MEDIUM
NONE
HIGH
LOW
NONE
NONE
NONE
NONE
NONE
LOW
HIGH
REMARKS:
a Refrigeration system operates.
The auxiliary heater control switch in the instrument

panel routes battery voltage to the auxiliary heater blower
motor when the auxiliary heater control switch is "ON"
and the ignition switch is in RUN.
In addition, the switch routes vacuum from the
vacuum tank to the vacuum actuator that opens the
auxiliary heater hot water valve. When open, the hot
water valve admits heated coolant to the auxiliary heater
inlet pipe and auxiliary heater core.
When the auxiliary heater control switch is turned
OFF," electric voltage to the blower motor is cut off and
the hot water valve vacuum actuator is vented to
atmospheric air to close the valve. This stops the flow of
coolant to prevent unwanted heat.
FRONT MANUAL
AIR CONDITIONING
VACUUM SYSTEM
The front manual air conditioning system uses
vacuum to operate the air valves (doors") that control
airflow through the air conditioning module.
Vacuum is supplied from the vacuum tank on the
cowl panel in the left corner of the engine compartment.
The vacuum supply line brings vacuum to the rotary
selectors valve that is operated by the mode lever of the
air conditioning control assembly in the instrument panel.
A vacuum hose harness brings vacuum from the ports in
the rotary selector valve to the vacuum actuators for the
air valves of the air conditioning system. All actuators
except the heater and air conditioning actuator are twoposition actuators controlled by one vacuum hose. The
heater and air conditioning actuator is a three-position
actuator with two vacuum hoses. Application of vacuum
or vented air to each actuator is determined by the
operating mode selected by setting the mode lever in the
control assembly. The following charts indicate the air
outlets that operate in each mode selection and the
response of the rotary selector valve to each mode lever
position.
b Inside air recirculated.
REMARKS
a, b
a
a
c
c
a
c Refrigeration system off; no air cooling available.
ROTARY SELECTOR VALVE OPERATING CHART

CONNECTIONS
VALVE
PORT NO.
TERMINAL
1
2
3
4
5
SOURCE
A/C MODE
HEAT MODE
RECIRC & PLENUM
DEFROST MODE
HOSE
COLOR
GRA
TAN
BLUE
ORN
BLK
MODE SELECTION
OFF
MAX
A/C
NORM
A/C
BI
LEVEL
VENT
HEAT
DEF
VAC
V EN T
VAC
VEN T
V EN T
VAC
VAC
VENT
VAC
VENT
VAC
VAC
VENT
VENT
VENT
VAC
VENT
VENT
VENT
VEN T
VAC
VAC
VEN T
VEN T
VEN T
VAC
VENT
VAC
VENT
VENT
VAC
VEN T
VAC
VEN T
VAC
CRUISE CONTROL VACUUM SYSTEM

The cruise control system uses vacuum to operate a
servo unit that adjusts throttle position to maintain a
desired vehicle speed. The electronic control module of
the cruise control system operates a vacuum valve and
a vent valve in the servo to trap enough vacuum in the
servo to hold the required throttle setting. A vacuum
release valve on the brake pedal bracket vents the
trapped vacuum to atmosphere when the brake pedal is
depressed, allowing the servo to quickly return the
throttle to idle.
Control Module Functions

The cruise control module continually interprets the
setting of the mode control switches, the position of the
servo linkage to the throttle and the output of the vehicle
speed sensor. In response to these inputs, the cruise
control module electrically signals the momentary
opening or closing of the vacuum and vent solenoid
valves in the servo unit.
Servo Unit Functions

The cruise control servo consists of a vacuumoperated diaphragm, a normally closed solenoid valve to
admit vacuum to the servo diaphragm chamber, a
normally open solenoid valve to vent the diaphragm
chamber to atmosphere, and a variable inductance
position sensor that signals the position of the servo
linkage - and accordingly, the throttle setting - to the
cruise control module.
When the system is engaged and operating, the

servo operates the throttle as follows:
Steady Cruise: Both the vacuum valve and the vent
valve are closed, trapping vacuum in the diaphragm
chamber to hold a steady throttle setting.
Vehicle Losing Speed: The cruise control module opens
the vacuum valve to increase the strength of the vacuum
in the diaphgram chamber. The vent valve remains
closed.
Vehicle Gaining Speed: The cruise control module
opens the vent valve to the atmosphere to reduce the
vacuum in the diaphragm chamber so the throttle return
spring can take over and reduce the throttle opening.
The vacuum valve remains closed.
The cruise control module pulses the opening of the
vacuum valve or the vent valve for minor speed
corrections until the vehicle reaches the set speed.
Under normal road load conditions, the vacuum valve will
remain completely open, instead of pulsing, when vehicle
speed drops 5 mph below the set speed. When the
vehicle speed exceeds 3 mph over the set speed, the
vent valve will remain completely open, instead of
pulsing.
The servo will go into a completely open vent valve
position, returning the throttle to idle, when the brake or
clutch pedal is depressed, when electrical voltage to the
system is lost (such as when the cruise control switch or
the ignition switch is turned off) or when there is an open
in the variable inductance position sensor coil in the
servo.
CIRCUIT OPERATION
POWER BRAKE BOOSTER VACUUM
SYSTEM
The power brake booster is a tandem diaphragm
vacuum-suspended unit. When the engine is running,
inlet manifold vacuum is transmitted to the booster unit
through a vacuum hose. A check valve at the power
brake booster end of the hose keeps air from flowing
from the hose into the booster unit and weakening the
power brake operating force when inlet manifold vacuum
is low.
With the service brakes released, vacuum is supplied
equally to both sides of the two diaphragms in the
booster unit. JJecause pressure on both sides of the
diaphragms are balanced, no boost is provided to the
braking system and the brakes are not applied.
When the driver presses down on the brake pedal,
the pedal pushrod depresses a spring-loaded air valve
within the power brake booster. The air valve opens to
admit air at atmospheric pressure to the back side of
both diaphragms. This forces the diaphragms forward
and causes a piston rod in the booster unit to push the
brake master cylinder pistons and apply the service
brakes.
The amount of atmospheric air admitted to the back
side of both diaphragms depends upon the force the
driver applies to the brake pedal. The greater the pedal
pressure, the more the valve opens. This provides a
power boost that multiplies the force applied to the
master cylinder pistons in proportion to the pressure on
the brake pedal.
When the brake pedal is released, the flow of
atmospheric air is cut off and inlet manifold vacuum
draws off the air behind the diaphgrams. As a result, air
pressures within the diaphgram chambers are once
again balanced so no power boost is developed.
EGR VALVE VACUUM SYSTEM

The exhaust gas recirculation (EGR) system allows a
small amount of exhaust gas to flow from the exhaust
manifold into the inlet manifold when the throttle is
opened beyond idle and inlet manifold vacuum is normal.
This reduces combustion temperatures in the engine to
control oxides of nitrogen emissions.
The EGR valve is operated by an integral vacuum
actuator that controls a pintle within the valve. The pintle
remains closed to prevent exhaust gas recirculation until
vacuum is applied to the actuator. The vacuum causes
the pintle to open, allowing the measured flow of exhaust
gas to enter the inlet manifold.
The EGR system used with gasoline engines remains

closed during periods of engine idle and deceleration to
prevent rough idle from excessive dilution of the air/fuel
mixture. It also remains closed at wide-open throttle to
prevent power loss. At other times, it rapidly cycles open
and closed to modulate the flow of exhaust gas as
required. Under certain circumstances, it may remain
fully open to provide the maximum EGR.
In gasoline engines, the manifold absolute pressure
(MAP) sensor measures the strength of inlet manifold
vacuum in the EGR vacuum circuit and sends a signal
back to the electronic control module (ECM). The ECM
uses the signal from the MAP sensor to control fuel
delivery and ignition timing. In addition, the ECM will
adjust the on-off intervals of the EGR valve to correct the
flow of exhaust gas into the cylinders if actual vacuum
differs from the preferred vacuum as calculated by the
ECM. This provides the required control of oxides of
nitrogen emissions while retaining engine performance
under all operating conditions.
Vacuum for the EGR system of gasoline engines is
taken from the throttle body and routed through a hose
to the electronic vacuum regulator valve (EVRV). This
valve is controlled by the 435 circuit from the ECM.
When the EVRV solenoid is energized, the valve routes
vacuum to the EGR actuator. The actuator opens the
EGR pintle valve to allow exhaust gas to flow into the
inlet manifold. When the EVRV solenoid is released, the
valve vents the EGR actuator to outside air to close the
EGR pintle valve.
In the LH6 diesel engine, the operation of the EGR
valve is assisted by the exhaust pressure regulator (EPR)
valve. At idle, the EPR valve increases exhaust back
pressure to force more exhaust through the EGR valve
and reduce combustion temperatures. The vacuum
which operates the EGR valve and the EPR valve is
supplied by an engine-driven vacuum pump.
The electronic control module (ECM) controls the
EGR valve solenoid to regulate the vacuum to the EGR
valve in the same way as with a gasoline engine. The
ECM calculates the amount of exhaust gas recirculation
based on inputs from the engine speed sensor and the
throttle position sensor, and pulses the EGR valve
solenoid to control EGR. The manifold absolute pressure
(MAP) sensor monitors the control of exhaust gas
recirculation as indicated by the air pressure in the EPR
vacuum line. If actual vacuum differs from the preferred
vacuum as calculated by the ECM, the ECM will adjust
the on-off intervals of the EGR valve to correct the flow
of exhaust gas into the cylinders.
When the ECM recognizes the operating range in

which no exhaust gas recirculation is needed, the EGR
vent solenoid opens to vent the vacuum at the EGR
valve.
At idle, the ECM energizes the EPR valve solenoid to
send vacuum to close the EPR valve. This increases
exhaust back pressure to force more exhaust gas
through the EGR system and lower combustion
temperatures to reduce oxides of nitrogen emissions.
PRELIMINARY CHECKS:
POWER BRAKE BOOSTER VACUUM
SYSTEM
Little or no power assist upon brake application can
be caused by a faulty power brake booster vacuum
system. A simple two-step procedure can be used to
check out the vacuum system if a visual inspection fails
to uncover the cause.
With the engine off, apply and release the brake a

number of times to exhaust all vacuum from the
power brake booster. As many as 8 to 10 strokes
may be required. Then hold your foot on the brake
pedal with a firm pressure (comparable to the
pressure required to bring the vehicle to a normal
gradual stop). While maintaining a steady pressure,
start the engine. If the vacuum system is working
properly, you should feel the brake pedal "fall away"
slightly under your foot as the engine starts. If there
is no power assist, refer to the R/V, G and P Truck
Service Manual, Section 5A-1.
With no pressure applied to the brake pedal, shut off

the engine and allow the vehicle to stand undisturbed
for 3-5 minutes. Then depress and release the brake
pedal a number of times until firm resistance is met
with very little brake pedal travel. A vacuum leak or
a faulty check valve at the booster unit end of the
vacuum hose is indicated if firm resistance is
encountered with very little brake pedal travel on the
first few strokes.
EGR VALVE
VACUUM SYSTEM
A leak in the EGR (exhaust gas recirculation) vacuum
system can upset the ECMs programmed control of
exhaust gas recirculation and adversely affect engine
operation. Too much exhaust gas recirculation at idle or
cruise with a gasoline engine can result in the engine
stalling after closed throttle deceleration, surging during
steady throttle cruising, or a rough idle. Too little
exhaust gas flow allows combustion temperatures to
become too high and bring about detonation ("spark
knock") or an overheated engine. In addition, nitrous
oxide emissions may be high enough to cause the
vehicle to fail an emissions test.
Because the source of an EGR system symptom
might be traced to a mechanical or electrical condition
as well as a faulty vacuum system, an effective
systematic diagnosis procedure should examine all three
categories of components - not just the vacuum system
alone. Therefore, no exclusive vacuum system diagnosis
procedures are provided here. For more information on
the EGR system, refer to the "Fuel and Emissions Service
Manual."
VACUUM SYSTEM A-163
A-164 VACUUM HOSE ROUTING
CRUISE CONTROL
AIR CONDITIONING
AUXILIARY HEATER
(SEE PAGES 94, 99, 124)
VACUUM
PUMP
I538-.8 DK GRN I
ECM
(SEE PAGE 65)
EPR
VALVE
SOLENOID = 3 VENT
EGR
VALVE
SOLENOID
BRAKE
PEDAL
DIAGNOSTIC
CONNECTOR
(SEE PAGE 65)
EGR VENT
VALVE
SOLENOID
ENGINE
GROUND
G115
POWER BRAKE BOOSTER VACUUM SYSTEM
EGR VALVE VACUUM SYSTEM (GASOLINE ENGINE)
MAP
SENSOR
EPR
VALVE
ACTUATOR
EGR/EPR VACUUM SYSTEM (DIESEL ENGINE)
VACUUM HOSE ROUTING A-165
C187
FRONT
OF VEHICLE
GT105
S112
12C10
Figure 1 - Daytime Running Lamps Relay
C100
1. Battery Junction Block

2. Windshield Washer Motor and Reservoir
LH High-Low Headlamp
4. LH High Beam Headlamp
5. LH Park and Turn Lamp
6. LH Front Side Marker Lamp
7. RH High Beam Headlamp
8. RH High-low Headlamp
9. RH Front Side Marker Lamp
10. RH Park and Turn Lamp
G105
FRONT ^
OF V E H IC L E ^
S111
GT105
C140 \ \ ^
C137
C139
VIEW
FRONT
OF VEHICLE
12H2
G105
G106
C149
FRONT ^
OF VEHICLE
S112
FRONT
OF VEHICLE
C154
C155
C150
S111
1.
2.
3.
4.
5.
6.
7.
S113'
Battery Junction Block

LH High-Low Headlamp
LH Park and Turn Lamp
LH Front Side Marker Lamp
RH High-Low Headlamp
RH Front Side Marker Lamp
RH Park and Turn Lamp
C145
C146
FRONT
OF VEHICLE
12H1
Figure 2 - Front Headlamps-Base
A-166 COMPONENT LOCATOR VIEWS
V )E W
C157
C153VIEW A I
C151 r i _9
C152
Figure 3 - Front Headlamps-Dual Headlamps-Quad Halogen
G107
S212
S209
1.
2.
3.
4.
5.
6.
Clutch Switch
Dimmer Switch
Backup Lamp Switch
Ignition Switch
Steering Column
Turn Signal Switch
C286
S210
S207
C100
FRONT
OF VEHICLE
FRONT
OF VEHICLE
1.
2.
3.
4.
5.
GT105
I/P Cluster
Headlamp Switch
Parking Brake Switch
Turn Signal Flasher
Fuse Block
12H37.2
12H37.1
V FRONT
OF VEHICLE
C206
VIEW A
VIEW B
Figure 4 - Headlamp Switch and Fuse Block
Figure 6 - l/P Ground
COMPONENT LOCATOR VIEWS A-167
1.
2.
3.
4.
5.
6.
C424
(INSIDE
HARNESS
WRAP)
LH Rear Marker Lamp

RH Rear Backup Lamp
RH Rear Taillamp
LH Rear Taillamp
LH Rear Marker Lamp
LH Rear Backup Lamp
FRONT
OF VEHICLE
G403 (LH SIDE)

G402 (RH SIDE)
C413
FRONT
OF VEHICLE
C300
S410
>C423 (INSIDE
HARNESS WRAP)
12H73.73.1
Figure 9 - Rear Lamps-Fleetside
Figure 7 - Rear Lamps Wiring Extension Harness
C428
1.
2.
3.
4.
5.
6.
7.
C413
C417 (LH SIDE)

C415 (RH SIDE)
1. LH Front Clearance Lamp

2. LH Rear Clearance Lamp
(LH shown, RH same)
RH Rear Taillamp
RH Rear Backup Lamp
License Lamp
LH Rear Backup Lamp
LH Rear Marker Lamp
LH Rear Taillamp
RH Rear Marker Lamp
FRONT
OF VEHICLE
'GT400 (LH)
12H101
Figure 8 - Rear Lamps-Suburban and Utility
A-168
COMPONENT LOCATOR VIEWS
12H100
Figure 10 - Side Clearance Lamps-Dual Rear Wheels
VIEW
1. Stoplamp Switch with Cruise Control

2, Stoplamp Switch
FRONT
OF VEHICLE
VIEW B
FigureJ 3 - Stop Lamp Switch
Figure 11 - Rear Lamps - Stepside
A
Figure 12 - Endgate Identification Lamps
Figure 14 - Convenience Center
A-169
"C239
VIEW |~A~|
FRONT
OF
VEHICLE
^
FRONT
^ C OF VEHICLE
VEHICLE
VIEW B
1.
2.
3.
4.
Right Roof Marker Lamp

Front Roof Identification Lamps
Left Roof Marker Lamp
Headlamp Switch
12H106
Figure 15 - Roof Marker Lamps
1. LH Battery
2. RH Battery
Figure 16 - Rear Lamps Extension Harness
Figure 18 - Batteries - 6.2L V8 and 6.2L V8 HD Engines
C200
C106
FRONT
OF VEHICLE
1. Generator
2. Starter Motor
3. Starter Motor Solenoid
12H12
Figure 19 - Generator and Starter Motor 5.7L and 7.4L Engines
Figure 21 - Battery - 5.7L and 7.4L Engines
C196
C171
^
1
9 ill
1 * HI
FRONT
OF
VEHICLE
C135
VIEW
C167
C106
FRONT ^
OF
VEHICLE
FRONT
OF V E H IC L E ^ ^
C198
C134
S107
12H19
VIEW B
G110
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Water in Fuel Sensor

Cold Advance Control Solenoid
Fast Idle Solenoid
Fuel Shut Off Solenoid
Coolant Temperature Switch
Throttle Position Sensor
Starter Motor
Cold Advance/Fast Idle Temperature Switch
Fuel Heater
Starter Motor Solenoid
Manifold Absolute Pressure Sensor
Generator
S103
VIEW C
Figure 22 - Engine Wiring, Right Side - 6.2L and 6.2L HD V8 Engines
VIEW D
C200
GT102
FRONT
OF VEHICLE
11
10
FRONT
OF V E H I C L E ^
G110
^
FRONT
^ O F VEHICLE
VIEW |~A]
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Electronic Control Module

Idle Air Control Actuator
Fuel Injector 2
Fuel Injector 1
Coolant Temperature Sensor
Generator
EVRV Solenoid
Knock Sensor
Auxiliary Cooling Fan Temperature Switch
Starter Motor Solenoid
1. Engine Temperature Sender

2. Fuel Pump Oil Pressure Switch
3. Generator
G115
12H16.4
Figure 23 - Engine Wiring, Right Side - 7.4L Engine
FRONT
OF VEHICLE
VIEW B
12H15
Figure 24 - Engine Wiring, Left Side - 7.4L Engine (Fleetside)
C106
C134
C217
GT102
S101
C200
G115
C124
C216
C148
FRONT
OF VEHICLE
S117
C170
C115
C136
1.
2.
3.
4.
5.
6.
7.
8.
9.

Fuel Injector 2
Fuel Injector 1
Knock Sensor
EGR Solenoid
Auxiliary Cooling Fan Temperature Switch
Fuel Pump Relay
C159
FRONT
OF VEHICLE
1.
2.
3.
4.
5.
6.
Generator
Coil
Distributor
Electronic Spark Timing Module
Fuel Pump Oil Pressure Switch
Oxygen Sensor
12H14.2
Figure 25 - Engine Wiring, Right Side - 5.7L Engine
12H14
Figure 26 - Engine Wiring, Rear Left Side - 5.7L Engine (Suburban Utility)
C200
GT101
C216
FRONT
OF V E H IC L E ^ ^
1. Electronic Control Module
12H21
Figure 29 - Electronic Control Module - LH6

1.
2.
3.
4.
5.
6.
7.
EPR Valve
EGR Valve
EGR Dump Valve
Water Temperature Sender
Glow Plug Controller
Oil Pressure Sensor
Cold Advance Glow Plug Inhibit Relay
5197
5198
5199
C168C104A
C136
C107A
FRONT
J r OF VEHICLE
FRONT
OF VEHICLE
1.
2.
3.
4.
5.
6.
Transmission
Transfer Case
VSS
Output Speed Sensor
Oxygen Sensor
Input Speed Sensor
12H8.2
Figure 28 - Diesel Engine Harness - LH Side
Figure 30 - MT1 Electronically Controlled Transmission
FRONT ^
OF VEHICLE
C106A
1. Auxiliary Fuel Tank
Selector Switch
2. Fuse Block
3. Bus Bar Ground
4. Grommet 105
FRONT
OF VEHICLE
Figure 33 - Auxiliary Fuel Tank Selector Switch
C170
C409
1. Auxiliary Fan Temperature Switch
G409
Figure 31 - Auxiliary Cooling Fan Wiring Harness

FRONT ^
OF VEHICLE
C100
12H34
FRONT
OF VEHICLE
1. Battery Junction Block
2. Auxiliary Cooling Fan Relay
3. Auxiliary Cooling Fan
C191
Figure 32 - Auxiliary Cooling Fan
1.
2.
3.
4.
5.
LH Fuel Tank (Production)

LH Fuel Sender Assembly
RH Fuel Sender Assembly
RH Fuel Tank (Auxiliary)
Fuel Tank Selector Valve and Motor Switch
Figure 34 - Auxiliary Fuel Tanks - Diesel
FRONT
OF VEHICLE
VIEW A
G409
G410
C305
A + fFRONT
ro n t
O F VEHICLE
1. LH Fuel Sender and
Pump Assembly
2. LH Fuel Tank (Production)
3. RH Fuel Sender and
Pump Assembly
4. RH Fuel Tank (Auxiliary)
5. Fuel Tank Selector Valve
and Motor Switch
VIEW
FRONT
OF VEHICLE \
Figure 35 - Auxiliary Fuel Tanks - Gasoline
C130
C200
FRONT
OF V E H IC L E ^ ^
C216
1. Electronic
Control Module
2. MAP Sensor
3. Idle Air Control Actuator
4. Fuel Injectors
5. Throttle Position Sensor
6. Coolant Temperature Sensor
7. ESC Knock Sensor
8. ESC Hybrid Function
9. EVRV Solenoid
10. Fuel Pump Relay
8
C159
S119
Figure 36 - Electronic Engine Controls, RH Side - 5.7L Engine
1. Transmission Converter Clutch Solenoid

2. Vehicle Speed Sensor
Figure 38 - Automatic 4-Speed Transmission Wiring
A-177
C131
C129
C189
C107
C100
12H15
C115
C103
> FRONT
OF VEHICLE
1.
2.
3.
4.
5.
6.
7.
8.

Fuel Pump Relay
Manifold Absolute Pressure Sensor
Fuel Injectors
ESC Knock Sensor
ESC Hybrid Function
1.
2.
3.
4.
5.
6.
12H14.2
Figure 39 - Electronic Engine Controls, RH Side - 7.4L Engine
EVRV Solenoid
Windshield Wiper Motor
Rear Wheel Antilock Controller Module
Brake Pressure Warning Switch
S145
VIEW A
Figure 40 - Electronic Engine Controls, LH Side - 7.4L
C218
C289
1.
2.
3.
4.
Heater A/C Control Assembly Lamp

Digital Ratio Adapter Controller Module
Courtesy Lamp
Cigarette Lighter
12H37
Figure 41 - Digital Ratio Adapter Controller Module
COMPONENT LOCATOR VIEWS A179
1. Fuse Block
2. Selector Control
3. Blower Switch - Front
VIEW [ a ]
Figure 44 - A/C and Heater Control Wiring Front
3. Fuse Block
12H61.1
Figure 45 - A/C Control Wiring - Rear
Figure 47 - Rear Heater Switch Wiring
FRONT ^
OF
VEHICLE
C426
C312
GT402
C425
1. Rear Blower Motor

2. Rear Resistors
VIEW [ a ]
12H61.3
Figure 48 - Rear Heater Blower Wiring
C222
C223
1.
2.
3.
4.
5.
Glow Plugs Wait Lamp

Water in Fuel Indicator
Check Engine Lamp Driver Module
Low Coolant Warning Module
Instrument Center
FRONT
*
OF
VEHICLE
FRONT
*
OF
VEHICLE
VIEW A
FRONT w
OF
VEHICLE
VIEW [ a ]
C225
FRONT
OF
VEHICLE
1. Safety Belt Retractor Switch
C306
Figure 49 - l/P Wiring - 6.2L V8 and 6.2L V8 HD Engine
Figure 50 - Safety Belt Retractor Switch Wiring
A-181
r n
1.
2.
3.
4.
5.
C246
C166
Four-Wheel Drive Indicator Lamp

Transfer Case Switch
Four-Wheel Drive Shift Lever Lamp
Diode Assembly
Fuse Block
2. Transfer Case Switch

OF V E H IC L E ^
12H121.1
Figure 52 - Transfer Case Wiring - V300

12H122
C224
FRONT
OF VEHICLE
v ie w
Figure 51 - Transfer Case Wiring - V100, V200
Pb ]
Figure 53 - Transfer Case - Power and Ground Connections
C251
FRONT
OF VEHICLE
FRONT
OF VEHICLE
1.
2.
3.
4.
5.
6.
Bus Bar Ground

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

Fuse Block
Cruise Control Module
Brake Switch
DRAC Module
12H72
12H72.1
FRONT
OF VEHICLE
C250
C252
FRONT
OF V E H IC L E ^ ^
^
FRONT
OF VEHICLE
VIEW
VIEW [ a ]
FRONT
OF VEHICLE
VIEW B
VIEW [A~|
C256
C244
FRONT
OF VEHICLE
VIEW C
Figure 54 Cruise Control Wiring - Manual Transmission
C253
C244
C289
FRONT
OF VEHICLE
VIEW C
Figure 55 - Cruise Control Wiring - Automatic Transmission
Figure 56 - Cruise Control Servo - 6.2L and 6.2L V8 HD Engines
Figure 57 - Cruise Control Servo - 5.7L and 7.4L Engines
Figure 58 - Cruise Control Actuator
GT602
C435
1. Glove Box Lamp Switch

2. Fuse Panel
OF VEHICLE
12H 1 2 7
12H 123
C438 (RH SIDE)

C437 (LH SIDE)
2 (FRONT)
3 (REAR)
VIEW A
Figure 59 - Dome Lamp Wiring
VIEW B
Figure 60 - Front Door Jamb Switch Wiring
12H7.1
Figure 61 - Vanity Mirror Switch Wiring
Figure 64 - Rear Gate Switch Wiring
FRONT
OF VEHICLE
1 2H 50
GT601
GT500
FRONT
OF VEHICLE
1.
2.
3.
4.
1. Tailgate Window Switch

Figure 66 - Tailgate Window Front Wiring
Power Door Lock Relay

Bus Bar Ground
In-Line Auto Fuse
Fuse Block
VIEW A
Figure 67 - Power Window, Locks, and Mirror Wiring
FRONT ^
OF V E H IC L E ^
C501 (LH)
FRONT
OF V E H IC L E -^
C502 (LH)
C603 (RH)
VIEW A
C501 (LH)
C602 (RH)
FRONT
OF VEHICLE
^
1. Rear Panel Door Lock Actuator
2. Contact Assembly
VIEW [ a ]
VIEW B
1. Power Door Lock Actuator

2. Power Door Lock Switch
FRONT
OF V E H IC L E ^
12H54
VIEW
TYPICAL
Figure 70 - Power Door Lock Wiring
Figure 68 - Rear Panel Door Lock Wiring
C500 (LH-2 DOOR)

C506 (LH-4 DOOR)
0603 (RH)
12H52.2
FRONT
OF VEHICLE
C700 (LH)
C800 (RH)
C508 (LH)
:C600 (RH)
%
^ -C 5 0 9
FRONT
C501 (LH)
C602 (RH)
0503 (LH)
0604 (RH)
1.
2.
3.
4.
Power Mirror Switch

Power Window Motor
Power Door Lock Actuator
Power Window Switch
VIEW [ a ]
TYPICAL
Figure 69 - Front Door Wiring with Power Door Locks, Windows and Mirrors
12H56
Figure 71 - Rear Door Power Windows and Locks
C904
C904
S908
, FRONT
^
OF
VEHICLE
FRONT
OF VEHICLE
S908
12H121
C904
C447
1. Tailgate Window Motor

2. Cut-Out Switch
3. Tailgate Window Switch, Key Operated
FRONT
*
OF
VEHICLE
FRONT
OF VEHICLE
1. Rear Tailgate Window Motor

2. Tailgate Window Switch, Key Operated
3. Cut-Out Switch
VIEW [A]
C448
C905
G904
G401
C405
FRONT ^
OF #
VEHICLE
FRONT ^
OF VEHICLE
C406
VIEW [ a ]
Figure 72 - Tailgate Rear Window Wiring - Utility
VIEW B
VIEW B
J T
FRONT
F VEHICLE
C905
VIEW C
Figure 73 - Tailgate Rear Window Wiring - Suburban
FRONT
OF VEHICLE
C214
1. Pulse Wiper Module Wiring
Figure - 78 Pulse Wiper Module Wiring
C118
1. Backup Lamp Switch
2. Vehicle Speed Sensor
FRONT
OF VEHICLE
C141
Figure 79 - Backup Lamp Switch - Manual Transmission
1. RH License Lamp
2. LH License Lamp
12H104
Figure 80 - License Lamps Wiring - Fleetside
FRONT
OF VEHICLE
C300B
FRONT
OF VEHICLE
S118
FRONT
OF VEHICLE
G109
GT 105
1. Auxiliary Battery Junction Block

2. Auxiliary Battery Relay
3. Auxiliary Battery
12H116
VIEW
FRONT ^
OF VEHICLE
Figure 85 - Auxiliary Battery
Figure 83 - Camper and Trailer Wiring - Utility
C300B
12H117.1
Figure 84 - Camper and Trailer Wiring - Fleetside
Figure 86 - Radio Wiring, Front Harness
VIEW |~A~l
COMPONENT LOCATION
A/C Compressor ...................................
A/C Diode ...............................................
Automatic Transmission
Backup Lamp Switch ........................
Auxiliary B attery......................................
Auxiliary Battery Relay, LH side .........
Auxiliary Cooling Fan
Temperature Switch ..........................
Page -- Figure
42
Front of engine.................................................... .............. 179
42
At A/C compressor............................................. .............. 179
Bottom of steering column ............................... .............. 167
LH side of vehicle behind headlam p.............. .............. 192
On inner fender w e ll.......................................... .............. 192
Lower RH side of e n g in e ............................... .............. 173
174
176
Below radiator s u p p o rt...................................... .............. 176
LH inner fender w e ll............................ .............. .............. 176
Auxiliary Cooling F a n ............................

Auxiliary Cooling Fan Relay .................
Auxiliary Fuel Tank Selector
Switch .................................................. RH side of d a s h .................................................. .............. 176
On inner fender w e ll........................................... .............. 191
Auxiliary Junction Block, LH side
192
Backup Lamp S w itc h ............................ At top of transmission........................................ .............. 191
Backup Lamp, LH ................................. LH rear of vehicle............................................... .............. 168
168
Backup Lamp, RH ................................. RH rear of vehicle............................................... .............. 168
168
Battery Junction B lo c k .......................... Engine compartment, LH C o w l........................ .............. 166
166
176
179
186
186
Blower M o to r.......................................... RH side of cowl .................................................. .............. 179
Brake Pressure Warning S w itc h ......... Below master cylinder........................................ .............. 178
Brake Switch .......................................... On top of brake pedal assem bly..................... .............. 183
183
..............
167
Bus Bar G round...................................... LH side of l / P ......................................................
176
180
182
183
183
187
190
191
Cargo Lamp Switch Upper ................ LH B-Pillar ........................................................................... 187
Check Engine Lamp Driver Module . . . Under l / P ............................................................. ................ 181
Cigarette Lighter ................................... . In ash receptacle ............................................... ................ 179
Clutch Start Switch................................. LH side of steering colum n............................................... 167
Clutch Sw itch.......................................... , On top of clutch pedal assembly ................... ................ 183
Coil ............................................................ Top rear of e n g in e ............................................................. 174
Cold Advance Control Solenoid ......... , Front LH side of engine ................................... ................ 172
Cold Advance Glow Plug Inhibit
Relay ...................................................., Engine compartment, LH rear side ................ ................ 175
Cold Advance/Fast Idle Temp Switch . Lower RH rear of engine................................... ................ 172
Combination Lamp, LH Rear .............. . LH rear of vehicle............................................... ................ 169
Combination Lamp, RH Rear .............. . RH rear of vehicle............................................... ................ 169
A-194 COMPONENT LOCATER INDEX
5
85
85
23
25
31
32
32
33
81
85
79
8
9
8
9
2
3
32
42
62
63
43
40
54
55
6
33
47
53
54
55
67
74
81
65
49
41
5
54
26
22
28
22
11
11
COMPONENT LOCATION
Convenience C enter...................
Coolant Temperature Sender
(7.4L G aso lin e)........................
Page -- Figure
LH side of l / P ...................................................................... 169
11
Lower LH side of engine................................................... 173
177
178
24
37
40
Top center of engine ........................................................ 173

177
178
Front
of
engine....................................................................
172
Coolant Temperature Switch (Diesel) .
173
Below
l/P
.............................................................................
179
Courtesy Lamp ......................................
Cruise Control A c tu a to r........................ Part of multi function switch ............................................ 184
Cruise Control M o d u le .......................... Behind l/P, on LH side of steering column ................... 183
183
Cruise Control Servo
(5.7L and 7.4L G asoline)................... Rear of e n g in e .................................................................... 184
Cruise Control Servo (6.2L Diesel) . . . Front of en gine.................................................................... 184
Cut-Out Sw itch........................................ Upper RH side of tailgate (Utility) ................................... 189
Cut-Out Sw itch........................................ Upper LH side of tailgate (Suburban) ............................ 189
DRAC Module ........................................ l/P near steering column................................................... 179
183
183
LH front inner fender ........................................................166
DRL R e la y ............
Top rear of e n g in e ............................................................. 174
Distributor ............
Above passenger seats on roof ...................................... 185
Dome Lamp, Front
Above rear cargo area on roof ........................................ 185
Dome Lamp, Rear
Under LH side of l / P .......................................................... 173
ECM .....................
174
175
177
178
EGR Dump V a lv e ................................... Top LH side of engine ...................................................... 175
EGR Solenoid ........................................ Top RH side of e n g in e ...................................................... 174
EGR V a lv e ............................................... Top LH side of engine ...................................................... 175
EPR V a lv e ............................................... Top LH side of engine ...................................................... 175
ESC Hybrid Function (5.7L Gasoline) . Top RH side of e n g in e ...................................................... 177
ESC Hybrid Function (7.4L Gasoline) . On RH side of cowl p an el................................................. 178
EVRV Solenoid........................................ Top front of engine............................................................. 173
177
178
Top
rear
of
e
n
g
in
e
............................................................
174
Electronic Spark Timing M o d u le .........
Engine Speed Sensor .......................... Top RH side of e n g in e ...................................................... 172
Evaporator Pressure Control Switch . . RH side of cowl ................................................................. 179
Fast Idle Solenoid ................................. On top of engine ............................................................... 172
In l/P cluster........................................................................ 182
Four-Wheel Drive Indicator Lamp
Four-Wheel Drive Shift Level Lamp . . . At transfer case shift lever ............................................... 182
Front Blower S w itch ............................... Center of l / P ........................................................................ 180
Front Resistor B lock............................... RH side of cowl panel........................................................ 179
Fuel Heater ............................................. Engine compartment, on cowl behind e n g in e .............. 172
23
36
40
22
23
41
58
54
55

(5.7L and 7.4L Gasoline) .
57
56
72
73
41
54
55
1
26
59
59
23
25
29
36
39
28
25
28
28
36
39
23
36
40
26
22
43
22
51
51
44
43
22
COMPONENT LOCATION
Page -- Figure
___
173
23
Fuel Injector . . ..................................... . Top center of engine ...............................................
173
24
174
25
177
36
178
39
26
(5.7L G asolin e)................................ . Top rear of e n g in e .................................................... . . . . 174
24
(7.4L G aso lin e)................................. . Lower LH side of engine........................................... . . . . 173
178
40
23
Fuel Pump R e la y ................................ . Engine compartment on cowl behind engine . . . ___ 173
174
25
177
36
178
39
27
___
175
.
In
fuel
ta
n
k
..................................................................
Fuel Pump and Sender Assembly . . .
176
33
177
35
___
172
22
.
Front
LH
side
of
engine
..........................................
Fuel Shut Off S olenoid.......................
Fuel Tank Selector Valve and Motor
34
Switch ............................................... . RH frame rail near auxiliary fuel ta n k ..................... . . . . 176
177
35
.
.
.
.
167
4
.
LH
side
of
l
/
P
.............................................................
Fuse Block............................................
176
33
180
44
180
45
180
47
182
51
182
53
183
54
183
55
185
60
187
67
64
186
___
171
19
.
Front
of
engine...........................................................
Generator ............................................
172
22
173
23
173
24
174
26
___
185
60
Glove Box Lamp S w itc h ..................... . In glove box on RH side of l/P ...............................
.
.
.
.
175
28
Glow Plug Controller ......................... . Top rear of e n g in e ....................................................
49
Glow Plugs Wait L a m p ....................... . In instrument cluster................................................. ___ 181
.
.
.
.
169
14
Hazard Flasher ................................... . LH side of l/P on convenience c e n te r ...................
5
Headlamp Dimmer Switch ................ . LH side of steering colum n...................................... ___ 167
3
Headlamp, LH High Beam (Quad) . . . LH front of vehicle .................................................... . . . . 166
3
Headlamp, LH Low Beam (Quad) . .. . LH Front of v eh ic le .................................................... . . . . 166
3
Headlamp, Low Beam (Quad) ......... . RH front of vehicle .................................................... ___ 166
3
Headlamp, RH High Beam (Quad) . . . RH Front of vehicle.................................................... . . . . 166
2
. RH front of vehicle .................................................... ___ 166
Headlamp, RH High-Low (Base)
41
Heater A/C Control Assembly Lamp . . Front center of l/P .................................................... . . . . 179
43
High Blower R e la y .............................. . Engine compartment near blower m o to r.............. ___ 179
4
I/P C lu s te r............................................ . LH side of l / P ............................................................. ___ 167
COMPONENT LOCATION
Page -- Figure
Idle Air Control A ctuator..................... . Top RH side of e n g in e .......................................... ............173
23
174
25
31
176
Ignition S w itc h ...................................... . RH side of steering column................................... ........... 167
5
In-Line Diode (4 W D )............................ . In 4WD harness at RH side of fuse block ......... ........... 182
51
In-Line Fuse (Camper/Trailer Wiring) . . Center of cowl panel in dash conduct................ ........... 191
81
In-Line Fuse (Underhood lamp)
(Diesel)............................................... . LH inner fender w e ll............................................... ........... 186
62
In-Line Fuse (Underhood lamp)
(Gasoline)..........................................
............186
63
In-line Fuse (TP2 O n ly )........................ . LH side on inner fender w e ll................................. ............191
81
Input Speed S e n s o r............................ . LH side of transmission ........................................ ............175
30
Instrument cluster ............................... . LH side of l / P .......................................................................181
49
Knock Sensor ...................................... . Lower RH side of engine ................................................. 173
23
174
25
178
39
184
56
LH B a tte ry ............................................. . Engine Compartment, front LH side ...............................170
18
LH H o rn ................................................. . LH front of vehicle ................................................. ............170
17
LH License L a m p ................................. . Rear center of vehicle............................................ ............191
80
LH Rear Door Jamb Switch ..............
59
........... 185
LH Rear Side Marker Lamp ..............
........... 168
8
9
168
License Lamp ...................................... . Rear center of vehicle........................................................ 168
8
Light S w itch.......................................... . LH side of l / P ........................................................... ......... 167
4
170
15
Low Coolant Warning M odule............ . Behind LH side of l/P ............................................ ............181
49
MAP S ensor.......................................... . Top RH rear of engine .......................................... ............172
22
177
36
178
39
Multi Function S w itc h .......................... . On steering column ............................................... ........... 184
58
Oil Pressure Sensor (Diesel)..............
........... 175
28
Output Speed Sensor ....................... . LH side of transmission ........................................ ......... 175
30
Oxygen Sensor ................................... . LH exhaust manifold............................................... ......... 174
26
175
30
Powertrain Control Module (PCM) . . . . Under LH side of l / P .......................................................... 173
23
Panel Door C ontractor.......................
........... 188
68
Park Brake Warning Switch .............. . Under LH side of l / P .......................................................... 167
4
Park and Turn Lamp, LH (Base) . . . . . LH front of vehicle ................................................. ........... 166
2
Park and Turn Lamp, LH (Quad) . . . . LH front of vehicle ................................................. ........... 166
3
Park and Turn Lamp, RH (Base) . . . . . RH front of vehicle ................................................. ......... 166
2
Park and Turn Lamp, RH (Quad) . . . . RH front of vehicle ................................................. ......... 166
3
Power Door Lock A c tu a to r................
........... 188
69
Power Door Lock A c tu a to r................ . RH front d o o r .......................................................... ........... 188
70
Power Door Lock A c tu a to r................ . Rear side d o o r s ................................................................. 188
71
Power Door Lock Relay ..................... . At RH side of steering column s u p p o rt.............. ........... 187
67
Power Door Lock Switch ................... . Upper RH front d o o r.......................................................... 188
70
Power Mirror S w itch ............................ . Upper LH front d o o r .......................................................... 188
69
Power Window M o to r.......................... . Lower LH front d o o r ............................................... ......... 188
69
Power Window M o to r.......................... . Rear side d o o r s ...................................................... ......... 188
71
Power Window Switch ........................ . At LH front d o o r ...................................................... ......... 188
69
69
Power Window M o to r.......................... . Lower LH front d o o r .......................................................... 188
COMPONENT LOCATER INDEX A-195
COMPONENT LOCATION
Page -- Figure
78
....................191
Pulse Wiper M o d u le ............................ . Under LH side of l / P ...............................
18
RH Battery............................................. . Engine compartment, front LH s id e .............. ....................1 7 0
171
RH Fuel Sender A ssem bly................ . RH Fuel T a n k .................................................... ....................1 7 6

17 7
RH
RH
RH
RH
Horn ...............................................
License Lam p.................................
Rear Door Jamb Switch ..............
Rear Side Marker Lamp ..............
. RH front of vehicle ..........................................

. Rear center of vehicle............................ ..
. On RH B-pillar .................................................
. RH rear of vehicle.............................................
Radio Receiver...................................... . Center of l / P ......................................................

Rear A/C Blower M otor.......................
Rear A/C Blower S w itc h .....................
Rear A/C and Heater Controls .........
Rear Gate S w itch .................................
Rear Heater Blower Motor ................
Rear Heater Blower Resistors............
Rear Panel Door Lock Actuator
Rear Resistor Block ...........................
Rear Wheel Antilock ...........................
Controller Module
Rear Window Defogger S w itch .........
Roof Identification L am p s...................
Roof Marker Lamp, L H .......................
Roof Marker Lamp, R H .......................
Safety Belt Retractor S w itc h ..............
Selector Control .................................
Side Marker Lamp, LH Front
(Base).................................................
(Base).................................................
(Quad) ...............................................
Side Marker Lamp, RH Front
(Quad) ...............................................
Speaker, F ro n t......................................
Speaker, Left Front..............................
Speaker, Left R e a r ...............................
Speaker, Right Front ..........................
Speaker, Right R e a r............................
Starter Motor U n d e r............................
Starter Motor L o w e r ..........................
Starter Motor S olenoid.......................
Starter Motor S olenoid.......................
Stop Lamp Switch ..............................
Tailgate Window Motor (Utility) .........
Tailgate Window Motor (Suburban)
Tailgate Window Switch
(Key O p erated).................................
21
34
35
....................1 7 0
....................191
17
80
....................185
....................168
168
....................192
193
....................1 8 0
....................180
....................1 8 0
....................186
....................181
................181
59
8
9
86
87
46
.
.
.
.
.
.
.
.
.
Top rear of v e h ic le ..........................................

Center of l / P ......................................................
Center of l / P .......................................... ..
RH rear of vehicle.............................................
Rear LH side of vehicle...................................
At rear heater blower motor ........................
At rear d o o r ................................................... ....................1 8 8
RH side of engine com partm ent .................. ....................1 8 0
LH side of master cylinder ............................ ....................1 7 8
.
.
.
.
.
.
Center of l / P ......................................................
Front top of ro o f...............................................
Front top LH side of roof ...............................
Front top RH side of roof ...............................
At safety belt assembly...................................
Center of l / P ...................................................
....................190
....................170
....................1 70
74
15
15
....................1 70
....................181
....................180
15
50
44
. Front LH side of vehicle .................................
....................166
. Front RH side of v e h ic le .................................
....................166
. Front LH side of vehicle .................................
....................166
.
.
.
.
.
.
.
.
.
.
....................166
................193
....................1 93
................... 193
3
87
87
Front RH side of v e h ic le .................................

Top center of l/P ..........................................
LH side of l / P ....................................................
LH rear side of vehicle ...................................
RH side of l / P ....................................................
RH side of vehicle ..........................................
RH side of engine.............................................
RH side of engine ..........................................
Under RH side of engine ...............................
Lower RH side of engine ..............................
. Above brake pedal ......................................
. RH center of tailgate ......................................
. LH center of ta ilg ate ......................................
................... 193
....................193
................... 171
................... 172
................... 171
................... 1 7 3
............... 1 6 9
................... 189
................... 1 8 9
. Center of tailgate ............................................. ................1 89

189
47
45
64
48
48
68
45
40
87
87
87
19
22
19
23
13
72
73
72
73
Page -- Figure
COMPONENT LOCATION
8
Taillamp, L H ........................................ . . Rear LH side of vehicle................................................. . . 168
168
9
8
Taillamp, RH ...................................... . . Rear RH side of vehicle .............................................. . . 168
168
9
22
Throttle Position Sensor (Diesel) . . . . . Front RH side of e n g in e .............................................. . . 171
74
Timer R e la y ........................................ . . Below fuse block .......................................................... . . 190
51
Transfer Case S w itch ........................ . . Top of transfer c a s e ..................................................... . . 182
Transmission Converter Clutch
38
Solenoid.......................................... . . LH rear of transmission................................................. . . 177
4
Turn Signal Flasher .......................... . . LH side of l/P, on fuse block........................................ . . 167
5
Turn Signal S w itch ............................ . . LH side of steering colum n.......................................... . . 167
63
Underhood Lamp (Gasoline) ......... . . RH side of cowl ............................................................ . . 186
62
Underhood Lamp (Diesel) .............. . . LH inner fender w e l l ..................................................... . . 186
30
Vehicle Speed S e n s o r ..................... . . Rear of transfer case (4WD) ........................................ . . 175
38
Vehicle Speed Sensor ..................... . . Rear of transmission (2WD) ........................................ . . 177
191
79
3
Washer Motor ................................... . . Engine compartment, LH fe n d e r................................. . . 166
28
Water Temperature Sender ............ . . Front LH side of engine .............................................. . . 175
49
Water in Fuel Indicator..................... . . In instrument cluster..................................................... . . 181
22
Water in Fuel S e n s o r........................ . . Engine compartment on cowl behind engine ......... . . 172
40
Windshield Wiper M o to r................... . . Top LH side of c o w l..................................................... . . 178
Connectors:
2
C100 ............................................... . . Engine compartment, LH cowl ................................... . . 162
166
3
186
63
167
4
168
7
175
28
176
31
62
C100A ............................................. . . In engine compartment at LH inner fender well . . . . . . 186
186
63
62
C101A ............................................. . . At underhood lam p....................................................... . . 186
.
.
178
40
C103 ............................................... . . At rear wheel anti-lock controller module...................
74
C103A ............................................. . . In lower LH side of engine compartment near cowl . . . 190
.
.
178
40
C104 ............................................... . . At brake pressure warning switch..............................
30
C104A ............................................. . . At top center of transmission ..................................... . . 175
30
C105 ............................................... . . At output speed sensor .............................................. . . 175
19
C106 ............................................... . . Front of engine at generator....................................... . . 171
172
22
174
26
33
C106A ............................................. . . At cowl, above steering column ................................. . . 176
22
C107 ............................................... . . At coolant temperature sensor ................................... . . 172
173
23
177
36
177
37
178
40
22
C107 ............................................... . . At coolant temperature switch..................................... . . 172
28
C108 ............................................... . . At cold advance glow plug inhibit re la y ..................... . . 175
26
C109 ................................................ . . At coil ............................................................................. . . 174
. . 172
22
C110 ...............................................
22
. , . At glow plug # 4 ............................................................ . . 172
. . 172
22
C112 ...............................................
cm ..............................
COMPONENT LOCATION
C113 ........................................
C114 ........................................
C115 ........................................
C118
C120
C121
C122
C123
C124
C125
C126
C127
C128
C129
C130
C131
C132
C133
C134
C134
C135
C136
C137
C138
C139
C140
C141
C142
C143
C144
C145
C146
.
.
.
.
Page -- Figure
At glow plug # 8 .................................................................. 172
22
Top of engine near c o il...................................................... 174
26
At fuel pump oil pressure sw itch...................................... 173
24
174
26
175
28
178
40
At backup lamp s w itch ...................................................... 191
79
At glow plug #1 .................................................................. 175
28
At glow plug # 3 .................................................................. 175
28
At glow plug # 5 .................................................................. 175
28
At glow plug # 7 .................................................................. 175
28
At electronic spark timing m odule.................................... 174
26
Engine compartment, near LH front of cowl .................166
2
166
3
167
4
LH inner fender, at daytime running lamp re la y ............166
1
In engine compartment at LH side of cowl ................... 187
66
In engine compartment at LH side of cowl ................... 187
66
At fuel injector 1 .................................................................. 173
23
174
25
177
36
178
39
At fuel injector 2 .................................................................. 173
23
174
25
177
36
178
39
At EVRV solenoid................................................................169
13
177
36
178
40
At ESC hybrid function...................................................... 177
36
178
39
At LH side of cowl p a n e l.................................................... 177
37
At TP sensor ....................................................................... 172
22
At throttle position sensor.................................................. 173
23
174
25
177
36
178
39
At map s e n s o r.................................................................... 172
22
177
36
178
39
At top center of transmission ........................................... 174
26
175
30
Front LH side marker la m p ............................................... 166
2
Front LH high-low headlam p.............................................166
2
Front LH park lamp ...........................................................166
2
Front LH turn la m p ............................................................. 166
2
At vehicle speed s e n s o r....................................................191
79
At LH h o r n ........................................................................... 170
17
At RH h o rn ........................................................................... 170
17
Front RH high-low headlamp .......................................... 166
2
Front RH side marker la m p ............................................... 166
2
Front park la m p .................................................................. 166
2
COMPONENT LOCATION
C147
C148
C149
C150
C151
C152
C153
C154
C155
C156
C157
C159
C161
C162
C163
C165
C166
C166
C167
C168
C169
C170
C171
C172
C173
C174
C175
C177
C178
C179
C180
C181
C184
C185
C187
C188
C189
Page -- Figure
............................................... . . Front RH turn la m p ........................................................ . . 166
2
............................................... . . At fuel pump relay ........................................................ . . 173
23
174
25
177
36
178
39
(Q u a d )................................... . . Front LH low beam headlam p...................................... . . 166
3
(Q u a d )................................... . . Front LH high beam h ead lam p ................................... . . 166
3
(Q u a d )................................... . . Front LH turn la m p ........................................................ . . 166
3
(Q u a d )................................... . . Front LH park lamp ...................................................... . . 166
3
(Q u ad )................................... . . Front LH side marker la m p .......................................... . . 166
3
relay.................................................................................. . . 167
4
(Q u a d )................................... . . Front RH low beam headlamp ................................... . . 166
3
(Q u a d )................................... . . Front RH high beam headlam p................................... . . 166
3
(Q u a d )................................... . . Front RH turn la m p ........................................................ . . 166
3
(Q u a d )................................... . . Front RH park lamp ...................................................... . . 166
3
............................................... . . At knock s en s o r............................................................. . . 173
23
174
25
177
36
178
39
............................................... . . At idle air control actuator............................................. . . 173
23
174
25
177
36
178
39
............................................... . . Engine compartment, near battery junction block . , . . 179
42
............................................... . . At engine temperature sender ................................... . . 173
24
175
28
............................................... . . At A/C compressor........................................................ . . 179
42
............................................... . . At clutch switch ............................................................. . . 183
54
............................................... . . Near steering colum n.................................................... . . 183
55
............................................... . . At cold advance control solenoid .............................. . . . 172
22
............................................... . . At glow plug controller................................................. . . . 175
28
............................................... . . At transmission converter clutch solen oid................ . . 177
38
............................................... . . At auxiliary cooling fan temperature s w itc h .............. . . 173
23
174
25
176
31
............................................... . . At fast idle solenoid ...................................................... . . 172
22
............................................... . . At rear LH side of transmission................................... . . 175
30
............................................... . . At input speed sensor ................................................. . . . 175
30
............................................... . . At EGR valve .................................................................. . . 175
28
............................................... . . At engine speed s e n s o r............................................... . . 172
22
............................................... . . At high blower r e la y ...................................................... . . . 179
43
............................................... . . At evaporator pressure control sw itch ....................... . . 179
43
............................................... . . At front resistor b lo c k ...................................................., . . 179
43
............................................... . . At front blower motor ...................................................., . . 179
43
............................................... . . At rear resistor block ..................................................... . . 180
45
............................................... . . At cruise control servo ................................................. . . . 184
56
184
57
............................................... . . In cruise harness near servo........................................, . . 184
56
184
57
3
............................................... . . At windshield washer bottle ......................................... . . 184
,
.
.
178
40
............................................... . . At windshield wiper m otor............................................
40
............................................... . . At windshield wiper m otor............................................ . . . 178
COMPONENT LOCATION
C190 ........................................
C191 ........................................
C192 ........................................
C193 ........................................
C194 ........................................
C195 ........................................
C196 ........................................
C197 ........................................
C198 ........................................
C199 ........................................
C200 ........................................
Page -- Figure
At auxiliary cooling fan re la y ...................................

At auxiliary cooling f a n .............................................
Engine compartment, LH side near c o w l..............
At EGR dump valve . .............................................
At EPR valve .............................................................
At EGR solenoid.........................................................
At fuel h e a te r.............................................................
At water in fuel sensor .............................................
At cold advance/fast idle temperature switch
At fuel shut off solenoid ...........................................
Under l/P near ECM /PCM /TCM ...............................
C202
At light switch.............................................................
C203
C204
C207
C208
C212
C214
C215
LH side of l / P .............................................................
At radio .......................................................................
At pulse wiper module .............................................
Near fuse block .........................................................
Under LH side of l/P near fuse block.....................
At pulse wiper module .............................................
Under l/P at ECM /PCM /TCM ...................................
C216
Under l/P at ECM /PCM /TCM ...................................
C217
C218
Under l/P near ECM /PCM /TCM ...............................

At courtesy lamp ......................................................
C219
C220
C221
C222
C223
C224
C225
C226
C227
C228
C229
C230
At fuse block .............................................................

At l/P courtesy la m p ..................................................
At heater A/C control assembly lamp ...................
At glow plugs wait la m p ..........................................
At water in fuel indicator...........................................
At fuse block .............................................................
At low coolant warning m odule...............................
At transfer case s w itch .............................................
At LH front door jamb switch .................................
At Lh front door jamb sw itch...................................
At RH front door jamb switch .................................
At glove box lamp switch ........................................
. . . . 176
___ 176
___ 176
___ 175
___ 175
___ 174
___ 172
___ 172
___ 172
___ 172
___ 171
173
174
175
177
178
___ 167
170
192
. . . . 167
___ 192
___ 191
___ 185
___ 190
___ 191
___ 171
173
174
175
177
178
. . . . 171
173
174
175
177
178
. . . . 174
___ 179
185
___ 185
___ 185
___ 179
___ 181
. . . . 181
___ 182
___ 181
___ 182
. . . . 185
. . . . 185
___ 185
. . . . 185
32
32
32
28
28
25
22
22
22
22
19
23
25
29
36
39
4
15
86
4
86
78
60
74
78
19
23
25
29
36
39
19
23
25
29
36
39
25
41
60
60
60
41
49
49
53
49
52
60
60
60
60
COMPONENT LOCATION
Page - Figure
C231 ...............................................
C232 ............................................... . . At auxiliary fuel tank selector switch ..........................
C233 ............................................... . . At selector control .................. .....................................
C234 ............................................... . . At front blower switch...................................................
C235 ............................................... . . l/P harness, near front blower switch ........................
C238 ............................................... . . LH side of l/P, near light switch...................................
C239 ............................................... . . At light switch.................................................................
.
.
.
.
.
.
.
.
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.
.
.
.
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.
.
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.
At
At
At
At
radio ..........................................................................
radio ..........................................................................
LH front speaker .....................................................
front mono-speaker .................................................
..
..
..
..
..
..
..
At
At
At
At
At
At
At
4WD shift lever c a m .................................................

LH front speaker .....................................................
RH front speaker .....................................................
DRAC module ..........................................................
brake switch...............................................................
cruise control module...............................................
brake switch...............................................................
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
At DRAC module ..........................................................

At fuse block .................................................................
At fuse block .................................................................
At fuse block .................................................................
In engine compartment near LH side of cowl .........
l/P harness, under RH side of l/P ..............................
At power door lock relay...............................................
At power door lock relay..............................................
Near fuse panel ............................................................
l/P harness, under RH side of l/P ..............................
At tailgate window s w itch ............................................
Under LH side of l/P near fuse block..........................
At rear window defogger switch .................................
In lower LH side of engine compartment near cowl .
At A/C heater controls .................................................
.
.
.
.
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.
C282 ............................................... . . RH side of l/P near A-pillar..........................................

C283 ............................................... . . . At fuse block .................................................................
C285 ............................................... . . . At fuse block .................................................................
C288 ............................................... . . . At 4WD indicator la m p .................................................
C289 ............................................... , . . At DRAC module ..........................................................
.
.
.
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.
.
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.
.
C240
C241
C242
C243
C244
C246
C247
C248
C250
C251
C252
C253
C254
C256
C258
C259
C260
C261
C262
C263
C264
C265
C266
C268
C271
C274
C275
C276
C277
C278
C279
C280
C281
C291
C299
C300
C300
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
.
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............................................... , .
............................................... , .
............................................... . .
............................................... . .
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l/P Harness, LH side, at diode assembly...................

At cigarette lighter ........................................................
LH side rail at rear crossmember (Utility)...................
LH side rail at rear crossmember (Fleetside)............
176
176
180
180
180
170
170
192
193
192
193
193
183
182
193
193
183
183
183
183
183
183
187
187
187
187
187
187
187
187
187
187
187
187
190
190
190
190
190
190
180
180
180
180
180
182
179
183
167
179
192
192
33
33
44
44
44
15
15
86
87
86
87
87
55
51
87
87
55
55
55
55
55
55
67
67
67
67
67
67
67
67
67
67
67
66
74
74
74
74
74
74
45
47
45
45
47
51
41
55
4
41
83
84
JOMPONENT LOCATION
Page -- Figure
............................................... . . Above rear crossmember, towards RH side

of veh icle........................................................................... . 168
168
C300 . . < ........................................ . . LH side rail at rear crossmember (Suburban) ............ . 191
C300A ............................................ . . LH side rail at rear crossmember (Utility)..................... . 192
C300A ............................................ . . LH side rail at rear crossmember (Fleetside).............. . 192
C300A ............................................ . . LH side rail at rear crossmember (Suburban) ............ . 191
C300B ............................................. . . LH side rail at rear crossmember (Utility)..................... . 192
C300B ............................................ . . LH side rail at rear crossmember (Fleetside).............. . 192
C300B ............................................ . . LH side rail at rear crossmember (Suburban) ............ . 191
C301 ............................................... . . Above rear crossmember, towards LH side of vehicle . . 8
C303 ............................................... . . At LH frame rail near fuel tank ...................................... . 175
C305 ............................................... . . At fuel tank selector valve and motor switch .............. . 176
177
C306 ............................................... . . At LH safety b e lt................................................................ . 181
C309 ............................................... . . At shift le v e r....................................................................... . 182
C310 ............................................... . . At fuse block .................................................................... . 183
183
.
C311 .............................................. . . . In LH kick p a n e l................................................................ 181
C312 .............................................. . . . In LH kick p a n e l................................................................ . 181
C313 .............................................. . . . RH side of fuse b lo c k ...................................................... . 182
C323 .............................................. . . . At RH side of l/P ............................................................... . 186
C324 .............................................. . . . At RH vanity m irror........................................................... . 186
C400 .............................................. . . . At door panel contactor ................................................. . 188
C401 .............................................. . , . At door panel contactor .................................................. . 188
C402 ............................................ . . . At LH B-pillar .................................................................... . 188
C403 ............................................ . . . At RH B -pillar.................................................................... . 188
C404 ............................................ . . . At RH B -pillar.................................................................... . 188
C405 ............................................ . . . LH side rear crossmember (Utility) ............................... . 189
C406 ............................................ . . . LH side rear crossmember (Utility) ............................... . 189
C409 ............................................ . . . At fuel pump and sender ............................................... . 175
176
177
.
176
C410 ............................................ . . . At RH auxiliary fuel t a n k .................................................
177
180
.
168
C411 ............................................ . . . At RH tail, stop and turn lam p ........................................
168
169
C412 ............................................ . . . At LH tail, stop and turn la m p ........................................ . 168
168
169
C413 ............................................ . . . At LH rear side marker la m p .......................................... . 168
168
C414 ............................................ . . . At RH rear side marker lam p.......................................... . 168
168
C415 ............................................ . . . At RH side front clearance la m p ................................... . 168
C416 ............................................ . . . At RH side rear clearance lamp ................................... . 168
C417 ............................................ . . . At LH side front clearance lamp ................................... . 168
C418 ............................................ . . . At LH side rear clearance la m p ...................................... . 168
C419 ............................................ . . . Rear lamp harness, towards LH side of veh ic le......... . 168
C420 ............................................ . . . At RH license la m p ........................................................... . 191
C300
8
9
82
83
84
82
83
84
82
8
27
34
35
50
52
54
55
48
48
51
61
61
68
68
71
71
68
72
72
27
34
35
34
35
46
8
9
11
8
9
11
8
9
8
9
10
10
10
10
9
80
COMPONENT LOCATION
C421
C423
C424
C425
C426
C427
C428
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
C429
............................................... . . At LH backup lam p ........................................................
C430
C431
C432
C433
C434
...............................................
...............................................
...............................................
...............................................
...............................................
C435
............................................... . . In LH B-pillar ..................................................................
C436
C437
C438
C439
C440
C442
C447
C448
C449
C450
C451
C452
C453
C454
C455
C456
C500
C501
............................................... , .
............................................... , .
............................................... , .
............................................... .
..............................................., .
............................................... .
................................................ .
..............................................., .
..............................................., .
................................................ .
................................................ .
................................................ .
................................................ .
................................................ .
................................................ .
..............................................., .
................................................ .
................................................ .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
At LH license la m p ........................................................
Rear lamp harness, LH side inside harness wrap . .
Rear lamp harness, RH side inside harness wrap . .
At rear heater blower motor ........................................
At rear heater blower motor ........................................
At rear crossmember, towards LH side of vehicle . .
At RH backup lamp ......................................................
At LH B-pillar
At LH B-pillar
At LH B-pillar
At LH B-pillar
In LH B-pillar
..................................................................
..................................................................
..................................................................
..................................................................
..................................................................
At cargo lamp ...............................................................

At LH rear door jamb sw itch ........................................
At RH rear door jamb switch........................................
At LH rear s p ea k er........................................................
At RH rear speaker........................................................
At RH rear gate s w itc h .................................................
Under LH side of rear bumper (suburban) ..............
Under LH side of rear bumper (suburban) ..............
Below bumper on LH side ..........................................
At LH panel door lock actu ato r...................................
At LH panel door lock actuator...................................
At RH panel door lock actuator...................................
At RH panel door lock actuator...................................
In LH B-pillar ..................................................................
In LH B-pillar ..................................................................
Rear of vehicle in roof p a n e l........................................
At LH power window switch (2-door)..........................
At LH power door lock sw itch......................................
C502 ................................................ . . At LH front power door lock actuator ........................

C503 ................................................ . . At LH power window m otor..........................................
C506 ................................................ . . At LH power window switch (4-door)..........................
C508 ................................................ . . At LH power m irror........................................................
C509 ................................................ . . At upper LH front d o o r .................................................
C600 ................................................ . . At RH power mirror........................................................
C602 ................................................ . . At RH power door lock switch.....................................
C603
C604
C700
C701
C702
................................................
................................................
................................................
................................................
............................................. .
.
.
.
.
.
.
.
.
.
.
At
At
At
At
At
RH front power door lo c k ........................................

RH power window motor ........................................
LH rear window s w itch .............................................
LH rear power window m o to r .................................
LH rear power door lock actuator..........................
Page - Figur
191
80
168
9
168
9
181
48
181
48
169
12
168
8
168
9
169
11
. . 168
8
168
9
169
11
. . 187
65
. . 187
65
. . 187
65
. . 187
65
. . 185
59
185
60
. . 185
59
185
60
. . 187
65
. . 185
60
. . 185
60
. . 193
88
. . 193
88
. . 186
64
. . 189
73
. . 189
73
. . 190
75
. . 190
77
. . 190
77
. . 190
76
. . 190
76
. . 187
65
. . 187
65
. . 186
64
. . 188
69
. . 188
69
188
70
. . 188
70
. . 188
69
. . 188
69
. . 188
69
. . 188
69
. . 188
69
. . 188
69
188
70
. . 188
70
. . 188
69
. . 188
71
. . 188
71
. . 188
71
.
.
.
.
.
.
.
.
.
.
.
.
.
.
COMPONENT LOCATION
Page - Figure
___ 188
___ 188
___ 188
___ 188
___ 188
___ 188
___ 189
189
___ 189
189
___ 189
189
___ 190
___ 190
. . . . 190
___ 190
___ 190
. . . . 190
___ 190
71
71
71
68
68
68
72
73
72
73
72
73
77
76
77
77
76
75
75
. . Engine compartment, RH C o w l............................... ___ 179

. . Engine compartment, RH C o w l............................... ___ 171
173
174
177
178
___ 173
............................................. . . Engine compartment, near LH cylinder head
174
175
177
178
............................................. . . Cowl panel, above transmission tu n n e l................ ___ 180
180
............................................. . . Engine compartment, LH C o w l............................... ___ 166
166
167
............................................. . . Engine compartment, top LH side of c o w l............ ___ 182
183
............................................. . . Cowl panel, above transmission tu n n e l................ ___ 176
187
___ 168
............................................. . . LH rear lamp harness, below RH rear lamps
___ 168
............................................ . . LH rear lamp harness, below LH rear lamps
............................................ . . LH side at kick panel ............................................... ___ 187
188
............................................ . . Between front LH door jamb and door ................. ___ 188
............................................ . . At LH A-pillar ............................................................. ___ 185
............................................ . . RH side at kick p a n e l............................................... ___ 187
............................................ , . . Between front RH door jamb and d o o r ................ ___ 187
............................................ , . . At RH A -p illar............................................................. ___ 185
............................................ , . . Between B-pillar and LH rear door ........................ ___ 188
............................................ . . . Between B-pillar and RH rear d o o r ........................ ___ 188
43
19
23
25
36
39
23
25
29
36
39
47
45
2
3
4
51
55
33
66
8
8
67
69
69
60
67
67
60
71
71
..
..
..
..
..
..
..
At
At
At
At
At
At
At
RH rear window sw itch........................................

RH rear power window m o to r............................
RH rear power door lock actuator.....................
rear panel door lock actu ato r............................
rear panel door contactor, door s id e ................
rear panel door contactor, door s id e .................
cut-out switch.........................................................
C800
C801
C802
C900
C901
C902
C904
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
...............................................
C905
............................................... . . At tailgate window motor ........................................
C906
............................................... . .
C907 ...............................................
C908 ...............................................
C909 ...............................................
C910 ...............................................
C911 ...............................................
C912 ...............................................
C913 ...............................................
Grommets:
GT100 .............................................
GT101 .............................................
GT102
GT103
GT105
GT106
GT107
GT400
GT401
GT500
GT501
GT502
GT600
GT601
GT602
GT700
GT800
..
..
..
..
..
..
..
At tailgate window switch (key operated)
............
In top LH panel door ...............................................

In top RH panel d o o r ...............................................
At LH panel door lock actuator...............................
At LH panel door lock actuator...............................
At RH panel door lock actuator...............................
At top LH side of tailgate ........................................
At center LH side of ta ilg a te ...................................
COMPONENT LOCATION
Page -- Figure
Grounds:
G105 ............................................... . . LH front of vehicle, above LH headlamps ................. . . 166
166
G106 ............................................... . . RH front of vehicle, above RH headlamps................. . . 166
166
G107 ............................................... . . RH front of vehicle on frame below RH headlamps . . . 166
166
G108 ............................................... . . In engine, compartment above auxiliary battery
junction block................................................................. . . 192
G109 ............................................... . . LH side of vehicle on radiator support........................ . . 192
G110 ............................................... . . Top RH rear of engine ................................................. . . 172
179
G110 ............................................... . . Top RH front of engine................................................. . . 173
G111 ............................................... . . RH front of vehicle above RH battery ........................ . . 170
172
G112 ............................................... . . Front of RH cylinder h e ad ............................................ . . 171
G113 ............................................... . . Front of LH cylinder h e a d ............................................ . . 170
G114 ............................................... . . At alternator bracket..................................................... . . 170
G115 ............................................... . . Rear of RH cylinder h e a d ............................................ . . 173
174
G117 ............................................... . . Above blower motor in engine compartment............ . . 179
G118 ............................................... . . In engine compartment at top of c o w l........................ . . 186
G200 ............................................... . . LH side of l / P ................................................................. . . 167
180
182
183
187
G201 ............................................... . . Under l/P near fuse panel............................................ . . 176
183
183
190
G401 ............................................... . . At LH rear crossmember (Suburban) ........................ . . 189
G402 ............................................... . . RH rear side of vehicle................................................. . . 168
168
G403 ............................................... . . LH rear side of v e h ic le ................................................. . . 168
168
G403 ............................................... . . LH side rail at rear crossmember .............................. . . 191
192
G404 ............................................... . . Under tailgate near LH side of vehicle....................... . . 169
G406 ............................................... . . LH rear side of v e h ic le ................................................. . . 169
G407 ............................................... . . RH rear side of vehicle................................................. . . 169
G409 ............................................... . . LH frame rail above fuel tank ..................................... . . 175
176
177
G410 ............................................... . . RH rail above fuel ta n k ................................................. . . 176
177
G411 ............................................... . . Above rear blower motor ............................................ . . 180
190
G904 ............................................... . . At rear tailgate window motor (Suburban)................ . . 189
2
3
2
3
2
3
85
85
22
42
24
18
22
21
18
18
24
26
43
63
6
47
53
54
67
33
54
55
74
73
8
9
8
9
82
84
12
11
11
27
33
35
34
35
46
77
73
COMPONENT LOCATION
Page -- Figure
Splices:
S 1 0 0 ................................................. . . Engine harness, near junction b lo c k .......................... . . 173
175
S 1 0 1 ................................................. . . Engine harness, front of LH valve cover ................... . . 174
S 1 0 3 ................................................. . . Engine harness, near starter m o to r............................ . . 172
174
S 1 0 4 ................................................. . . At LH inner fender w e ll................................................. . . 192
S 1 0 5 ................................................. . . At LH inner fender well near auxiliary
battery re la y .................................................................... . . 192
S 1 0 6 ................................................. . . Engine harness, near junction b lo c k .......................... . . 174
S 1 0 7 ................................................. . . Engine harness, near g en erato r................................. . . 172
S 1 0 8 ................................................. . . Engine harness, near starter m otor............................ . . 172
S109 . . ............................................. . . Engine harness, near center of e n g in e ..................... . . 175
S 1 0 9 ................................................. . . Engine harness, top rear ............................................. . . 172
S 1 1 0 ................................................. . . Forward lamps harness, LH s id e ................................. . . 166
S 1 1 1 ................................................. . . Forward lamps harness, in front of
RH headlam ps............................................................... . . 166
166
S 1 1 2 ................................................. . . Forward lamps harness, in front of LH
headlamps...................................................................... . . 166
166
S 1 1 3 ................................................., . . Forward lamps harness, LH side behind
headlamps...................................................................... . . 166
S 1 1 4 .................................................. . . Forward lamps harness, LH side in front of
washer b o ttle .................................................................. . . 166
S 1 1 7 .................................................. . . Engine harness, rear top of e n g in e............................ . . 173
174
520
24
28
26
22
25
85
85
26
22
22
28
22
2
2
3
2
3
3
3
23
26
S 1 1 8 .................................................. . . At LH inner fender well near auxiliary battery relay . . . 192

S 1 1 9 .................................................. . . Engine harness, center of RH valve c o v e r................ . . 172
177
S121 (6.2L Diesel)......................... . . . Engine harness, rear top of e n g in e............................ . . 130
S130 (6.2L HD D iesel).................. . . . Engine harness, rear top of e n g in e............................ . . 130
S 1 3 6 .................................................. . . Engine harness, RH side of e n g in e ............................ . . 172
173
174
S 1 3 7 .................................................. . . Engine harness, RH side of e n g in e ............................ . . 172
173
174
S 1 3 8 ............................................... . . . Under l/P near E C M ...................................................... . . 175
S 1 3 9 ............................................... . . . Engine harness, rear top of e n g in e ............................ . . 173
174
85
25
36
28
28
22
24
25
22
23
25
29
23
26
S 1 4 0 ............................................... . . . Engine harness, rear top of e n g in e ............................ . . 173

174
23
26
S 1 4 5 ..............................................
S 1 6 9 ..............................................
S 1 7 1 ..............................................
S 1 9 7 ...............................................
S 1 9 8 ...............................................
S 1 9 9 ..............................................
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
LH side of cowl panel near antilock control module .

Engine harness, RH rear of e n g in e ............................
Engine harness, center of LH valve c o v e r.................
Engine harness, rear center of engine .....................
.
.
.
.
.
.
.
.
.
.
.
.
178
172
175
175
175
175
COMPONENT LOCATION
40
22
28
28
28
28
5202
5203
5205
5206
5207
5209
521
521
0
1
521 2
521 3
S 2 1 5 ..........................................
521 7
521 8
5257
5258
5259
5260
526
5300
530 1
5302
S304 ........................................
5304
5305
5305
5306
5306
5307
5307
5308
S 3 1 0 ........................................
531 2
531 3
5326
5327
5328
5329
5400
540 1
Page -- Figure
l/P harness, LH s id e ........................................................... 167
4
193
87
4
4
179
41
l/P harness, behind steering column support .............. 183
54
183
55
l/P harness, LH side of steering column ........................167
5
l/P harness, bottom of steering colum n..........................167
5
l/P Harness, LH side under l/P ........................................ 167
4
193
87
4
l/P harness, behind steering column support .............. 183
54
183
55
l/P harness, LH side under l/P ........................................ 167
4
l/P harness, above ra d io .................................................... 179
41
4
l/P harness, above fuse b lo c k .......................................... 185
60
l/P harness, above glove b o x ........................................... 185
60
l/P harness, beneath l / P .................................................... 187
67
67
67
l/P harness, behind l/P cluster ........................................ 187
67
188
69
l/P harness, behind l/P cluster ........................................ 187
67
188
69
Rear lamps extension harness, at rear crossmember . 170
16
16
Rear lamps extension harness, at rear crossmember . 1 6 8
8
170
16
82
LH side rail at rear crossmember (Suburban) .............. 191
192
83
LH side rail at rear crossmember (Fleetside)................ 192
84
82
192
83
84
82
192
83
84
LH side rail at rear crossmember ................................... 191
82
192
83
84
8
l/P harness behind LH kick panel ................................... 188
69
l/P harness behind LH kick p a n e l................................... 188
69
l/P harness behind LH kick p a n e l................................... 188
69
Auxiliary fuel tank harness, at crossm em ber................ 176
34
Auxiliary fuel tank harness, at crossmember ................. 176
34
Auxiliary fuel tank harness, at crossm em ber................. 177
35
Auxiliary fuel tank harness, at crossm em ber................. 177
35
Rear of vehicle at top LH s id e .......................................... 190
77
Rear of vehicle at top LH s id e .......................................... 190
77
COMPONENT LOCATION
Page - Figure
8
S 4 0 2 .................................................. . . LH rear lamp harness, above rear crossmember . . . . . 168
168
9
8
S 4 0 3 .................................................. . . RH rear lamp harness, below RH rear lam ps......... . . . 168
168
9
9
S404 ................................................. . . Rear lamp harness, near center of vehicle ............ . . . 168
8
S405 ................................................. . . RH rear lamp harness, below RH rear lam ps......... . . . 168
8
S406 .................................................. . . LH rear lamp harness, above rear crossmember . . . . . 168
9
S 4 1 0 ................................................. . . Rear lamp harness, toward LH side of vehicle . . . . . . . 168
80
S 4 1 1 ................................................. . . Rear center of vehicle behind bumper ................... . . . 191
S 4 1 2 .................................................. . . Rear dome lamp harness, behind LH B-pillar,
59
above LH rear door .................................................... . . . 185
51
S 4 1 3 ................................................. . . Rear dome lamp harness, above LH rear door . . . . . . 182
72
S908 ................................................. . . RH side of tailgate (Utility) ........................................ . . . 189
73
S908 ................................................. . . LH side of tailgate (Suburban) ................................. . . . 189
73
S909 ................................................. . . LH center of tailgate (Suburban)............................... . . . 189
72
S909 ................................................. . . Center of tailgate (Utility) .......................................... . . . 189
SECTION B
P MODEL
(COMMERCIAL)
SECTION B - P-MODEL
B-1
BULKHEAD
CONNECTOR
(SEE PAGES 4, 5)
BATTERY JUNCTION
BLOCK
(SEE PAGES 4,5)
STEERING
COLUMN
SWITCHES
(SEE PAGES, 32, 34)
DRL
RELAY
(SEE PAGE 28)
FUEL TANK
SENDER
(SEE PAGE 54)
BATTERY
(SEE PAGES 4,5)
REAR
LAMPS
HARNESS
(SEE PAGE 76)
FUEL PUMP
RELAY
(SEE PAGE 48)
REAR
BODY
CONNECTOR
(SEE PAGE 54)
8-2
PHANTOM VIEW
ESC
MODULE
(SEE PAGE 42)
SYMPTOMS INDEX
SYMPTOM
PAGE
BRAKE WARNING SYSTEM

Brake indicator remains on with ignition switch in RUN and park brake o f f ............................................. B-73
Alarm will not s o u n d ........................................................................................................................................... B-73
Alarm will not shut o f f ................................................................................................................. ....................... B-73
DIESEL ENGINE FUEL CONTROLS
Fuel heater does not o p e ra te ........................................................................................................................... B-62
Water in fuel indicator lights with no water in fuel ........................................................................................B-62
Water in fuel indicator does not light briefly with ignition switch turned to RUN ....................................B-62
Fuel gage indicates full or beyond at all tim e s ...............................................................................................B-66
Fuel gage indicates empty when there is fuel in the ta n k ............................................................................ B-66
Fuel gage is inaccurate ...................................................................... ......................................................... B-66
Temperature indicator stays on at all times with ignition switch in RUN .................................................. B-66
Temperature gage indicates cold all the time ...............................................................................................B-67
Temperature gage is in a cc u ra te ...................................................................................................................... B-67
Temperature gage indicates hot with engine coolant below operating temperature and ignition
switch in R U N ..................................................................................................................................................B-67
Oil pressure gage is not a ccu ra te .................................................................................................................... B-67
Oil pressure gage indicates high pressure at all tim e s .................................................................................B-67
Oil pressure gage indicates low pressure when oil pressure is g o o d .......................................................B-67
Low coolant indicator does not light with coolant level low (diesel o n ly ) ..................................................B-67
Low coolant indicator is lit when coolant level is g o o d .................................................................................B-68
REAR EXTERIOR LAMPS

None of the rear lamps operate .................................................................................................................. b -75
Backup lamps do not operate...................................................................................................................... b -75
START AND CHARGE
Starter solenoid clicks, engine does not crank or cranks slowly.............................................................. b -39
Engine does not crank and starter solenoid does not click .................................................................... b -39
Battery is undercharged or overcharged.................................................................................................... b -39
TURN LAMPS
Turn signals do not o p e ra te ........................................................................................................................ b -33
Turn signals do not operate on one side.................................................................................................... b -33
Turn signal lamps flash rapidly.................................................................................................................... b -33
WIPER/WASHER
Wipers do not operate in any mode ........................................................................................................... b -37
Wipers do not operate in HI ........................................................................................................................ b -37
Wipers do not operate in L O ........................................................................................................................ b -37
Washer motor does not operate................................................................................................................. b -37
Washer motor does not shut o f f ................................................................................................................. b -37
GLOW PLUGS
Wait indicator does not flash or flashes for the incorrect amount of time when engine is
below operating tem perature........................................................................................................................ B-59
HEADLAMPS
Headlamps do not illuminate high or low beams - both sides .................................................................. B-22
Low beam lamp(s) do not operate ..................................................................................................................B-22
High beam lamp(s) do not o p e ra te ..................................................................................................................B-22
HEADLAMPS (WITH DRL)
Headlamps do not illuminate high or low beams - both sides .................................................................. B-25
Low beam lamp(s) do not operate ..................................................................................................................B-25
High beam lamp(s) do not o p e ra te ..................................................................................................................B-26
Canadian daytime running lamps do not operate ....................................................................................... B-26
HORNS
Hom(s) will not operate ....................................................................................................................................B-35
Horn sounds continuously without depressing horn switch ....................................................................... B-35
PARK, MARKER AND HAZARD LAMPS
Park lamps do not o p e ra te ............................................................................................................................... B-30
Hazard warning lamps do not operate .......................................................................................................... B-30
Side marker lamp(s) do not o p e ra te ............................................................................................................... B-30
Rear marker lamp(s) do not o p e ra te ............................................................................................................... B-30
SYMPTOM INDEX
B-3
RPOCODES
. ._ _ _ _ _ _ 2-32.0 BLK _ _ _ _ _ _ _- .
B3D - SCHOOL BUS EQUIPMENT
CLUTCH
START
SWITCH
. .- - - - - 6-3,0 PPL _ _ _ _II
. ._ _ 5-3,OYEL _ _ _. _
,11______ 1-19.0 BLK _ _ _ _
'r.-~:
2_
BATTERY
8917053
1000001
BODY BUILDER
100 AMP JUNCTION
BLOCK (B3D ONLy)
~ ~
0
S207
C298
1201966
51
-----.
ai ~
II:
C299
6294641
_ _ _ _ 4-5,0 BRN _
_1 ____________
300-5,00RN
HEADLAMP
SWITCH
J
K
150-+--_
PANEL DIMMER
SWITCH
\o:...J
ira:
STARTER
MOTOR
00
~;g
if
III
II:
12020030
-.S205
_ _ __
S198.
C209
12020029
_
BREAKER
25AMP
.;;
Cl00
'"
12020184
. .- - - - - 1 _ 2 - 5 , O R E D _ _ _ _ _ _
S208
(SEE PAGE 70)
:5III
0
oj
ENGINE
~
3
4O-t---
~8A~
[g~ m [BJ
POWER DISTRIBUTION
GASOLINE ENGINES WIMAN TRANS
IGN
,
~
=
Cl00
12020183
HTR PWR
IGNITION COIL
(SEE PAGE 42)
QRA~ ~
TAIL LPS
INJ
HTR
ACC-RADIO
S~
ECM-CRNK
AUX
WIPER
if
III
~~OO~
HTR
25 AMP
LIGHT
SWITCH
~~
ALT
CRNK
TQ5J
Qsp~
INSTR-LPS
5AMP
51
II:
"1
ECM-BAT
10 AMP
10AMP
ACC-RADIO
TAIL LPS
20 AMP
-;rir-..!~~~h::~~
STOP-HAl
15AMP
ns:l~DD~
o
SHEET
METAL
GROUND
G110
IQQS
HEAO
-- -II:
~DD~qwp
~M
'PARK
--~"'r-I
m:l@@omoo
ACC
OFF
---.
--~I_:r
~
ENGINE
GROUND
G111
Sl11
(SEE PAGE 46)
--
6-3,0 PPL _ _ _
_2-5,ORED_
I/PCLUSTER
(SEE PAGE 70)
_3-5,OPNK_
S197
@~
2-5,0 RED _ _ _ _ _ __
. . . . " . . . . " ...."
m:l m:l @ ill~ m [BJ 0
Cl0B
12045896
II
:5III
...J
l..
l..
GENERATOR
-'o:H;::"EA"Orl--t-- 10
'9-1,OBRN
- - - - - <Xl - - - - - - " " ' "
(FUSIBLE LINK)
---r-'e--- 158
DOME
CIRCUIT
300-5,0 ORN _ _ _,
II:
_ _ _ _ _ 2-1,ORST _ _ _ _S199
_ __
START
RUN
OFF
LOCK
ACC
44
. .-
B-4
2-13.0 RED
(B3D)
'z
0
IGNITION
SWITCH
_ _ _ _ 2-5,0 RED _ _ _ _- .
INJ
FRONT
10AMP
FUSE BLOCK
12089776
CRNK
10 AMP
15AMP
RPOCODES
.~
_ _ _ _. . . 2-32.0 BLK _ _ _ _ _ _ _ _
IGNITION SWITCH
"'lIlIIII____ 1-19.0 BLK _ _ _ _
-r3
+
BATTERY
2-13.0 RED
(B3D)
'f1!
0
10 0 0 0 0 1
"_.~
C298
1201966
111
START
RUN
OFF
LOCK
ACC
__ I
BODY BUILDER
100 AMP JUNCTION
BLOCK (B3D ONLy)
33
C299
6294641
44
_ _ _ _ _ _ 6-3.0PPL _ _ _ _ _ _
3-S.0 PNK
..._ _ _ _ _ 4-S.0 BRN_
300-S.0 ORN
__ . -:1-----------1
fil5
::J
~~
qffi
PANEL DIMMER
SWITCH
a:z
0
MO
;;;~
"'::>
NI:!:-
STARTER
MOTOR
S198.
Sl92
l~~
d!
Il?;::)M
N ~,Q1
co
~
Cl00
12020184
_2-S.0RED
S199
2-1.0 RST
(FUSIBLE LINK)
'"
oj
-b
S197
Slll
._
(SEEP~~
C106
12045896
c;j
_ _ _
HEAD
.9-1.0BRN
.---------
~8A~ ~ m~ OJ
3-S.0 PNK _ _ _ __
2-S.0 RED - - - - .
'PARK
----
lID lID ~ ill ~ OJ
HTR
2SAMP
GAUGES
20 AMP
HORN/DM
lSAMP
lID 0
[ffi
a:
IGN HTR PWR
GAUGES
a:
0
'"
~OOOODD
ECM-BAT
10 AMP
PWR
TAIL LPS
20 AMP
OOOODOc=J
HORN/OM INSTR-LPS
TAIL LPS
,
~
if
a
~,a
-- -ENGINE
GROUND
G111
TRANS
ECM-BAT
HTR
ACC-RADIO
OO~OOOO
co
SHEET
METAL
GROUND
G110
IGNITION COIL
(SEE PAGE 42)
Cl00
12020183
ACC
if
10
OFF
300-S.0 ORN _ _ _
IID!ID~OOJOO
... _
40-+-......- .
S206
I/PCLUSTER
(SEE PAGE 70)
D;;:
~
a
C209
12020029
ENGINE
-~7i1
AI 39-.8 PNKlBLK
(SEE PAGE 70)
..J
Q.
Q.
'-,PARK
I
_2-S.0 RED _ _ _ _ _ __
S208
:s
'"a
1tIl: ._S2.1~.~.~ .7_~
~~:i
",0
156
DOME
CIRCUIT
BREAKER
25AMP
w 0w
a: a:
q
150-~-_
qUiD
GENERATOR
HEADLAMP
SWITCH
12"
INJ
15AMP
nstl~ODOO
S~ ECM-CRNK AUX
WIPER
00 00
~ Qspg
ALT
CRNK
FRONT
12089776
CRNK
10AMP
POWER DISTRIBUTION
GASOLINE ENGINE W/AUTO TRANS
B-5
RPOCODES
_ _ _ _ _ _ 6-3.0 P P l - - - - - - - - - - e ,A
B
5-3.0 YEl _ _ _ _ _ _ _ _ _ _
._ S6
___
CLUTCH
START
SWITCH
IGNITION SWITCH
C219
8911921
LH
BATTERY
RH
BATTERY
a:
8917053
10 0 0 0 01
o
ai
_L
0
C298
1201986
1-32.0 BlK (B3D ONLy)
C299
6294641
3-5.0 PNK
STARTER
MOTOR
~
7'
II~-" 'iC5~
~
q
I-Z
~
(f) ~
:J
M
Q;!
N~
\!:-
S195
C191
~........:;:-;:;,
2-1.0RST_
(FUSIBLE LINK)
2-13.0 RED_._ _
(~
S197
~2-1.0RS~._2-3.0RED'
(FUSIBLE LINK)
GLOW PLUG
CONTROLLER
'"
,~"
a:
&
CD
CD
q a
01
cw'""
M , . , eN",,", - - '"
(SEE PAGE 70)
(SEE PAGE 70)
::""._~ _~2 :2 ~t. ~ .,~-it!~m~t3jfilT-;~'=:'-,
ENGIN-l-=
GROUND
RH
0
-,-
SHEET
METAL
CYLINDER GROUND
HEAD G113
G110
DIESEL ENGINE WIMAN TRANS
7-1
AI
U!J ~ III ~ ITl lHl 0

L
ACC
DmDD
IGN HTR PWR
DO 00 0 0
00 O~
L.r-.J
o
M
TRANS
ECM-BAT
'
H"" ____
00
OHTRO
A~O
AUX
STOP-HAZ ECM-CRNK
~
t?
11~
a:
co
ECM-BAT
10AMP
HORN/DM
15AMP
[jUG
~~~~
lID lID !Al III ~ ill [ill 0
IIDIID@
,
'PARK
_--"'!oiH-,
LIGHT
SWITCH
HORN/OM
~ INSTR-LPS
t;-;;-fl
300-5.0 ORN _ _ __
4O-1---~
HEAD
ATir
-- -
GENERATOR
10
OfF
.--------.;.
12015982
POWER DISTRIBUTION
-.S205
HEAD
Cl00
12020184
2-5.0 RED _ _ _ _ _ _ __
a
ffi ffi I HI
---- ------~
:
12020030
~ 0 c::::::;, 0
~--------""
ENGINE
GROUND
LH
CYLINDER
HEAD
G113
CIRCUIT
BREAKER
25 A ....
156
150-.----
PANEL DIMMER
SWITCH
S192
@@"'
B-6
_ _ _ _ _ 4-5.0 BRN _
-1-----1
-- ..
--
(B3D)
~~ (FUSIBLE LINK)
'
300-5.00RN
"_~ t0~2-1.0RST_
I
II
START
RUN
OFF
LOCK
44
~t!~~------6-3.0 PPl _ _ _ _ _ _. . .
BATTERY
JUNCTION
BLOCK
BODY BUilDER
100 AMP JUNCTION
BLOCK (B3D ONLy)
. ._ _ 1-50.0 BlK _ _ _ _ __
~':
f.~t
2-13.0 RED
(B3DONly)
~~
ALT
ACC-RADIO
10AMP
~
WIPER
CRNK
T~ QS/P~
ECM-CRNK
10AMP
fRONT
FUEL SHUT
OFF VALVE
(SEE PAGE 63)
FUSE BLOCK
12089776
CRNK
10AMP
TURN-B/U
15AMP
20 AMP
RPO CODES
IGNITION SWITCH
3
LH
BATIERY
1000 0 01
BODY BUILDER
100 AMP JUNCTION
BLOCK (B3D ONLy)
. ._ _ 1-S0.0 BLK _ _ _ _ __
1-32.0 BLK (B3D)
fj~~~
_____ 6-3.0 PPL _ _ _ _ _ _. . .
START
RUN
OFF
LOCK
ACC
44
..._ _ _ _ _ 4-5.0 BRN _
300-S.0 ORN
S196
1....,~_It:I=tttL ".-YI-+---i
PANEL DIMMER
SWITCH
a:
.,;
N -.
"J '-0'-o:=="..-'~
----- ~ ------"'"
tJ
C100
12020184
co
-'
"q
"-
@cr:
0:
"-0
_,'
-~
3-3.0PNK. ;;; -
C128
'"
u;>"
~
..~~
q a
C\I
~ ~
_I_.!-_.
1201S982
ENGINE
GROUND
LH
CYLINDER
HEAD
G113
~~ ~
l ..
@
~ ~
I/P CLUSTER
S206
(SEE PAGE 70)
AT@
-,
~o
3-S.0 PNK
2-S.0 RED
~ [g~CD
[IDlID~D[i]DD
=
~---------------------'
sa
----.
--.~
"o
oj
SHJET
METAL
CYLINDER GROUND
HEAD G113
G110
Z
~
a:
0
0
HORN/OM
lSAMP
TRANS
ECM-BAT
HTR
ACC-RADIO
AUX
WIPER
INJ
STOP-HAZ ECM-CRNK
c?
ALT
Sl13
c=J
TAIL LPS
20 AMP
00D800~
~~DDOO
o 00 [}?f]
TAIL LPS
INSTR-LPS
SAMP
--- i - .............
-------J
..
HTR PWR
[jUG
HORN/OM INSTR-LPS
--~t--I-,
LIGHT
SWITCH
~DDOODD
~ 00
O
O
-1 O_ -:::=-
IGN
HTR
2SAMP
__
lID lID ~ m~ CD [BJ 0

ACC
[BJ 0
RH
S299
_ _ __
44-1.0DKGRN _ _
-- .
.9-1.0BRN
-------
________
CIRCUIT
BREAKER
25 AMP
-....
~~g~%~
I~
..
.--11- - Cl07
12045896
...
C209
12020029
300-S.0 ORN _
-2-S.0RED-------7i-
39-.8 PNK/BLK
S208
(SEE PAGE 70)
s~~~~~~30
DOME
tD
"?
.......-+--il-- 156
150-~-_
A
~1
S192
HEADLAMP
SWITCH
-- --11-----------1
-- ..
GENERATOR
C299
6294641
3-S.0 PNK
STARTER
MOTOR
!I~:
0
o
C298
1201966
BATTERY
JUNCTION
BLOCK
89170S3
ai
;Jj'~.
cr:
o
RH
BATIERY
(B3D')
ow
2-13.0RED~
lSAMP
CRNK
T~ Qs/pQ
FRONT
3-3.0PNK _ _ _ _. . .~
FUEL SHUT
OFF VALVE
(SEE PAGE 63)
FUSE BLOCK
12089776
GAUGES
20 AMP
TURN-B/U
15 AMP
POWER DISTRIBUTION
DIESEL ENGINE W/AUTO TRANS
B-7
RPOCOoES
2-13.0REo~
(B30)
II:
_
_ _ _ _ _ _ _ _ _ _ 6-3.0PPl _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
8917053
LH
BATTERY
RH
BATTERY
100 0001
GT104
+
ow
MTI - AUTO TRANS, Ho, 4-SPO., WITH OVERDRIVE

MT8 - MAN TRAN8, 5-SPO., WITH OVERDRIVE
BODY BUILDER
100 AMP
JUNCTION
BLOCK
. ._ _ _ _ _ 3-3.0 PNK _ _ _ _ _. .
...J
Cl00
12020164
lIP
-------BGl
. .- - - - - - 1-50.0 BlK
1-32.0 BlK (B30)
BATTERY
JUNCTION
BLOCK
STARTER
MOTOR
It--~I-{r
---.
---- ---.
o I ~=--+-i'-;
~
I- ~
(J)
-'
\
~2-1.0RST-.-2-3.0RED~
(FUSIBLE LINK)
S 197
ffi
CO?
(jj
i~
I
oW
II:
<Xi
I'"
GLOW PLUG
CONTROLLER
8195
--
-'
B-8
POWER DISTRIBUTION
DIESEL ENGINE (DRIVEAWAY)
~ ~ isE~l~:~~~O)
11
--
._1 _____
IGN
20~AMP
~ __ J
CD '"
~ CD~
~
-. -
ENGINE
GROUND
RH
CYLINDER
HEAD
G112
3-3.0 PNK
Ii3
.,
FUSE
HOLDER
C'l
12010105
'a..z"'
'za.."'
CD
0
. ._ _ _ _
SHEET
METAL
GROUND
G110
3-3.0 PNK _ _ _ _ _
.~
..,<',i
FUEL SHUT
OFF VALVE
(SEE PAGE 63)
FUSE BLOCK
FRONT
INJECTION
ECM
7.5 AMP
10 AMP 20 AMP
0
W
II:
a..
Cl00
12020183
-1l-fi:==*~i!!:!!="11
A
/~~ ~,
ENGINE
GROUND
LH CYLINDER
HEAD
G113
S113
o!!!.
n.
-.J
--
CD
a;
... -
'"'
'""'II
--.1.._..........
[]'[)
CD
eD
8205
---
-'
Cl07
12045696
29
v
S208
... - -
GENERATOR
15
If 14
, - - - - 2-3.0 RED - - - - - - - - - - - - - - - - - -
l
M
. ._ _ _ 3-3.0 PNK _ _ __
~-~I
11
12
. . - . - 39-.8 PNK/BLK . . . . . . ,
S208
(SEE PAGE 70)
r~
-'
a..
a..
r-
II: W
S192
B I ......L-+-..-+-T..LI
C
12052472
(MT1)
RPO CODES
BSD - SCHOOL BUS EQUIPMENT
TEMPORARY RUN
IGNITION SWITCH
FRONT
ENGINE
GROUND
G111
SHEET
METAL
GROUND
G110
FUSE BLOCK
12052472
POWER DISTRIBUTION
GASOLINE ENGINE (DRIVEAWAY)
B-9
8-1.0 GRA-
240-1.0 ORN - HORN RLY - DOME LAMP

SHUNT 12041235
8-.8 GRA - INSTRUMENT LAMPS
8-1.0 GRA---------------------------------------------
44-1.0 DK GRN - LT SW RHEOSTAT

40-1.0 ORN - TAIL LAMPS
481-1.0 RED - INJECTORS
140-1.0 ORN - STOP LAMP SW - HAZ FLSHR
439-1.0 PNK/BLK - ECM (FUSED)
16-.8 PPL - TURN SIGNAL SW
75-.8 DK BLU - BACK-UP LAMP SW
3-5.0 PNK IGN SW - ENG IGN

39-.8 PNK/BLK - INSTRUMENT CLUSTER
39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID
6-5.0 PPL - CLUTCH START SWITCH
6-5.0 PPL - STARTER SOLENOID FEED
908-.8 PPL - CRANK DISCONNECT (FUSED)
38-.8 DK BLU - TURN SIGNAL -
COLOR
MALE CONN
BRN
12004887
BLK
12004886
GRN
12004885
NAT
12004888
BLU
12004884
B-10
FUSE BLOCK
GASOLINE ENGINE W/MAN TRANS
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
CONDITION
ACC-RADIO
12004007
RED
10 AMP
HOT IN ACC
OR RUN
ALT
12004009
YELLOW
20 AMP
HOT IN RUN
OR START
CRNK
12004007
RED
10 AMP
HOT IN
START
ECM-BAT
12004007
RED
10 AMP
HOT AT
ALL TIMES
ECM-CRNK
12004007
RED
10 AMP
HOT IN RUN
OR START
GAUGES
12004009
YELLOW
20 AMP
HORN-DM
12004008
LT BLUE
15 AMP
DESCRIPTION
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
RADIO ACCESSORIES
HTR
12004010
WHITE
25 AMP
HOT IN
RUN
ALTERNATOR
INJ
12004006
BRN
7.5 AMP
HOT IN RUN
OR START
ELECTRONIC CONTROL MODULE

CRANK CIRCUIT
INSTR-LPS
12004005
TAN
5 AMP
HOT W/ HEADLAMP IN
PARK OR HEAD
STOP-HAZ
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
STOP LAMPS
HAZARD FLASHER
ELECTRONIC CONTROL
MODULE IGNITION 1
TAIL LPS
12004009
YELLOW
20 AMP
HOT AT
ALL TIMES
TAIL LAMPS
HOT IN
RUN
PROVISIONS FOR GAGES
TURN-B/U
12004008
LT BLUE
15 AMP
HOT IN RUN
OR START
TURN SIGNALS
BACK-UP LAMPS
HOT AT
ALL TIMES
PROVISIONS FOR
HORN AND DOME LAMPS
WIPER
12004010
WHITE
25 AMP
HOT IN
ACC OR RUN
HOT
DESCRIPTION
HEATER
INJECTORS
WINDSHIELD WIPERS
8-1.0 G R A 1
xc>
BAT
mi>
L
(U S I
0S
(El
[3
ACC
gcg
[M] 0
K l
PWR
[X ] K ] D
_3_
K l [Jt] D3
Dd D D]
EG 0 D
IM1P o
HORN/DM INSTR-LPS
TAIL LPS
350-.8 PNK/WHT - FUEL CYC MDL

250-1.0 BRN - TRANSMISSION
440-1.0 ORN - ECM
2-5.0 RED - BATTERY
50-3.0 BRN
300-5.0 ORN - IGNITION
m
IGN HTR PWR
GAUGES
_15A^_
090
B] \B
INJ
STOP-HA : ECM-CRNK
TRANS
ECM-BAT
HTR
ACC-RADIO
AUX
WIPER
ALT
CRNK
t Or n -b Tu
fus / p lr

SHUNT 12041235
8-1.0 GRA ---------------------------------------------

40-1.0 ORN TAIL LAMPS
-141-1.0 BRN/WHT
4-5.0 BRN - IGN SW
93-3.0 WHT - WINDSHIELD WIPER


3-5.0 PNK - IGNITION
3-5.0 PNK - IGN SW - ENG IGN

FRONT
12034359 - BLOCK MOLD
12089776 - PRINTED BLOCK
38-.8 DK BLU - TURN SIGNAL
COLOR
MALE CONN
BRN
12004887
BLK
12004886
GRN
12004885
NAT
12004888
BLU
12004884
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
INJ
12004006
BRN
7.5 AMP
HOT IN RUN
OR START
ALTERNATOR
INSTR-LPS
12004005
TAN
5 AMP
HOT W/ HEADLAMP IN
PARK OR HEAD
STOP-HAZ
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
STOP LAMPS
HAZARD FLASHER
TAIL LPS
12004009
YELLOW
20 AMP
HOT AT
ALL TIMES
TAIL LAMPS
TRANS
12004007
RED
10 AMP
HOT IN RUN
OR START
TRANSMISSION
PROVISIONS FOR
HORN AND DOME LAMPS
TURN-B/U
12004008
LT BLUE
15 AMP
HOT IN RUN
OR START
TURN SIGNALS
BACK-UP LAMPS
WIPER
12004010
WHITE
25 AMP
HOT IN
ACC OR RUN
DESCRIPTION
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
ACC-RADIO
12004007
RED
10 AMP
HOT IN ACC
OR RUN
RADIO ACCESSORIES
ALT
12004009
YELLOW
20 AMP
HOT IN RUN
OR START
ECM-BAT
12004007
RED
10 AMP
HOT AT
ALL TIMES
ECM-CRNK
12004007
RED
10 AMP
HOT IN RUN
OR START
GAUGES
12004009
YELLOW
20 AMP
HOT IN
RUN
HORN-DM
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
HTR
12004010
WHITE
25 AMP
HOT IN
RUN
ELECTRONIC CONTROL
MODULE IGNITION 1
HEATER
DESCRIPTION
INJECTORS
WINDSHIELD WIPERS
FUSE BLOCK
B-11
-8-1.0 GRAA
ATA
a i a 0; m
GU 1)
a
ACC
a-B
m a n
a n
l\
&
350-.8 PNK/WHT - FUEL CYC MDL-
IGN HTR PWR
0 nr
ii
0 in
F I i n i
240-1.0 ORN - HORN RLY DOME LAMP
SHUNT 12041235
8-1.0 GRA --------------------------------------------
q ' t ! tfe A i
Okfl m
IB w
I
DPWRJP
50-3.0 BRN
[ID
0
-141-1.0 BRN/WHT
4-5.0 BRN - IGN SW

Pel

.40-1.0 ORN - TAIL LAMPS
[ I/
i ski 1 I k s
-140-1.0 ORN - STOP LAMP SW - HAZ FLSHR
-3-5.0 PNK - IGN SW - ENG IGN

-39-.8 PNK/BLK - INSTRUMENT CLUSTER
B<1
-39-1.0 PNK/BLK - ALTERNATOR - EGR SOLENOID
REAR
FRONT
38-.8 DK BLU - TURN SIGNAL-
COLOR
MALE CONN
BRN
12004887
BLK
12004886
GRN
12004885
NAT
12004888
BLU
12004884
B-12
FUSE BLOCK
DIESEL ENGINE W/MAN TRANS
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
ACC-RADIO
12004007
RED
10 AMP
HOT IN ACC
OR RUN
ALT
12004009
YELLOW
20 AMP
HOT IN RUN
OR START
GAUGES
12004009
YELLOW
20 AMP
HOT IN
RUN
HORN-DM
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
HTR
12004010
WHITE
25 AMP
HOT IN
RUN
DESCRIPTION
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
RADIO ACCESSORIES
INSTR-LPS
12004005
TAN
5 AMP
HOT W/ HEADLAMP IN
PARK OR HEAD
ALTERNATOR
STOP-HAZ
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
STOP LAMPS
HAZARD FLASHER
PROVISIONS FOR QAQES
TAIL LPS
12004009
YELLOW
20 AMP
HOT AT
ALL TIMES
TAIL LAMPS
PROVISIONS FOR
HORN AND DOME LAMPS
TURN-B/U
12004008
LT BLUE
15 AMP
HOT IN RUN
OR START
WIPER
12004010
WHITE
25 AMP
HOT IN
ACC OR RUN
HEATER
DESCRIPTION
TURN SIGNALS
BACK-UP LAMPS
WINDSHIELD WIPERS
8-1.0 GRA

SHUNT 12041235
8-1.0 GRA----------------------------------------------



COLOR
MALE CONN
BRN
12004887
BLK
12004886
GRN
12004885
NAT
12004888
BLU
12004884
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
ACC-RADIO
12004007
RED
10 AMP
HOT IN ACC
OR RUN
RADIO ACCESSORIES
ALT
12004009
YELLOW
20 AMP
HOT IN RUN
OR START
ECM-BAT
12004007
RED
10 AMP
HOT AT
ALL TIMES
ECM-CRNK
12004007
RED
10 AMP
HOT IN RUN
OR START
GAUGES
12004009
YELLOW
20 AMP
HOT IN
RUN
HORN-DM
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
DESCRIPTION
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
HTR
12004010
WHITE
25 AMP
HOT IN
RUN
ALTERNATOR
INSTR-LPS
12004005
TAN
5 AMP
HOT W/ HEADLAMP IN
PARK OR HEAD
STOP-HAZ
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
TRANS
142004007
RED
10 AMP
HOT IN
RUN OR START
TAIL LPS
12004009
YELLOW
20 AMP
HOT AT
ALL TIMES
PROVISIONS FOR
HORN AND DOME LAMPS
TURN-B/U
12004008
LT BLUE
15 AMP
HOT IN RUN
OR START
TURN SIGNALS
BACK-UP LAMPS
WIPER
12004010
WHITE
25 AMP
HOT IN
ACC OR RUN
WINDSHIELD WIPERS
ELECTRONIC CONTROL
MODULE IGNITION 1
DESCRIPTION
HEATER
STOP LAMPS
HAZARD FLASHER
TRANSMISSION
TAIL LAMPS
FUSE BLOCK
B-13
LAMP BULB DATA

Lamp Usage
Headlamp1
Quantity
2
Trade
No.
Power Rating
at 12V, Watts
6014
50/60 W
Candle Power
Park and Signal Lamp2
2057
32-2
Tail and Stoplamp3 (Union City Body Co.)
1157
32-3
Tail and Stoplamp2 (Except Union City Body Co.)
2057
32-2
Front Side Marker Lamp
194
Rear Side Marker Lamp
194
License Lamp
67
Backup Lamp4
Instrument Cluster Illumination Lamp
PC194
PC194
Headlamp High Beam Indicator Lamp
PC74
.7
Service Brake Warning Indicator Lamp
PC74
.7
Park Brake Warning Indicator Lamp
PC74
.7
Transmission Control Illumination Lamp
73
.3
Low Coolant Indicator Lamp5
PC74
.7
Glow Plug Indicator Lamp5
PC74
.7
Water in Fuel Indicator Lamp5
PC74
.7
Service Engine Soon Indicator Lamp
PC74
.7
Trans Indicator Lamp5
PC74
.7
Fasten Safety Belts Indicator Lamp6
PC74
.7
Door Ajar Indicator Lamp
PC74
.7
Daytime Running Lights Indicator Lamp7
PC118
.7
1.
2.
3.
4.
5.
6.
7.
B-14
BULB DATA
Double filament sealed beam: 50W low beam, 60W high beam.
Double filament lamp: 32 CP high, 2 CP low.
Refer to body manufacturers specifications.
Diesel only.
When used by body manufacturer.
Canada only.
& < z
RH HIGH-LOW
HEADLAMP
(SEE PAGE 23)
LH HIGH-LOW
HEADLAMP
(SEE PAGE 23)
[ 150-.8 BLK
(DRIVEAWAY ONLY)
150-.8 BLK |
(DRIVEAWAY ONLY)
>
d
!
tr
o
COPPER BRAID i
&
ENGINE
GROUND
G110
SHEET
METAL
GROUND
G111
FRAME
GROUND
G106
SHEET
METAL
GROUND
G107
SHEET
METAL
GROUND
G105
FRAME
GROUND
G104
SHEET
METAL
GROUND
G106
SHEET
METAL
GROUND
G105
FRAME
GROUND
G104
ENGINE
GROUND
G120
DASH
PANEL
GROUND
G121
GROUND DISTRIBUTION
FORWARD LAMPS
B-15
. ._ _ _ _ _ _ _ _ _ _ _ 486-.8 BRN
rI
II r"
-----CC
450-.8 BLKlWHT -
-~
450-.8 BLKlWHT - . . -
ESC HYBRID
FUNCTION
(SEE PAGE 44)
EVRV (L05 ONLy)

(SEE PAGE 46)
FUEL PUMP RELAY

(SEE PAGE 54)
II
II
r
I ".-_.'mKIW""_ - - - - - '"'' ~ ....... """""'-
"-450-.8BLKlWHT _ _ - - - - - -
-_
,\''t '~_450-.8BLKlWHT_
\
\...
,,
~
-.r - - -
"""""'
-GROUND DISTRIBUTION
GASOLINE ENGINE WIMAN TRANS
ECM
(SEE PAGE 45)
....
DRAC
(SEE PAGE 64)
... 450-.8 BLKlWHT _
....
ECM
(SEE PAGE 45)
. - 450-.8 BLKlWHT _
...
ALDL
(SEE PAGE 45)
450-.8 BLKlWHT -
..-450-.8 BLKlWHT ___
GT100
12020107 (UPPER)
12020708 (LOWER)
~_ _ 413-.8 TAN
,,t
,,
,,
,
\
ALTERNATOR
BRACKET
GROUND
G101
B-16
--, - - ....,
m
C!
...-.c
-.r - - - - - -
-=-
ENGINE
GROUND
G100
----lICe
ECM
(SEE PAGE 45)
"..., ...., -
-,
r
,
,
450-.8 BLK/WHT
450-.8 BLK/WHT
FUEL PUMP RELAY

-
....,
......
I(SEE PAGE 54)
--c
EIIRV (L05, L19)

(SEE PAGE 46)
I
I
,I
,I ,. , -
... 450-.8 BLK/WHT..........
450-.8 BLK/WHT - - -
"..., -
"..., -
"..., -
VI:~-~"~~-
S102
"..., ... 450-.8 BLK/WHT ~
If _
t,
, ,
~_ -
, ,
DRAC
(SEE PAGE 64)
"..., -
....,
.,
,
, I
~-
ALTERNATOR
BRACKET
GROUND
G101
... 450-.8 BLK/WHT....

-
.......
--
551-.8 TAN/WHT " . . . , .....
PCM
(SEE PAGE 51)
;~~ PAGE 51)
GT100
, \.. ,- -.,.,""""'- -1
"
"
i
',
*
~
,...., -
~"'-"''''_'''O"'~-.- -
,~ ,
"
ALDL
(SEE PAGES 45, 47)
120201071UPPER)
120201081LOWERI
. ._ _ 413-.8 TAN - - - -. . .
PCM
(SEE PAGE 51)
'
''
'
,,
,~ '.
, i
, ~
'"'
ENGINE
GROUND
G100
GROUND DISTRIBUTION
B- 17
RPO CODES
T61 CANADIAN DAYTIME RUNNING LAMPS
l/P CLUSTER
CONNECTOR
(SEE PAGE 70)
l/P
GROUND
G200
B-18
GROUND DISTRIBUTION
GASOLINE ENGINE
RPOCODES
. .-
_ _ _ _ _ _ 150-3.0 BLK _
PANEL DIMMER SWITCH

(SEE PAGE 72)
....I
~
0
()
150-.8 BlK
150-.8 BlK
--C
150-.8 BlK
--II
DRAC
(SEE PAGE 65)
150-.8 BlK
--C
lOW COOLANT MODULE

(SEE PAGE 70)
150-.8 BlK
--C
liP
. ._ _ _ _ 150-.8 BLK - - - -. . .
~_ _ _ _
150-.8 BlK
-----CC
FUEL HEATER
(SEE PAGE 63)

(SEE PAGE 63)
Cl
150
39
419
31
439
35
F
G
2
440
K
L
M
N
~1
PARK BRAKE SWITCH

(SEE PAGE 70)
Cl
~_ _
WIPER SWITCH
(SEE PAGE 38)
Cl00
12020184
" '_ _ _ _ 150-.8 BlK - - - -. . GLOW PLUG CONTROllER

(SEE PAGE 61)
ENGINE
DRl RELAY (T61)

(SEE PAGE 27)
'-_
' -_ _ _ _ 150-1.0 BlK
[,
I 6 1250148111 H
I 440 1470 1 824 \I G
I 2 I 1ltD "" ~ F
E
439
35
1
I
I
I 311 ~@
1m -.:
\ 419 1
I 39 11111
I 1120 I
1
2
3
150
I
1
150-.8 BlK _
DRl MODULE (T61)

(SEE PAGE 27)
IS2I
~
15O-.8BlK
--II
150-.8 BlK
--C
0
C
129
liP CLUSTER
CONNECTOR
Cl00
12020183
-ENGINE
GROUND
G100
(SEE PAGE 70)

150-.8 BlK
--C
150-.8 BlK
--C
liP
GROUND
G200
GROUND DISTRIBUTION
DIESEL WIMAN TRANS
B-19
,..-..
,,
,,
RPOCODES
~
..-.. ...-r
,..-..
,,
,,
,,
,
,,
,,
,,
,,
,,
,,
,,
,,
~-
ENGINE
GROUND
G102
B-20
S114
.... 551-.8 TAN/WHT
551-.8 TAN/wHT
...
. . - . ....... TCM
(SEE PAGE 58)
"450-.8 BLKlWHT ~....c
~ ...- 450.8 BLKlWHT'"
TCM
(SEE PAGE 58)
. .- - - - 150-3.0 B L K "
. ._ _ _ _ 150,.8 BLK _ _. .
150'.8 BlK
ALDl
(SEE PAGE 57)
150-.8 BLK
DRAC
(SEE PAGE 65)
PANEL DIMMER SWITCH

(SEE PAGE 72)
GT100
. ._ _ 150-.8 BLK _ _. .
12020107 (UPPER)
12020108 (LOWER)
. .- - - - - - - - - - - 150-.8 BlK
------------l1li((
150-.8 BlK....
150-.8 BlK....
FUEL HEATER
(SEE PAGE 63)
50-.8 BlK _ _ _ _ _ _ _ _ _ _ _ _. (.
1
WIPER SWITCH
(SEE PAGE 38)

(SEE PAGE 63)
.1________________ '50-.8 Bll("
lOW COOLANT WARNING MODULE

(SEE PAGE 70)
150-.8 BlK....
11_ _ _ _ _ _ _ _ _ _ _
PARK BRAKE SWITCH

(SEE PAGE 70)
------------1((
DRL RELAY (T61)

(SEE PAGE 27)
S203
DRl MODULE (TS1)
(SEE PAGE 27)
GLOW PLUG CONTROLLER

(SEE PAGE 61)
150-.S BLK _ _
' -_ _ _ _ _ _ _ _ _ _ _ 150-.SBlK _ _ _ _ _ _ _
150-.S BLK _ _
. .- - - - -_ _ _ _ 150-.S BlK _ _. .
lIP CLUSTER
CONNECTOR
(SEE PAGE 70)
Cl
C100
12020183
E!J
ENGINE
GROUND
G100
GROUND DISTRIBUTION
DIESEL W/AUTO TRANS
D
0
150
39
3
2
31
439
35
440
420
250
~1
---
150-.BBlK . . . .
11
12
Di::;;;;;:;;;;;:J0Cl
lS0-.SBlK . . . .
Cl00
12010184
ENGINE
I:I~:~~
29
--lIP
GROUND
G200
~.!IJi!t;.-------
. ._ _ _ 150-1.0 BLK _ _ _ _ _ _.~'"
150-.8 BLK - - - -
S404
150-.8 BLK - -. . .
"" - 150-.8 BLK
---C.
PROVISIONS FOR
RH SIDE MARKER
(SEE PAGE 76)
PROVISIONS FOR
LH SIDE MARKER
(SEE PAGE 76)
12065158
--
FRAME
GROUND
G400
C402
12034342
---
SHEET
METAL
GROUND
G402
GROUND DISTRIBUTION
REAR
B-21
CIRCUIT OPERATION

TEST

Breaker. The Circuit Breaker opens when the Light
Switch circuit draws too much current. When the Circuit
current flow, the Circuit Breaker cools off and resets

Dimmer Switch directs voltage to either the Low Beams
or the High Beams. The HI Beam Indicator also receives
voltage along with the High Beams.
RESULT

GO to step 2.
Test lamp lights.
ISOLATE problem in body

builders installed wiring.
2.
Connect test lamp from TAN

ground.
GO to step 3.
Test lamp lights.

(12) wire from headlamp dimmer
connector C101.

ground.

switch connector C210 to light
Test lamp lights.

switch.
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS BOTH SIDES
ACTION
RESULT
TEST
1.
2.
3.
Connect a test lamp from RED

Test lamp lights.
GO to step 2.

(2) wire from light switch
connector C209 to battery
junction block.
With the light switch on and

the dimmer switch to HIGH
BEAM, connect a test lamp from
YEL (10) wire at light switch
Test lamp lights.
GO to step 3.

ground.
Test lamp lights.
3.

TEST
1.

from headlamp dimmer switch
connector C210 to connector
C100.
switch.
2.
3.
B-22
HEADLAMPS
BASE
ACTION

dimmer switch to HIGH BEAM
from LT GRN (11) wire at
Place headlamp dimmer switch
in HIGH BEAM position. Connect
a test lamp from LT GRN (11)
ground.
RESULT
ACTION
GO to step 2.
Test lamp lights.

GO to step 3.
Test lamp lights.


Test lamp lights.

switch.
JUNCTION
BLOCK
S197
HEADLAMP
DIMMER
SWITCH
C210
8917693
BASE HEADLAMPS WIRING
B-23
RH
SIDE MARKER
LAMP
1iL| VJJ
HORN
C145
L47 12077765
115-.5 DK BLU |
S121
NOTE: This harness is shipped

along with the vehicle and is
installed by the body builder.
LH
SIDE MARKER
LAMP
G106
B-24
FORWARD LAMP HARNESS
G107
SHEET
METAL
GROUND
G105
12077765
FRAME
Q / GROUND
G104
CIRCUIT OPERATION

TEST
the DRL Indicator in the Instrument Panel and energizes

the DRL Relay.
When energized, the DRL Relay
disconnects the LT BLU/ORN (593) wire from ground and
internally connects it to the LT GRN/BLK (592) wire
causing it to be 12 volts.
Battery voltage is applied to the Daytime Running

Lamps (DRL) Module from the BRN (50) wire and the
HTR fuse.
With the Headlamps on, the DRL Relay is not
energized and the LT BLU/ORN (593) wire is grounded
to BLK (150) wire inside of the relay. This serves as
ground for the LH Headlamp.
The LT BLU/ORN (593) wire feeds the LH High beam

which is connected in series to the RH Headlamp
through the LT GRN (11) wire. Grounding of the entire
DRL circuit is accomplished through the BLK (151) wire
at the RH Headlamp.
This results in High beam
headlamps that are less intense for daytime driving and
should provide longer service.
With Ignition in RUN, headlamps off and Parking

Brake released, the DRL Module applied battery voltage
to the LT GRN/BLK (592) wire. This action illuminates
RESULT
1. Turn light switch ON and dimmer

switch to LOW BEAM position.
(12) wire at connector C100 to
ground.
GO to step 4.
Test lamp lights.
GO to step 2.
2.

BLU/ORN (593) wire from light
connector C100 to DRL relay
connector C243.
Test lamp lights.
GO to step 3.

(150) wire at the DRL relay
REPLACE DRL relay.
Test lamp lights.

connector C243 to ground G200. If
not open is found, ISOLATE
problem in body builders installed
wiring.

GO to step 5.
Test lamp lights.

(12) wire from connector C100 to
headlamp dimmer switch
connector C209.


Test lamp lights.

switch.
3.

BLU/ORN (593) wire at DRL relay
DIAGNOSIS - HEADLAMPS (WITH DRL)

PRELIMINARY CHECKS:
Lamp(s) are inoperative, refer to the HIGH BEAM
LAMP(S) DO NOT OPERATE test procedures. If the
High Beam Lamp(s) are operative, use the following
diagnostic procedures, after placing the Light Switch
to OFF position.
Before checking the DAYTIME RUNNING LAMPS

system, do the following:
Switch to HIGH BEAM position. If the High Beam
HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS - BOTH SIDES

TEST
1.
2.
3.
ACTION
RESULT

C209 to ground.
Test lamp lights.
GO to step 2.

(2) wire from light switch connector
C209 to fuse block.

C209 to ground.
Test lamp lights.
GO to step 3.

Test lamp lights.

C100.
Test lamp does light.

switch.
ACTION
4.
5,
CANADIAN DAYTIME RUNNING LAMPS (DRL)
B-25
CANADIAN DAYTIME RUNNING LAMPS DO NOT OPERATE

TEST
1.
2.
TEST
ACTION
RESULT

ground.
GO to step 4.
Test lamp lights.
GO to step 2.

BLU/ORN (593) wire to ground at
DRL relay connector C243.

BLU/ORN (593) wire between
connector C100 and DRL relay
connector C243.
1. With ignition in RUN, headlamps

off and park brake released,
connect a testlamp from ORN
C242 to ground.
2.
3.
4.
5.

C243 to ground.


Test lamp lights.
GO to step 3.
REPLACE DRL relay.
Test lamp lights.

connector C243 to ground G200.
GO to step 5.
Test lamp lights.

GRN (11) wire from connector
C100 to headlamp dimmer switch
connector C210.
Test lamp lights.

3.
4.

switch.
5.
B-26
CANADIAN DAYTIME RUNNING LAMPS (DRL)
Connect J 34029-A Multimeter

from BRN (50) wire at DRL module
Measure voltage.

from B R N (50) wire at DRL module
connector C242 to BLK (150) wire
at each component connector.
Measure voltage.

BLU/ORN (593) wire at connector
C101.
RESULT
ACTION

(240) wire between DRL relay
connector C242 and fuse block. If
no open is found REPLACE DRL
fuse.
Test lamp lights.
GO to step 2.
Battery voltage at only one

connector.

(50) wire between splice S212 and
connector with missing voltage.
No battery voltage at either

connector.

fuse block. If no open is found,
REPLACE HTR fuse.
Battery voltage at both

connectors.
GO to step 3.
No voltage.

(150) wire between suspect
connector and ground G200.
Battery voltage.
GO to step 4.
No voltage.

GRN/BLK (592) wire between the
DRL relay and the DRL module. If
no open is found, REPLACE DRL
module.
Battery voltage.
GO to step 5.

BLU/ORN (593) wire between DRL
relay connector C242 and
found, ISOLATE problem in body
Test lamp lights.
Daytime running lamps are

operational.
RH
SIDE MARKER
LAMP
RH
HIGH-LOW
HEADLAMP
~
~"
C145
12077765
_ _ _ 11-H) LTGRN
11
12
C137
12004267
151
a:
to
C144
2973386
-I
. ._ _ _ _ _ _ 151-.8BLK _ _
15-.8 OK BLU_
d>
_15-.50KBLU _ _ _ _ _ _ _ _ __
_ . _ _ _
15-.8 OK BLU
8124
a:
:.::
l!l
RH PARK AND
TURN LAMP
'--~-i'. BLK~
.,8
C143
2984855
_______
8121
r~.'"
,
------,
I :,
,,
------,, ~
a:
1--.. .
CO
Ll)
8123
14-.8LTBLU _ _
LH PARK AND
TURN LAMP
'--~~....,.8
- . ---.
'"
8122-- 9-.8 BRN - - - - - - - - -
12-.8TAN _ _ _ _ _ _. .
C101
12020100
12-.8 TAN
11
12
I-
29~11
C>
to
1H.OLTGRN _ _ _ __
... . . . , AI 593-.8 OK BLU/WHT r
9
..
,I
'"ch
2973386
11
12 ill~
593 15
a:
C140
1-
..,
l!l
l!l
150
1-
1'3
a:
a:
LH
HIGH-LOW
HEADLAMP
"WWHO'
_14-.8 LT BLU
-9-.8BRN
14-.5 LTBLU
BLKL
C142
2984855
Cd>
..oj
. . . , ..
---
--------~
. . . , . . . , . . . , . . . , ..
. . . , . . 593-.80KBLU/WHTr
...,
151-3.0 BLK
LH
SIDE MARKER
LAMP
C141
12077765
G105
SHEET
METAL
GROUND
--

FRAME
GROUND
G104

W/DRL
8-27
JUNCTION
BLOCK
HTR
25 AMP
HORN/OM
15 AMP
1------------------------.R.O.E.~Ly--50-3.08AN - - .
~
~
~--. 50-3.0 8AN - - - _ _ _ _ ...
~---2-1.0R8T-------.
~
(FU818LE LINK)
. ._ _ _ _.240-1.0 DAN _ _ _ _ _ _ _ _ _ _
8197
8298
(8EE PAGE 36)
5O-3.08AN _
8212
_
592-.8LTGAN/8LK _ _
50-3.0 8AN _ _ _ _ _...~
C243
12052287
. ._ _ _ _ _ _ _ _ _ _ 240-.8 DAN _ _ _ _ _ _ _ _ _ _
..J
. ._ _ _ _ _ _ _ _ _ 150-.8 8LK _ _ _ _ _
IIj.~
:=
o
u
oW
C100
12020183
ENGINE
0::
lS
e2J
A
B
G
H
~
Z
0::
1'20 1 1340 I
I 33 I 39 1450 I
OJ 14191 3 I
~~@~
" ....
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ , _ _ _ _ _ _ _ _ _ _ _ _ 12-.8TAN _ _ _ _ _........
UP
I 31 1
135 1439
II I 1440 I
11143419061 6 I
~
<Xl
~r
,
.
_____________
----~
JJ~l=.*==~==:;-----------
11-1.0 LT GAN - - - - -
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 11-1.0LTGRN _ _ _ _ _
....
a
_________
593-.8DKBLUIWHT_
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2-3.0 AED _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2-3.0 RED _ _ _ _ _
8-28
HEADLAMPS WIRING
W/DRL
~~~
I/P CLUSTER
CONNECTOR
(SEE PAGE 69)
C205
12040744
44
LIGHT
SWITCH
LIGHT
SWITCH
l/P
(O )
GROUND
G200
HEADLAMPS WIRING
W/DRL
B-29
HAZARD WARNING LAMPS DO NOT OPERATE
CIRCUIT OPERATION
TEST
applied to both Front and Rear Turn Lamps. Alt of the

Turn Lamps and both Turn Indicators flash on and off.
Voltage is applied through the TAIL LPS Fuse to the

or HEAD, voltage is applied to the Park, Tail, Marker, and
License Lamps. The Front Marker Lamps are grounded
through the LH and RH Park and Turn Lamps.

as they did in TURN RIGHT and TURN LEFT, if the Lamp
Switch is in OFF, they flash on when the Hazard Lamps
are on. If the Lamp Switch is in either PARK or HEAD,
they flash on when the Hazard Lamps are off and off
HAZARD SIGNAL LAMPS

Voltage is applied at all times, through the STOP-HAZ
contact of the Hazard Switch in the Turn Signal Switch.
With the Hazard Switch in HAZARD FLASH, voltage is
1.
RESULT

making a turn.

hazard warning lamps ON.
ACTION
GO to step 2.
Refer to "Turn Signals Do Not

Work On One Side" symptom.
Test lamp lights.
CHECK condition of STOP/HAZ

REPAIR open in ORN (140) wire
and B R N (27) wire. If fuse and
wiring are good, REPLACE hazard
flasher.
In HAZARD, the circuit is always open, and the

Hazard Flasher Control the Lamps.
SIDE MARKER LAMP(S) DO NOT OPERATE
DIAGNOSIS - PARK, MARKER AND HAZARD LAMPS
TEST
1.
PRELIMINARY CHECKS:
If only one lamp is inoperative, inspect wire(s) to
affected lamp socket, check bulb-to-socket fit or replace
bulb.
2.
PARK LAMPS DO NOT OPERATE
TEST
1.
2.

from O R N (40) wire at light
ground.
Test lamp lights.
GO to step 3.
GO to step 2.
Connect a test lamp form RED

(2) wire at fuse block to
ground.
Test lamp lights.
4.

wire connector C100 to ground.
B-30
ACTION

ground.
Test lamp lights.
GO to step 2.

light switch connector C209.
Remove bulb from socket, then

connect a test lamp between BRN
(9) wire and LT BLU (14) or DK
BLU (15) wire(s) at connector
C100.
Test lamp lights.
ISOLATE problem in body builders

installed wiring.

BLU (14) or DK BLU (15) wire(s)
from connector C100 to turn signal
REAR MARKER LAMP(S) DO NOT OPERATE
3.
ACTION
RESULT
RESULT
CHECK condition of TAIL LPS

fuse. If fuse is good, LOCATE
and REPAIR open in ORN (40)
wire.
(2) wire from fuse block to
battery junction block.
Test lamp lights.
GO to step 4.
Test lamp lights.


PARK, MARKER AND HAZARD SIGNAL LAMPS
TEST
1.
2.
RESULT
ACTION
Place light in PARK position.

wire at LH rear lamp harness
connector C402.
Test lamp lights.
GO to step 2.

(9) wire(s) from rear lamp harness
connector C402.
Connect a test lamp between BRN

(9) wire and BLK (150) wire(s) at
rear lamp harness connector
C402.
Test lamp lights.

installed wiring.

(150) wire from rear lamp harness
yvw w w w u
S
HOT AT ALL TIMES ^
'1------c..___....r
>VVVV\\VVWVM
40 1 ORN
140-1.0
TAIL LPS:
TAIL LPS 5
20
20 AMP
AMP
PANEL DIMMER SWITCH
- ,OORN - - - - - - - - - - - - - - - .
44
K A B c n
M l i 1 5 0 1 156 j 44 j L L ^ i
'Li------ 1
C297
12020030
9-,8 BRN
LIGHT
SWITCH
150 ---;r----e
156
DOME
2
CIRCUIT
\PARK
,
BREAKER
25AMP
10
HEAD
\
40-1-_'-;
OFF
'PARK
9
LIGHT
SWITCH
. ._ _ _ _ _ _ _ 40-1,OORN_-II-_ _ _
REAR BODY
CONNECTOR
6
REAR
LAMP
HARNESS
zII:
III
340
450
439
II:
III
440
~1
Cl00
12020184
FRAME
GROUND (O )
G400
-
"=
PARK AND MARKER SIGNAL LAMPS
8
..31
B-31
STOP-HAZ
15 AMP
_ P I I - - - - - - - - 1 4 0 - 1 . 0 0 R N - - - - - - - - -
........_ _ _ _ _ _ _.140-1.0 ORN _ _ _ _ _ _ _ _ _ _ _
.1
,--
,..
... -
(STEERING COLUMN SWITCHES)
, ,_ _ _ _ 17-1.0 WHT
---------..J.F::U
__
__
__
.19-1.0
GRRIN::.:::::::::I~~
_
18-1.0 DK
YEL
, . . . . . 15-.5 DK BLU
--------~w=lIJr
_ _ _ 14-.5LTBLU_
P .L..:.:......I1..-1.O WHT ---------_-+_~~_-+-I.-----....

1.0 DK GRN
N
-1..+-.3
1.0 YEL _ _- . - - - - - -_ _
M
L
.8 PPL
K
1.0 BRN
+-_-+__
.5 LT BLU - - - - - - - -
.5 BLK - - - - - - - - - .
a:
C!
F
E
HORN
~q ~q ffi
PRNDL
LAMP
.........- - .5 GRA
(SEE PAGE 72)
BLU _ _ _ _ _ _ _. . .
14-.5 LT
r-!.
REAR
LAMP
HARNESS
KEY
C206
12004147
a:
TURN
SIGNAL
SWITCH
BLU _ _ _ _ _ _. . .
NORMALLY
OPEN
SWITCHES
lIP CLUSTER
CONNECTOR
..J
15-.5 DK
3:
0
0
(SEE PAGE 70)
18-2.0YEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. -. . . . . . . . . . . . . .. -. . .
5
6
~ItIeL
/~
1 t~
)\.
,~
..
':'
18
19
30
241
I~
liP ~l....r~
19-2.0 DKGRN
........- - - - - - -...- -...............-
......- -...- -...-
REAR BODY
CONNECTOR
C 102
12020099
'"
340
450
39
419
31
439
35
I'
440
~1
120
33
:J
I!
III
93 III
906 434 11
\J
STOPLAMP
SWITCH
(CLOSES WHEN
BRAKE PEDAL
IS DEPRESSED)
III! 340
18
IQ)
,
r
94
"
...,
"'"-
9
120
19
11
12
15
593
14
29
v
6
N
2984235
4r:Sf/
ClOO
12020184
27-1.0 BRN
17-1.0WHT
,
140-1.00RN
~o'
~_ "'A::,=::27-1.0
BRN _ _ _ _ _ _1
~
C228
2973385
HAZARD
FLASHER
8-32
HAZARD SIGNAL LAMPS
...-
......... .
CIRCUIT OPERATION
TEST
TURN SIGNAL LAMPS

applied through the TURN/BU Fuse and Turn Flasher to
the normally closed contact of the Hazard Flasher Switch
in the Turn Signal Switch.
Lamp will find a path to ground through Splice S123 and

the Park and Turn Lamp to ground. This Lamp provides
low resistance paths to ground. The Marker Lamps will
flash with the Turn Lamps.

LH Front Park and Turn Lamp LT BLU (14) wires.
Voltage is applied to the LH Tail, Stop and Turn Lamp
YEL (18) wire.

voltage is applied through the TAIL LPS Fuse, Lamp
Switch, and Splice S122 to the Marker and Park Lamps.
If the Turn Signal Switch is in TURN LEFT, the LH Side
will go out. When the Flasher removes voltage to the
the Turn Lamp and will go on. In this way, the LH Side
Marker Lamp will flash on when the LH Park and Turn
Lamp goes off, and off when the Turn Lamp goes on.

when the current flow heats up the Timing Element in the
Flasher and it repeatedly opens and closes the circuit.
The voltage applied to the LH Park and Turn Lamp
will also be applied to the LH Side Marker Lamp. If the
Lamp Switch is in the OFF position, the LH Side Marker
With the Turn Signal Switch in TURN RIGHT, voltage

will be applied to the RH Lamps in the same way.
DIAGNOSIS - TURN LAMPS
RESULT
1. Turn hazard warning system on.

Lights flash.

GO to step 2.
Test lamp lights.
GO to step 4.
GO to step 3.
Connect test lamp from PPL

(16) at turn signal switch
Test lamp lights.
Connect test lamp from LT BLU

(depending on which side did
not work) at park and turn lamp
ground.
Test lamp lights.


either LT BLU (14) or DK BLU
(15) wires between turn signal
connector C100.
2. Turn hazard warning system

off. Place ignition switch to
RUN and turn signal to side
that does not work. Connect
test lamp from LT BLU (14) or
DK BLU (15) wire (depending on
which side does not work) at
turn signal switch connector
C206 to ground.
3.
4.
ACTION

TEST
1.

on position.
2. Connect a test lamp from PPL

(16) wire at turn signal
ground.
RESULT
ACTION
GO to step 2.
REFER to "Hazard Lamps Do Not

Operate" symptom.
Test lamp lights.

fuse and an open in PPL (16)
wire or DK BLU (38) wire. If
fuse and wiring are good,
TURN SIGNAL LAMPS FLASH RAPIDLY

TEST
Turn hazard lamp switch ON.
Check front signal lamps and rear
taillamps.
RESULT
ACTION
One side of turn signal lamps flash

rapidly.

bulb.
Only one side of turn signals light

but do not flash rapidly.
REFER to "Turn Signals Do Not

TURN SIGNAL LAMPS
B-33
FUSE BLOCK
12103404
Al
[IJ:ITl
(BJ
(BJ
lID lID 00 [IJ:ITl
lIDlIDOODITlDD
ACC
IGN HTR PWR
000000
17
19
18
27
27-1.0 BRN
15
15-.5DKBLU~
[AJ [jUGB
HORN/OM INSTR-LPS
INJ
16
17-1.0 WHT
19-1.0DKGRN _ _
18-.8 YEL
lS-.8 PPL
TRANS
TURN
SIGNAL
SWITCH
~~oo
TAIL LPS
N
M
L
HTR
s~E~:LOA~~
14-.5 LT BLU
28-.5 BLK
OO~
~ Pu::D
HORN
C20S
12004147
KEY
~~~--~~.I ~
'-+-~-...,
~
I
NORMALLY
OPEN
SWITCHES
PRNDL ~ 8-.5 GRA

LAMP
(SEE PAGE 72)
BACKUP
_ _...~ LAMP SWITCH
(SEE PAGE 78)
a:
..J
(!)
. ._ _ _ _ _ _ _ _ _ _ _ _ _ 14-.5 LTBLU _ _ _ _ _ _ _ _ _ _ _...
>-
a,
cJ,
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ 15-.5 DKBLU _ _ _ _ _ _ _ _ _ _
TURN
FLASHER
~.~
liP CLUSTER
CONNECTOR
(SEE PAGE 70)
3 :3
~
o
10
.h
':J
10
14
29
2 DOt::;;;;;;;::JO::J
Cl00
12020184
8-34
TURN SIGNAL LAMPS
Cl02
12020099
12065158
CIRCUIT OPERATION
coil of the Horn Relay is grounded. The relay is
energized. Its contacts close and battery voltage is
applied to the Horn.
DIAGNOSIS - HORNS
PRELIMINARY CHECKS:
Check to see that the HORN D/M fuse is not blown.
REPLACE if blown.
HORN(S) W ILL NOT OPERATE

TEST
1. Connect a test lamp from DK GRN
ground. Press horn switch.
2.
3.
4.
RESULT
ACTION
Test lamp lights.

GO to step 2.
Test lamp lights.
GO to step 3.

(240) wire between horn relay
connector C207 and fuse block.
Install horn relay.

connector C206. Use a jumper
wire to ground BLK (28) wire at
turn signal switch connector
C206.
GO to step 4.
Horn sounds.
REPLACE horn switch.
Disconnect horn relay.

Install a jumper wire from ORN
(240) terminal to DK GRN (29)
terminal at horn relay
connector C207.
Horn sounds.
REPLACE horn relay.

GRN (29) wire from horn relay
connector C207 connector C100.
Remove horn relay. Connect a

test lamp from ORN (240) wire
at horn relay connector C207
to ground.
HORN SOUNDS CONTINUOUSLY WITHOUT DEPRESSING HORN SWITCH

RESULT
TEST
1.
2.

connector C206.
Disconnect horn relay
connector C207.
ACTION
Horn stops.
GO to step 2.
Horn stops.
REPLACE horn relay.

connector C207 and horn
switch.
HORN
B-35
HOT A T A L L TIM ES C
HORN/DM
15 AMP
240-1.0 ORN I
HORN
RELAY
28-.5 BLK
PRNDL
LAMP
^
(SEE PAGE 72)
CL
O
TURN
SIGNAL
SWITCH
O
O
S298
240-.8 ORN
340
120
! 450
39
419
31
439
35
2
440
6
33
J %
( r
n
906 434
<=c
B-36
HORN
PROVISIONS FOR
DOME LAMPS
(SEE PAGE 38)
240-.8 ORNl
WIPERS DO NOT OPERATE IN LO
CIRCUIT OPERATION
TEST
WIPER
is through the PPL wire, the Wiper/Washer Switch and
the BLK wire to ground.
The Wiper Motor is supplied battery voltage with the

Ignition Switch in START or RUN, with ground supplied
by the Wiper/Washer Switch.
1.
RESULT
Place ignition in RUN and wipers

to LO. Connect a fused jum per
from GRA (91) wire at wiper switch
ACTION
Wiper m otor does not run.

connector C188 and wiper switch
found, REPLACE wiper motor.
Wiper m otor runs.
REPLACE wiper washer switch.
WASHER
When the Wiper Motors is in LO, Battery voltage is
supplied to the motor through the WHT wire and the
ground circuit is through the GRA wire, the
Wiper/Washer Switch and the BLK wire to ground.
Battery voltage is applied to the washer pump

through the WHT wire, to the switch and to ground
through the BLK wire. The washers are operational as
long as the paddle switch on the Wiper Switch arm is on.
WASHER MOTOR DOES NOT OPERATE

TEST
When the wiper is in HI, battery voltage is supplied to

the motor through the WHT wire and the ground circuit
1.
RESULT
Place ignition switch in ACC
Test lamp lights.
GO to step 2.
from WHT (93) wire at

LOCATE and REPAIR open in WHT

(93) wire between connector
C224 and fuse block.
Connect a test lamp from WHT

(93) wire at washer pump
Test lamp lights.
GO to step 3.
LOCATE and REPAIR open in WHT

(93) wire between washer motor
C224.
3.
Connect test jum per from PNK
Washer motor runs.
GO to step 4.
Washer motor does not run.
REPLACE washer motor.

ground.
Washer motor runs.
GO to step 5.

(94) wire between washer motor
C224.
Washer motor runs.
GO to step 6.
washer switch connector C221.

(94) wire between connector
C224 and windshield wiper
washer switch connector C221.
Washer motor runs.

(150) wire between windshield
wiper washer switch connector
C221 and ground G200.
REPLACE windshield wiper

washer switch.
DIAGNOSIS -- WIPER/WASHER
2.
PRELIMINARY CHECKS:
Check condition of WIPER fuse. If fuse is in good
condition, use the following diagnostic procedures.
TEST
1. Place ignition in RUN and turn
wipers to HI. Connect a test lamp
from WHT (93) wire at wiper motor
2.
ACTION
RESULT


block.
Test lamp lights.
GO to step 2.
Wiper motor runs.

connector C221 and ground G200.
4.
5.

ACTION
RESULT
TEST
1. Place ignition in RUN and wipers
to HI. Connect a fused jumper
from PPL (92) wire at wiper switch

Wiper motor runs.
ACTION
6. Connect test jumper from BLK

(150) wire at windshield wiper
washer switch connector C221
to ground. Press wash switch.
WASHER MOTOR DOES NOT SHUT OFF

TEST
1.

wiper switch to WASH. Disconnect
wiper switch connector C221.
RESULT
ACTION
Washer motor pumps.

ground in PNK (94) wire between
wiper switch connector C221 and
washer motor connector C187.
WINDSHIELD WIPERS/WASHERS
B-37
WIPER
25 AMP
PROVISIONS
FOR
DOME LAMPS
93-3.0 WHT |
PANEL DIMMER
SWITCH
(SEE PAGE 72)
S298
(SEE PAGE 36)
WIPER
MOTOR
12010429
WASHER
MOTOR
HORN RELAY
(SEE PAGE 36)
WINDSHIELD
WIPER/WASHER
SWITCH
S203
(SEE PAGE 18)
l/P
GROUND
G200
B-38
CIRCUIT OPERATION
TEST
1.
START
position, battery is applied to the Starter Solenoid. Both
solenoid windings are energized. The circuit through the
Pull-In Winding is completed to ground through the
Starter Motor. The windings work together magnetically
to pull in and hold in the Plunger. The Plunger moves
the Shift Lever. This action causes the Starter Drive
Assembly to rotate as it engages the Flywheel ring gear
on the engine. At the same time, the Plunger also closes
the solenoid switch contacts in the Starter Solenoid. Full
battery voltage is applied directly to the Starter Motor
and it cranks the engine.
contacts cranking the engine.
voltage applied to the Pull-In Winding is now opposing
contacts to open simultaneously.

As soon as the
CHARGE
The AC voltage is converted to DC by the rectifier bridge
terminal.
supply the Rotor current and thereby control the output
voltage. The Rotor current is proportional to the width of
magnetic field.
Regulator sensor Generator rotation by detecting AC
by controlling the pulse width.
This regulates the
The digital regulator controls the VOLTS Indicator light
with a solid-state light driver. The light driver turns on
the light whenever undervoltage, overvoltage or a
stopped Generator is detected.
2.
3.
4.
RESULT
Place transmission in PARK (auto)

and depress clutch pedal (man).
wire at starter solenoid to ground.
Turn ignition switch to START
position.
Battery voltage.
GO to step 2.
No voltage.
GO to step 3 (man trans).

GO to step 5 (auto trans).
Connect voltmeter from PPL (6)

Battery voltage.
REPLACE starter solenoid.

surface.
Battery voltage.
GO to step 4.
No voltage.
GO to step 5.
Engine cranks.
REPLACE clutch start switch.
Engine does not crank.
CHECK condition of CRNK fuse. If

open in PPL (6) wire from clutch
start switch connector C219 to
starter solenoid.
Battery voltage.
No voltage.

(2) wires and fusible link from
battery junction block to ignition
Disconnect clutch start switch

voltmeter from YEL (5) wire at
clutch start switch connector C219
to ground. Ignition switch must be
in START position.
Depress clutch and put
transmission in neutral. Apply
parking brake. Connect a fused
jumper from YEL (5) to PPL (6) at
clutch start switch connector
C219. Turn ignition switch to
START position.
5. With ignition switch OFF, connect

a voltmeter from cavity B terminal
at ignition switch connector C298
to ground.
BATTERY IS UNDERCHARGED OR OVERCHARGED

TEST
1.
Connect voltmeter from RED (2)

wire at generator connector
C107.
RESULT
1.
Remove CRNK fuse. Connect a

voltmeter to positive and negative
battery terminals. Turn ignition
switch to START.
2. Connect a voltmeter from negative

3. Connect voltmeter from positive
terminal at BLK (2) wire.
RESULT
GO to step 2.
No voltage.

generator connector C107 to

Refer to Section 6D in Service
Manual.
Reading of less than or

greater than 13-16 volts.
REPAIR generator.
ACTION

GO to step 2.
Voltage less than 9.5 volts after 15

seconds cranking.

Refer to Section 6D in Service
Manual.
Less than .5 volts.
GO to step 3.
More than .5 volts.
Less than .5 volts.
More than .5 volts.
2.
Connect generator connector

accessories turned off and
engine running at fast idle.
Connect voltmeter from
battery terminal on generator
to ground.
ACTION
Battery voltage.

TEST
ACTION
STARTIN G/C HAR GIN G
B-39
r--------2-32.0 BLK
., , ,
6-5.0PPL _ _ _ _ _ _ _ _ _~
CLUTCH
START
SWITCH
MTl
TRANS HD, 4-SPD., WITH OVERDRIVE
MT6 -_ AUTO
MAN TRANS'
, 5-SPD., WITH OVERDRIVE
C219
6911921
1-19.0 BLK
~ ~
~
z
0
::;;
RPOCODES
ro
~~
..J..J
roro
0'<
ai~
BATTERY
!..!:,
..J
S196
DD-
~6-5.0PPL
I
I
ow
IGNITION
COIL
(SEE PAGE 42)
z
::J
w
tia:ixl
RUN
OFF
eS207
_..
' _ _ __
LOCK
6-5.0 PPL _ _ _ _ _ _ _ _ _ __
ACC
-~
oUi
o
IGNITION
SWITCH
2-5.0 RED
"'::J
N~
1.___________~S:9-
---
2-3.0 RED
.a:
o
'"z
5111
(SEE
BATTERY
JUNCTION
BLOCK
/~--
,
e
E!J
lS
C
0
~
Z
~
cD
S197
~2-1.0RST
(FUSIBLE LINK)
GENERATOR
Cl07
R.
'H,
I:~
13! 1150
IL31
3
Cl00
12020163
IEiI
..J
DD-
..J~
...u-_l _1 _--JJ
182414201440
IL 431 I 350 I
I .-
135 1439
12
29
..........-
__ 5
~ CRNK
~ 10 AMP
c:=::JO
:)-----~
2-5.0 RED
Z
D-
ALT
20 AMP
ClOD
12020164
eD
. ._ _ _ 1-19.0BLK . ._ _ _"
e __
39-.6 PNK/BLK'
5206
(SEE PAGE 70)
ENGINE GROUND G111
GASOLINE ENGINE
3: 6
~~
STARTING/CHARGING
_e _ _ _ _ __
lIP
UJIL419 I 3
@1:
-..-:-p
D-
. ._ _ _ _ 3-5.0 PNK _ _ _ _ _ _ __
D-
- - 39-.6 PNK/BLK ENGINE
PAGE46f
:)
ro
8-40
START
_ _ _ _ _ _ _ _ _ __
STARl ER MOTOR
'SZ'
C299
6294641
(SEE PAGE 4) . ._ _ _ 3-5.0 PNK: _ _ _ _ _ _ _ _ __
o
2-3.0RST
(FUSIBLE LINK)
C296
12010966
S206
-=-
SHEET
METAL
G110 GROUND
--906-.6 PPL _ _ _ _ _ _ _.~ ECM

(SEE PAGE 45)
,
(MT60NLy)
RPO
CODES
RPOCODES
6-3.0 PPL
5-3.0 VEL
CLUTCH
START
SWITCH
(MT8)
C219
8911921
RH
BATTERY
_ _ .6-3.0 PPl _ _ _
LH
BATTERY
830 - SCHOOL BUS EQUIPMENT

MTl - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
MT8 - MAN TRANS, 5-SPD., WITH OVERDRIVE
_ _ _ _ _ _ _ _ _ _ _ _ _. .
. ._ _ _ _ _ 3-5.0 PNK _ _ _ _ _. .
IGNITION
SWITCH
...J
3:
o
u
-------.1:3
Cl00
12020184
liP
. .- - - - - - 1-50.0 BlK
1-32.0 BlK (B3D ONLy)
BATTERY
JUNCTION
BLOCK
~~
2Z
00
STARTER
MOTOR
(FUSIBLE LINK)
~~
_
2-3.0 RED
S197
~ ~
I~
S195
Iri
GLOW PLUG
CONTROLLER
-'
it
oW
o
M
a:
~ '~'=~ '"
<Xl
Cl07
12045896
-- -.. ... - -
'"-'
~
Z
~~
_L
START
RUN
OFF
LOCK
ACC
3-5.0 PNK..
. . . 2-3.0 RED
_2-3.0 RED
Sl13
_
_ 3-3.0 PNK
-'::<
WC')
o@.
N ~
7 al
1 1 1
~
1_____
/~ ~ ~'"
ENGINE
GROUND
LH CYLINDER
HEAD
G113
C298
12010966
",0
'?
ENGINE
GROUND
RH
CYLINDER
HEAD
G112
1_ -----.
_6-5.0PPL
S205
S206
(SEE PAGE 4)
1!21
<L
<Xl
'"
2-5.0 RED _ _ _ _ _ _ _ _ _
di
C')
<LW
<L>00
~ 39-.8 PNKlBlK ~ _
a:
L
....
GENERATOR
~j~
ALT
20 AMP
'" '"
C)
fa
12
29
~1
r-
0-'
<L
<L
0
11
-'
<b
~ 2-1.0 RST _
-'-'
S196
1-2
~~
<L
1-1-
-r
3
3-3.0 PNK - -_ _ _...~
C299
6294641
Cl00
12020183
FUEL SHUT
OFF VALVE
(SEE PAGE 63)
SHEET
METAL
GROUND
G110
STARTING/CHARGING
DIESEL ENGINE
8-41
RPO CODES
WVWVvVVVVVVVV/
< HOT IN START OR RUN <
m v v w v v v \v v \^
5
10 AMP
439-.S PNK/BLK r
e c m -c r n k
439-.8 PNK/BLK I
ALT
20 AMP I _________________ ___________________________________________________________________________________________ _______ _______
I
i
\
I
I
I
______
439-.a pn k/blk r
439-.8 PNK/BLK I
I
C120
12078082
IGNITION MODULE
-ESI-------------------- - 423 | u
DISTRIBUTOR __ ,
430 | C
REFERENCE HI
424 | B
DISTRIBUTOR
REFERENCE LO
mm 423-.8 WHT
^
IL
424-.8 TAN/BLK V
453-.S BLK/RED^
453 | A
439-.8 PNK/BLK .
439-.8 PPUWHT
430-.8 P P L y W H T iV '
^
453-.S BLK/REDBBT
" I " """
. 453-.8 BLK/RED'
W
430-.8 PPL/WHT'
423-.S WHT |
I 430-.8 PPL/WHT
ELECTRONIC
CONTROL MODULE
CONNECTORS
I423-.8 W H T ^ H
424-.S TAN/WHT
--------------------------r
----------------------------------------------------------------h
. 424-,8 TAN/WHT
GT100
C199
12C15791
12020107 (UPPER)
12020108 (LOWER)
12010996
i
i
*
i
i
k.
*
3
CD
\
^
GENERATOR
(SEE PAGE 40)
ENGINE
c = l
DISTRIBUTOR
E 9
A
B
440 | *1
2
Hill
ra
S112
DRAC
I 439-.8 PNK/BLK
;*
i i 2 i
i
hi
r ---- i
(SEE PAGE 64)

^
k
I
39
14
9
12
2 I
Lj J
11
150 | JJ
:
_Q _
29
439 I
31
250 | '
| S241 420
439-.8 PNK/BLK*
19
18
24
30
f 1481
J UT
1824
r
9
I
250
420
440
35
439
31
ESC MODULE
(SEE PAGE 42)
IGNITION
SWITCH
(SEE PAGES 4, 5)
120
C100
12020183
B-42
IGNITION
GASOLINE ENGINE
|
1
S208
(SEE PAGE 70)
439-.8 PNK/BLK
M tm 439-.S PNK/BLK ^
39-.8 PNK/BLK jm m
l/P
PNK/BLK I
CIRCUIT WIRE
SIZE
NO.
COLOR
465
.8
DK GRN/W HT
435
419
439
.8
.8
.8
GRA
BRN/WHT
PNK/BLK
461
451
437
452
450
.8
.8
.8
.8
.8
ORN
WHT/BLK
BRN
BLK
BLK/WHT
440
120
453
.8
.8
.8
ORN
TAN/WHT
BLK/RED
430
.8
PPL/WHT
485
.8
BLK
CAVITY
DESCRIPTION
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
FUEL PUMP RELAY DRIVE

NOT USED
NOT USED
EGR SOLENOID (LB4) EVRV (L05)
C H EC K ENGINE LAMP
12V IGNITION FUSED
NOT USED
SERIAL DATA
ASSEMBLY LINE DIAGNOSTIC LINK
DRAC MODULE
5V RETURN B
SYSTEM RETURN
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
12V BATTERY FUSED

ELEC FUEL PUMP FUSED FEED
DISTRIBUTOR REF LOW
NOT USED
DISTRIBUTOR REF HIGH
NOT USED
SPARK RETARD CONTROL
NOT USED
NOT USED
NO T USED
NOT USED
NOT USED
CIRCUIT WIRE
SIZE
NO.
COLOR
444
443
441
442
.8
.8
.8
.8
LT
LT
LT
LT
906
410
432
.8
.8
.8
PPL/W HT
YEL
LT GRN
417
416
468
440
.8
.8
.8
.8
DK BLU
GRA
DK GRN
ORN
450
455
.8
.8
BLK/W HT
PPL
423
424
413
412
.8
.8
.8
.8
W HT
TAN/BLK
TAN
PPL
468
467
467
.8
.8
.8
DK GRN
DK BLU
DK BLU
GRN/BLK
G RN/W HT
BLU/W HT
BLU/BLK
ELECTRONIC CONTROL MODULE CO NNECTOR
CAVITY
DESCRIPTION
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
NO T USED
NO T USED
STEPPER COIL B LOW
STEPPER COIL B HIGH
STEPPER CO IL A HIGH
STEPPER COIL A LOW
NO T USED
NO T USED
CRANK SIGNAL (FUSED)
COOLANT TEMPERATURE
MANIFOLD ABSOLUTE PRESS.
NO T USED
THROTTLE POSITION SENSOR
5V SENSOR REFERENCE
INJECTOR B (2) DRIVE
12V BATTERY FUSED
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
SYSTEM GROUND
5V RETURN A
NOT USED
HEI SPARK TIM ING
HEI BYPASS
OXYGEN SENSOR LOW
OXYGEN SENSOR HIGH
NOT USED
NOT USED
NOT USED
NOT USED
NO T USED
NOT USED
INJECTOR B (2) DRIVE
INJECTOR A (1) DRIVE
INJECTOR A (1) DRIVE
ELECTRONIC CONTROL MODULE - GASOLINE ENGINES
ELECTRONIC CONTROL MODULE (ECM) - PINOUTS

GASOLINE W/MAN TRANS
B-43
MAP
SENSOR
i 439-.S PNK/BLK I
1440-1.0 ORN |
452-.8 BLK I
I 417-.8 DK BLU l
4 1 6 -.8 G R A ^ "
TP
SENSOR
455-.8 PPL 1
432-.8 LT GRN I
! 432*.8 LT GRN I
I 417-.8 DK BLU I
I 416-.8 GRA ^
417-.8 DK BLU I
COOLANT
TEMPERATURE
SENSOR
416-.8 GRAI
' 410-.8 YEL I

I 452-.8 BLK I
410-.8 YEL I
I 452-.S BLK I
S101
485-.8 BLK I
i
m
ESC KNOCK
SENSOR
412-.8 PPL I
486-.8 BRN
i 439-1.0 PNK/BLK I
EVRV SOLENOID
(LOS)
(SEE PAGE 46)
439*.8 PNK/BLK
ESC
MODULE
94
29
39
33
12
93
11
15II
420
439
14
J
f l
440
806
39
140
120
31
ll 9 3
OXYGEN
SENSOR
C100
12020183
C124
12010996
12015791
I 440-.8 ORN I
B-44

INPUTS - GASOLINE ENGINE W/MAN TRANS
^ 5 0 /1 3 0 )
3 ^
<136
18 I 120 I 9
35
97
422
92
440-.8 ORN
p
N
439-.8 PNK/BLK
------- - - -
---------.
439-.8PNK/BLK
_____ _
. . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 440-.80RN _ _ _ _ _ _ _. .
.I."~B,,,
~~-----
_ _ _ _ _ 440-1.00RN
______
44O-.80RN _ _. . .
Ii
44O-.80RN _ _ _
illQ]
~ 04
@ill
43
CJ
_465-.8BLK
--
GT100
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-412020197 (UPPER)
~_
455-.8 PPL
..
432-.8 LTGRN
..
.
.
416-.8
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
417-.8 GRA
DKBLU
----------------------------t
----------------------------t
..
_ _ _ 450-.8 BLK/WHT .... _
2020708 (LOWER
432-.8 LT G RN
417-.8 DK BLU
416-.8 GRA
410-.8YEl _ _ _ _ _ _ _ _ ,
452-.8 BLK
455-.8 PPL
I-
410-.8 VEL
_ _ _ _ _ _ _ _ _ _ _ _ _ __
_
...
485-.8 BLK 1
..
412-.8PPl
------ ,
c: ...
452-.8 BLK
450-.8 BLK/WH T ' _
450-.8 BLK/WHT - - . . . . . . . .
....-
412-.8 PPl
~~.~:,::--: ~~
,
,,
,,
S102'-'- . . . 450-.8 BLK/WHT . ,

(SEE PAGE 16)
...-. ....,
413-.8 TAN
450-.8 BLK/WH T _ ...
....
I::::
.J"': -"=
I-
0)
;;:
~
0)
In
"'
--
.. _413-.8 TAN
C250
12045575
,,
-'
....
CAANK SIGNAL
(FUSED)
(SEE PAGE 40)
-- =,
-.
--,
:==========~J
: :440-.8
416-.8 OAN
GRA
_417-.8 DK BLU _ _ _ _ _ _ _ _ _ _ _. .
_432-.8 LTGAN _ _ _ _ _ _ _ _ _ _ _ _. .
''
I
:
_ _ _ _ _ _ 410-.8YEl _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
'"
l:
c....a
-M
....+--c=+-"--1I~
--
ECM
CONNECTORS
..
ENGINE
GROUND
G100
__
<Xl
,,
GENERATOR
BRACKET
GROUND
G101
======-!J
461-.8 BAN
ORN
437-.8
AI 451-.8 WHT/BlK -
455-.8 PPl
(SEE PAGE 70)
,
,,,-
450-.8 BLK/WHT _
452-.8 BlK
SERVICE
ENGINE
SOON
LAMP
J:
-t
__
DRAC MODULE
(SEE PAGE 64)
_ .,,
'"
a::
'$f
.....
-1 . ~419-.8BRNM'HT
0)
J:
'_412-.8 PPl
L05 - ENGINE. 5.7L (350 CID) V8 GAS ENGINE, VIN K
..J
'".:;
I-
,-~
437-.8 BRN
- r-
III
--
..
- -....
_A
J:
z..:
43
'--
APO CODES
......
I-
,,
486-.8 BRN
--
485-.8 BLK
--------t-t
L.
.
,AI
I":M""-=:-"-'-'L.._
46
,c
-----.-T
-
- - .- '-
45
~3
C251
12047946
S104
(SEE PAGE 47)
,,
ALDL
C201
12020043

INPUTS - GASOLINE ENGINE WIMAN TRANS
8-45
l/\AIVV\.IVV\J~ ~
ECM-CRNK
L
10AMP
ALT
20 AMP
'--439-1.0 PNK/BlK
..,..,. ..,..,. ..,." ..,..,.
439-1.0 PNK/BlK
..,..,...,..,...,..,. _
..,..,. ..,..,.
~39-1.0 PNK/BlK - - ECM - BAT

481-1.0 RED
44O-1.00RN _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 44O-1.00RN _ _ _ _ _ _ _ _ _ _ _ _ _ _
10AMP
..,..,. ..,..,. ..,..,. . . , . " ..,..,. ..,..,. ..,..,. . . , . " . . . 39-1.0 PNK/BlK - . . ..,..,. ..,..,. ..,..,. ..,..,.
_ _ .. 439-1.0 PNK/BlK _
12V IGNITION FUSED

SPARK RETARD
ESC GROUND
ESC SENSOR
ELECTRONIC
SPARK
TIMING
423
424
430
453
--
430-.8 PPlJWHT
-I-
___
453-.8 BlK/RED
ra... _
C120
12040754
EVRV
SOLENOID
12010996
424-.B TAN/BlK ..,..,.
-,
(L05)
.,450-.8 BlK/WHT ,
435-.8GRA _ _ _ _ _ _ _ _ _ _ , . ,
~R
439-.B PNK/8lK . . , . " -
,~
'a:=====~:::::~::~::==...=
~
Cl14
12047950
12010639
o
e
S105
468-.8_
DKGRN
INJ-2
FUEL
PUMP
RELAY
'"
'"
'"
,
L
[19:
...
.."
ESC
. . . . 439-.11rl
MODULE
PNK/BlK
..

OUTPUTS (GASOLINE WIMAN TRANS)
:::::: ___________
_ _ _ ___ 467-.B DK BLU
. .,..... ..,..,...,." 1_ . . F...,

1___.
_
~. Sl12
-.r _ , . . - . . _ _ _
..,..,.
I _ - 120-20 GRA
r- __
441-.8 IT BlU/WHT
442-.B IT BlU/BlK
..
-I.
--....
..--~
...
_ _ 423-.8WHT
....
. . . ,. .... 430-.8PPlJWHT.r
-- ,...
,.
''-'"
_
_
..,..,. 424-.8 TAN/BlK
....
. r ... 453-.8 BlK/RED..,..,. ~

_
435-.8 GRA _ _ _ _ _
~
...
...
r;;
r
....
467- 8 IT BLU
... 450-.8 BlK/WHT ~
~--
~
....
S107
_
r:
..
467-.8 IT BLU
....
465-.8 DK GRN/WHT
-t_468-.8lTGRN
...
FUEL
PUMP CYCLE
......
~
_E_NG_IN_E_ _ _ _...._ _ __
435-.BGRA_ . . . .
,I
.l
~ ,~S;
. . . ._ 1 2 0 - 1 . 0 G R A _ - - . . I
C127
12052641
-il_+--fI
l
M
'.1~~~~~di~~~~11l
CD: " . .,.,.J:: .,""""' - - -- ...".,.",.""'"'GENERATOR

(SEE PAGE 4 0 ) " 39-.8 PNK/BlK", Sl11
481-1.0 R E D _
III
~~I~:-+--UN
=
=
Cl00
12020183
. ._ _ _ _ _ 440-1.0 ORN _ _ _ _
Cl00
12020184
SOLENOID
1.______________________________________________
490-.8RED _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. . .
(LB4)

OUTPUTS - GASOLINE ENGINE WIMAN TRANS
_ 450-.8 BlK/WHT--C
(!l
..,..,. ..,..,. ..,..,. .
465-.8DKGRN/wHT~ 7E
(!l
...
~
______11 _________ 1 _
.A_ _ _ _ _ 44O-.80RN
120-1.0 GRA
465-.8DKGRN/WHT_ ...
j------r
... . - 443-.8 LT GRN/WHT F
S109
,--------.---I
.
.
.
-..
.
.
-t - - .... !- - . . ''IF
-
JI
II
439-.8 PNK/BlK
_ _ _ _ _ _ _ _. .
_ _ _ _ _ _ _ _ __
....
120-.8 GRA
_ _ 468-8lTGRN
.-450-.BBlK/WHT-..
1 ___
444-.8 LT GRN/BlK
.-
"..01
....
........
44O-.80RN
,...
~.
S106
~-
440-.8 ORN
~~
(SEE PAGE 44)
..,..,. ..,..,.
I
i
-_--._ _
.I_______
I
'-'1_ ., - ..,."
~,
. - . . . 450-.B BlK/WHT . . , . " _ _
'"
GRN
.... ..,..,. _
'l1li
_ _ _ _ _ 120_2.0GRA _ _ _ _ _
C118
12065401
8-46
467-.8 DK BLU _
Cl03
12065169
FUEL PUMP
OIL PRESSURE
SENSOR AND
SWITCH
:::::::D
.....
..,..,. . . , . " 453-.8 BlK/RED,. _
482- 8 WHT
INJ-1
. . , . " ..,..,. _
481-1.0RED_
. .,
1 _,...I
GT101
~~
L..--_I___ __::::m___ _
-',
-"' _
-..,..,.
- . ...
--
STEPPER
Cl15
12015798
~.
w....______
C-
__
lI"r"'\\m'~ ~::::
..,..,.
lAC
ACTUATOR
--..,
_ _ .-424-.8TAN/BlK _ _
...
44O-1.00RN
44O-.80RN
"".....111!!11_ _ _ _ _ _ _ 423-.8 WHT _ _ _ _ _ _ _ _ _
o
c
..-..
RPOCOOES
RPO CODES
_ _ _ _ _ _ _ .-439-.8PNK/BLK _ _ _ -
:7i
44O-1.00RN
44O-.B ORN
44O-.80RN
44O-.80RN
--
.....
_ _ _ _ _ _ _ 443-.8LTGRN/WHT _ _ _ _ _ _
_______
...... _ _ _ _ _ _ _
_____
_____
....... _ _ _
rn
. ,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 435-.8GRA _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
..... -
........- - - - - - - - - - - - - - - - - - - 467-.B LT BLU - - - - - - - - - - - - - - - - - - - -. .
~-
450-.B BLK/WHT,. -
.......- - - - - - - - 467-.B LT BLU - - - - - - - - - - -
~-
_465-.80KGRN/WHT _ _ _450
BBLK/WHT~
...
-------------------..
.. -
SYSTEM
ENGINE
GROUND
G100
'~""
~-
... .
III.
Lf - -
."
......
.:~
-'
-~.
r- ,~
- .~
~:~S;N~ ~~
--
..
~ .~
"'~I
-146B-.BLTGRN_~_.illll!l~---..
467-.8 LT BLU
--
-1
. . 441-BLTBLU/wHT_
443-.BLTGRN/WHT.r -
~~ :~~BLK
_,
~_
468-.8 LT GRN
ECM
CONNECTORS
tI
t, I
...
~ _467-.BLTBLU
--~
...,
465-.80KGRN/WHT_
444-.B LT GRN/BLK _
..r _ _ _
I,
_~. . . .~
~ ~
.J
413-.8TAN-"'~
--'-90a~-.8~PPLII
rnn.....
IIIIj~
~J i i
..
' __
CRANK
SIGNAL
(SEE PAGE 40)
__
---,
, r
450-.B BLK/WHT _ _
,.
_
450-.8 BLK/WHT
450-.B BLK/WHT
..
_ 450-.B
BLK/WHT
413-.B T A N _
~ 450-.B BLK/WHT : . .
450-.8 BLK/WHT'
423-.8 WHT
450-.8 BLK/WHT
c
C250
12045575
".
413-.BTAN _ _ _ _ __
o
u
. ._ _ _ _ _ _ 486-.8 BRN _ _ _ _ _ _. . ,. ESC MODULE
.2..
-
(LOWER)
,.
_450-1.0BLK/WHT,..J
450-1.0 BLK/WHT
~ ~
TO SYSTEM
CHECK LAMP
(SEE PAGE 70)
~:::::;B;I::::A:;:jL.J
~~.
~.r_.::::~ ~=...~III
~
~~
-
..
435-.8 GRA
'
,
=
.
(
:
.
,
.
-.
:
:
:
L
r'' .' ' ' ------,,---,...
[illJI....._
12047946
,-
419-.8 BRN/WHT
419-.B
S102
1
-
~"
J~~
"
Gl0l
.-:=.-.....1._.
~ 430-.8 PPLlWHT
.r
, -, - - - - - - - .
I ,
I ~
'- '1",.J. _
r~
j .,
:-
467-.8 LT BLU
':1
.....--.--.,.:",,,,,"
GENERATOR
BRACKET
GROUND
424-.B TAN/BLK
12020107 (UPPER)
8~
,.~ ~ ~
453-.BBLK/REOr
435-.BGRA_~ -
,+---r:II___
120201~8
..,
...
. .- - - - - - - - 46B-.B LTGRN
~-
_
_
_ _ _ 44O-.B ORN _ _ _ _ _ _
::::~H:-:' ~
GT100
42~WHT
453-.8BLK/REO' _
LB4 - ENGINE, 4.3L (262 CIO)

CID)
va
V6 GAS ENGINE, VIN Z
.....,
~ 'L!~ t~ _ ...!!~ :::~~;=
...... _ _ _ _ _ _ _
____
L05 - ENGINE, 5.7L (350 CIO)

CID)
V8 GAS ENGINE, VIN K
r - ...
430-.8PPLlWHT _ _ _ _ _ _ _
424-.8TAN/BLK~
450-.BBLK/WHT
--~---.....~..
~
...... _ _ _ _ _ _ _ 441-.BLTBLU/WHT _ _ _ _ _ _
____
____
. . .- - - - - , ---44O-.80RN _ _ _ _ _ _. . .
44O-.80RN
_ _ _ _ _ _ _ 442-.8LTBLU/BLK
_ _ _ _ 439-1.0PNK/8LKr
. . . . _ _ _ _ _ _ _ 444-.8LTGRN/BLKr _ _ _ _
...... _ _ _ _ _ _ _ _ 120-.8GRA-... _ _ _ _ _ _
......
S104
(SEE PAGE 44)
ow
c:
11--t-:--1.L
~ ~
450-.8 BLK/WHT _
.J
'"
C201
12020043
_ _ _ _ _ _ _ _ _ _ _.490-.8 REO _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .

OUTPUTS - GASOLINE ENGINE WIMAN
W/MAN TRANS
8-47
B-47
.. 439-1.0PNKlBLK _ _
INJ
INJ
7.5 AMP
OXYGEN
OXYGEN
SENSOR
OAMP
~~
MAP SENSOR
(SEE PAGES 44,50)
(!)
co
cb
GT100
SENSOR
. ._ _ _ _ _ 412-.8 PPL
:t
~416
~.
"">oe---t-
r----:i~~",------.416-.8
GRA _
, . ._ _ _ _ _ _ 417-.8 OK BLU _ _ _ _ _ _ _ _ _ _ 417-.8 OK B

417
' - - - - t - 452
'-----"
_ _ _ _ _ _
467-.8 LT B
LU
_ _ _ _ _ _ 467-.8 LT BL
U
cooJ
TEMPERATURE
SENSOR
(SEE PAGE 44)
(.Q;06
. .lIIIr-----::~.:
.
~TN:
~ ~
5
482-.8WHT
~~
'''-_-+468'
IT]
- 1,
,
~l
.-
D12~
CJ 11 452
!ml10 ~~
c:J 9 [IDJ
[IDa ~
@ill7 ~
439,
.. -
417-.8 OK BLU
467-.8 LT BLU _ _ _ _ _ _ _
467-.8 LT BLU
468-.8 LT GRN _ _ _ _ _ _ ,
468-.8LTGRN______
BLK
--
.... --
439-.8 PNKlBLK _
_.J
ECM
CONNECTOR
L.. _ _
--.
S112
(SEE PAGE 52).
a::
C>
J
K
E2J
ClOD
12020184
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 481-1.0 RED' _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
ClOD
12020183
B-48
THROTTLE BODY INJECTION
ow
a::
,,
,,
,,
,,
,,
,,
,,
,,
,,
CL
416-.8 GRA _
:
: _ _
452-.8 BLK _ _ _ _ _ _ _ ,
..
>.::
C>
C250
12045575
r -I~'
~
,----+481
ll.,~
INJECTOR 2
RN
,
,
Ci
INJECTOR 1
~~,
'-
...__- - - - 468-.8 LT GRN
co
LU
S101_ _ _ _ _ _ _ 452-.8 BLK

t;Jr-,,_______ 452-.8 BLK _ .
ClOD
12078090
C251
12047946
412-.8 PPL _ _ _ _ _ _ _ ,
12020107 (UPPER)
12020108 (LOWER)
S100
_ _ _ _ _ _ _ 416-.8 GRA
___
TP
,
,
,
412-.8PPL
C124
12015791
r - - - --
('-_ _ _ _ _ _ _ _ _ _ _ _ _.481-.8 RED
412
. . . ~ . - . - . - ~.- . - . - . - . . 439-1.0
439-1.0PNKlBLK
PNK/BLK I. . . . _
.-.- _
.- .- .-
....a
CIRCUIT WIRE
SIZE
NO.
COLOR
465
1223
1222
422
.8
.8
.8
.8
DK GRN/W HT
YEL/BLK
LTG RN
TAN/BLK
419
.8
BRN/WHT
435
420
.8
.8
GRA
PPL
1226
1225
1224
1229
1228
1230
1231
437
59
.8
.8
.8
.8
.8
.8
.8
.8
.8
RED
DK BLU
PNK
LT BLU/WHT
BLK/RED
DK BLU/WHT
GRA/RED
BRN
DK GRN
CAVITY
DESCRIPTION
CIRCUIT WIRE
SIZE
NO.
COLOR
CAVITY
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12

SOLENOID B DRIVER
SOLENOID A DRIVER
TCC DRIVER
NOT USED
NOT USED
SYSTEM C H EC K LAMP
NOT USED
NOT USED
NOT USED
EVRV SOLENOID
BRAKE SIGNAL
439
450
551
416
417
441
442
444
443
432
1061
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
PNK/BLK
BLK/W HT
TA N/W H T
GRA
DK BLU
LT BLU/W HT
LT BLU/BLK
LT GRN/BLK
LT G RN/W HT
LTG RN
O RN/BLK
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
NOT USED
PRESSURE SW ITCH MANIFOLD C
PRESSURE SW ITCH MANIFOLD B
PRESSURE SW ITCH MANIFOLD A
NOT USED
NOT USED
FORCE M OTOR LOW
FORCE M OTOR HIGH
INPUT SPEED HIGH
INPUT SPEED LOW
DRAC MODULE
AIR CO NDITIO NING (L05)
413
412
468
467
.8
.8
.8
.8
TAN
PPL
DK GRN
DK BLU
440
455
452
474
496
451
120
.8
.8
.8
.8
.8
.8
.8
ORN
PPL
BLK
GRA
DK BLU
W HT/BLK
TAN/W HT
D1
D2
D3
D4
D5
D6
D7
W HT
TAN/BLK
BLK/RED
PPL/WHT
BLK/YEL
YEL
D8
D9
D10
D11
D12
D13
D14
D15
D16
POWERTRAIN CONTROL MODULE CO NNECTOR

423
424
453
430
1227
410
.8
.8
.8
.8
.8
.8
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
DESCRIPTION
12V IGNITION FUSED
SYSTEM GRO UND
SYSTEM GROUND
5V SENSOR REFERENCE
TPS
STEPPER CO IL A HIGH
STEPPER COIL A LOW
STEPPER CO IL B LOW
STEPPER CO IL B HIGH
MAP
SERIAL DATA
NO T USED
OXYGEN SENSOR GRO UND
OXYGEN SENSOR
INJECTOR B (2) DRIVER
INJECTOR A (1) DRIVER
12V BATTERY FUSED
SENSOR GRO UND
SENSOR GROUND
5V SENSOR REFERENCE
KN O C K SIGNAL
ALDL
ELECTRIC FUEL PUMP FEED
FUSED
NO T USED
NO T USED
NO T USED
HEI SPARK TIM ING
HEI BYPASS
DISTRIBUTOR REFERENCE LOW
DISTRIBUTOR REFERENCE HIGH
TRANSM ISSIO N TEMPERATURE
COOLANT TEMPERATURE
POWERTRAIN CONTROL MODULE CO NNECTO R
POWERTRAIN CONTROL MODULE (PCM) PINOUTS
B-
439-.8 PNK/BLK
440-.8 ORN
I 450-1,0 BLK/WHT w
r 551-,8TAN/WHTr -
-II-
417-.8 DK BLU
-n-
416-.8 GRA
:n:
I 496-.S DK BLU
432-.8 LT GRN
474-.8 GRA
-II-
496-.8 DK BLU
ii
455-.8 BLK
455-.S PPL
452-.8 BLK
1227-.8 BLK/YEL
410-.8 YEL
I 410-.8 YEL
412-.8 PPL
1226-.8 RED
1230-.8 DK BLU/WHT I
ESC KNOCK
SENSOR
1225-. SDK BLU
COOLANT
TEMPERATURE
SENSOR
1231-.8 GRA/RED
1224-.8 PNK
C117
12015375
412-.8 PPL
OXYGEN
SENSOR
INPUT
SPEED
SENSOR
0:
1230-.8 DK BLU/WHT !
1231-.8 GRA/RED
Jk
C173
12078084
B-50
POWERTRAIN CONTROL MODULE (PCM)

INPUTS - GASOLINE ENGINE W/AUTO TRANS
ALTERNATOR
BRACKET
G101
TRANSMISSION
CONNECTOR
ENGINE
GROUND
G100
F439-.8 PNK/BLK ,
RPO CODES
I 440- 8 ORN S f l
1450-1.0 BLK/WHT W
S102
(SEE PAGE 17)
w m
J M f
450-.8 BLK/WHT '
I 551-.0 TAN/WHT W
L05 - ENGINE, 5.7L (350 CID) V8 GAS ENGINE, VIN E
A 450-.8 BLK/WHT ^
^ 5 5 1 - .8 T A N /W H T -
I 417-.8 DK BLU I
I 416-.8 GRA |
416-.8 GRA
I 432-.0 LT GRN
I 474-.B GRA I
474-.8 G RA w m
S104
(SEE PAGE 52)
417-.8 DK BLU
416-.8 GRA
I 432-.8 LT GRN J
I 496-.8 DK BLU I
496-.8 DK BLU
451-.8 W HT/BLK
440-.8 ORN
I 455-.8 PPL I
455-.S PPL
I 452-.8 BLK
452-.S BLK
I12 2 7 -.8 BLK/YEL I
1227-.8 BLK/YEL
I 410-.8 YEL |
I 410-.8 YEL
I 412-.8 PPL I
412-.8 PPL
1226-.8 RED I
1226-.8 RED
I 1230-.8 DK BLU/WHT
450-1.0 BLK/WHT
417-.8 DK BLU
^ 123 0-.8D K BLU/WHT V
I 1225-.8 DK BLU I
1231-.8 GRA/RED I
1231 *.8 GRA/RED
i 1224-.8 PNK
1224-.8 p n k
413-.8 PPL
413-.8 PPL
1225-.8 DK BLU
"
413-.8 PPL
439-.8 PNK/BLK W
rf
420
440
439
806
39
14Qf
120
3>i f
r
3
436
35
93
97
422
91
92
422
451
436
C
B
451
450
J
ALDL
C100
12020183
-I A
DRAC
(SEE PAGE 64)
C201
12020043
PROVISIONS FOR
AIR CONDITIONING

INPUTS - GASOLINE ENGINE W/AUTO TRANS
B-51
439-1.0 PNK/BLK
ECM-BAT
10 AMP
480-1.0 ORN
450-.8 BLK/WHT
I 439-1.0 PNK/BLK tW
IDLE AIR
CONTORL
ACTUATOR
IDLE AIR
CONTROL
ACTUATOR
0-19)
(LB4/L05)
EVRV
i | v
(L05/L19)
V
453-,8 BLK/RED *
WW
430-.8 PPL/WHT
j a
W
^
ja m 424-.S ta n /i
430-.8 PPIVWHT
M I
H B 4 3 5 -.8 G R A ^ H | B B | B B k
EGR
(SEE PAGE 46)
* * 453-,8 BLK/RED
1229-.8 LT BLU/WHT
^ 4 3 5 - .8 GRA
465-.8 DK GRN/WHT
I
I
"
Tz
..
ELECTRONIC
SPARK
TIMING
n.
i H
| B
^k 1^ -------------- ^"1 22 8 -8 BLK/RED *

5
I
i ^ 'H
I i
i | | n
1 II
- I
_
120-.8 TAN/WHT
^ rn I >? 422-.8 TAN/BLK V
l l k M
l"
4 S
7 . . 8
DK BLI
I' | ! ^
H 4 6 B -.8 D K Q R N
r - H
. CO w
A r
.
J . l, .
i l l ? ohm
0
5
I 3
hm
r k B T 4 6 5 - . 8 D K G R N /W H T
L
r J
------ ------ -
<422-.8 TAN/BLK
467-.8 DK BLU
'
I 468-.S DK GRN I
-------------- r r z (
LhtfcI
| 4 4 4 -.8 L T G R N /B L K
INJ-2
| a | M 1 2 2 2 -.8 LT GRN
g k -
-A U
i r i t i
INJ-1
H 1223-.8 YEL/BLK H |
'
FUEL PUMP
OIL PRESS
SWITCH
FUEL PUMP
RELAY
oioa
Jtmm
^m r
C103
12052287
120-2.0 GRA
440-. 8 ORN M
B-52

OUTPUTS - GASOLINE ENGINE W/AUTO TRANS
C100
12020183
ALTERNATOR
G100
BRACKET
ENGINE
GROUND G101 GROUND
RPO CODES
1481-1.0 RED
LB4 - ENGINE, 4.3L (262 CID) V6 GAS ENGINE, VIN Z
19-.8 BRN/WHT

OUTPUTS - GASOLINE ENGINE W/AUTO TRANS
B-53
CIRCUIT WIRE
SIZE
NO.
COLOR
1224
1225
1226
1223
1222
451
.8
.8
.8
.8
.8
.8
PNK
DK BLU
RED
YEL7BLK
LTG R N
WHT/BLK
440
.8
ORN
420
422
1234
1061
1233
1232
.8
.8
.8
.8
.8
.8
PPIVBLK
TAN/BLK
GRA/RED
ORN/BLK
DK GRN/YEL
LT BLU
CAVITY
DESCRIPTION
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
NO T USED
NOT USED
SOLENOID B DRIVER
SOLENOID A DRIVER
ALDL
NOT USED
NOT USED
NOT USED
12V BATTERY FUSED
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
NOT USED
NOT USED
NOT USED
BRAKE SIGNAL
TCC
NOT USED
NOT USED
NO T USED
SERIAL DATA
OUTPUT SPEED SENSOR LOW
OUTPUT SPEED SENSOR HIGH
CIRCUIT WIRE
SIZE
NO.
COLOR
450
551
452
416
.8
.8
.8
.8
BLK/WHT
TA N/W H T
BLK
GRA
1229
439
.8
.8
LT BLU/WHT
PNK/BLK
437
1231
1230
.8
.8
.8
BRN
DK BLU/W HT
GRA/RED
121
476
417
.8
.8
.8
W HT
BLK/PNK
DK BLU
1227
433
.8
.8
BLK/YEL
GRA/BLK
1229
.8
LT BLU/WHT
TRANSMISSION CONTROL MODULE CONNECTOR
CAVITY
DESCRIPTION
SYSTEM GROUND
SYSTEM GROUND
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
SENSOR GROUND
5V SENSOR REFERENCE
NO T USED
NO T USED
NO T USED
NO T USED
NOT USED
NO T USED
NO T USED
NO T USED
NOT USED
NOT USED
FORCE M OTOR HIGH
12V IGNITION FUSED
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
NOT USED
DRAC MODULE
INPUT SPEED LOW
INPUT SPEED HIGH
NO T USED
ENGINE SPEED
SENSOR GROUND
TPS
NO T USED
NOT USED
NO T USED
NO T USED
TRANSM ISSIO N TEMPERATURE
MAP
NO T USED
FORCE MOTOR HIGH
TRANSM ISSION CO NTRO L MODULE CO NNECTO R
TRANSMISSION CONTROL MODULE (TCM) - PINOUTS

6.2L V8 HD DIESEL ENGINE W/HD AUTO TRANS AND OVERDRIVE
B-55
Y M A / v m /v w v /
^
HOT A T A L L TIMES <
^VVWVWWWN
ECM-BAT
10 AMP
W VW W W W W VV
yvw w vw w
>
HOT IN STAR T >
Za /WVWWV^
A.
ECM-CRNK y
10 AMP
I 250-1.0 BRN I
I 250-1.0 BRN.I
HOT IN STAR T OR RUN ^
>VVVVVVWV\WvÂ
TRANS
1 0 AMP
^ a a r
i
TP SENSOR
3 f
1223-.8 YEL/BLK
250-1.0 BRN A M
250- 1.0 b r n
439-.S p n k / b l k v
1440-1.0 ORN I
476
417
jm
476-.S b
lk /p n k ^
BLK/PNK
I 417-.8 DK BLU
1416-.8 GRA
I 455-.S PPL
1433-.S GRA/BLK m
l416-.8GRA'**i^
I
S1 i l k
MAP
SENSOR
"
M ^ H 4 1 6 -.8 G R A
H IH H
-1231
INPUT
SPEED
SENSOR
1230-.8 DK BLU/WHT ,
C173
12078084
1231-.8 G R A / R E D ^
452~ )
A
452-.S BLK I
It
B
ENGINE
SPEED
SENSOR
B-56
121-.8 W H T l
C126
12015792
121
TRANSMISSION CONTROL MODULE (TCM)

ENGINE
GROUND
G100
CIRCUIT OPERATION
W AIT INDICATOR DOES NOT FLASH OR FLASHES FOR THE INCORRECT AMOUNT OF TIME W HEN

wire from Junction Block. The relay is operated by a
Solid-State Controller. The Controller responds to engine
temperature and also to an Ignition Switch Start Input.
After the initial time period the relay will be de-energized

for five seconds then will cycle ON/OFF for approximately
10 seconds.
ON/OFF after the Ignition Switch is returned to RUN.
stops.
TEST
RESULT

controller connector C190 to
ground.
Test lamp lights.
GO to step 2.

2.
Connect test lamp from PNK (3)

wire at glow plug controller
Test lamp lights.
GO to step 3.

(3) wire from glow plug controller
connector C128 to ground terminal
G102.
Connect test lamp from PNK (3)

wire to BLK (150) wire at glow
plug controller connector C128.
Test lamp lights.
GO to step 4.

Connect test lamp from PPL (906)

connector C128 to ground. Move
ignition switch to START position.
Test lamp lights.
GO to step 5.

starter motor.
Test lamp lights.
GO to step 6.
Disconnect glow plug controller

polarity ohmmeter, check
continutity between ORN (503)
and BLK (150) wires.
GO to step 7.

(503) wires from glow plug
controller connector C128 to splice
S116.
Reconnect glow plug controller

connector. Connect test lamp from
ORN (503) and ORN/BLK (509)
wires at glow plug controller
connector C191 to ground. Turn
ignition switch momentarily to
START and then release to RUN
position.

goes off.
GO to step 8.


(503) and ORN/BLK (509) wires
from glow plug to glow plug
controller connector C191.

more glow plugs.

lamp did not light.
3.
PRELIMINARY CHECKS:
A check of the glow plug system should be
performed before doing diagnostic procedures.
ignition switch to RUN. The WAIT indicator should light.
After approximately 10 seconds, the WAIT indicator must
out.

START and return to RUN position. The WAIT indicator
out.
ACTION
4.
With engine at normal operating temperature, turn

ignition switch to RUN. The WAIT indicator should flash.
5.
6.
7.
8.
Place ignition switch to OFF

ORN (503) and ORN/BLK (509)
wires at glow plug controller
Remove all connectors from glow

GLOW PLUGS
B-59
I 1-32.0 BLK
a: eg
O 0)
ci p
1
LEFT BANK
GLOW PLUGS
GROUND
G113
B-60
SHEET
METAL
GROUND
G111
GLOW PLUGS
I
RIGHT BANK
GLOW PLUGS
GROUND
G114

6-5.0 PPL I
2-3.0 RED I
505-.5 RST I
(FUSIBLE LINK)
6-5.0 P P L !
RPO CODES
2-8.0 RED
*z
CL
C190
CLUTCH START SW
(MTS ONLY)
(SEE PAGE 41)
GLOW PLUG
CONTROLLER
I 509-5.0 ORN/BLK
S114
(SEE PAGES 19, 20)
I 503-5.0 ORN
503-1.0 ORN
C299
12010966
l/P
S205
ENGINE
3
CD
0
1
3-3.0 PNK I
508
:
503
450
3
68
2
<
430
2
:
24
6
35
i
94
508
7
15
593
14
29
821
93
11
12
C100
12020184
1505-1.0 YEL1
ENGINE
GROUND
G102
6-5.0 PPL
2-5.0 RED
GLOW PLUGS
B-61
WATER IN FUEL INDICATOR LIGHTS WITH NO WATER IN FUEL
CIRCUIT OPERATION
TEST
therm ostatic switch. The switch opens or closes, to turn
the fuel.
The Diesel Fuel Filter System combines six functions

1. It heats diesel fuel to prevent wax-plugging of the
filter;
2. It combines very small droplets of water in the fuel
into larger drops and separates the water from the
fuel;
3. It filters the diesel fuel;
4. It detects an excessive pressure drop indicating filter
plugging; (Vacuum Switch)
5. It detects the presence of excess water in the fuel;
and
6. It provides a means to drain the water it has
separated.

light the SERVICE FUEL FILTER Indicator.
A times delay circuit in the Water In Fuel Module
grounds the Indicator bulb briefly to test the bulb each
DIAGNOSIS - DIESEL ENGINE FUEL CONTROLS

FUEL HEATER DOES NOT O P E R A TE _____________
2.
ACTION
RESULT
Disconnect fuel heater

ignition switch to RUN
position. Connect voltmeter
from PNK/BLK (39) wire at fuel
heater connector C132 to
ground.
Battery voltage.
GO to step 2.
No voltage.
CHECK condition of ALT fuse. If

open in PNK/BLK (39) from fuel
heater connector C132 to fuse
block.

C132.
Battery voltage.
REPLACE fuel heater.
No voltage.

(150) wire from fuel heater
connector to ground G102.
B-62
FUEL CONTROLS
DIESEL ENGINE
ACTION
Water in fuel indicator stays

on.

YEL/BLK (508) wire between
C130 and water in fuel
indicator.
Water in fuel indicator goes

out.
REPLACE water in fuel sensor.
WATER IN FUEL INDICATOR DOES NOT LIGHT BRIEFLY WITH

____________ IGNITION SWITCH TURNED TO RUN
TEST
RESULT
ACTION
1. Disconnect water in fuel

sensor connector C130 and
place ignition switch in RUN.
Connect a voltmeter from
PNK/BLK (39) wire at water in
fuel sensor connector C 130 to
ground.
Battery voltage.
GO to step 2.
No voltage.

open in PNK/BLK (39) wire from
C130 to fuse block.
2.
Battery voltage.
GO to step 3.
No voltage.

(150) wire from water in fuel
sensor connector C 130 to
ground G102.
Battery voltage.
No voltage.
CHECK water in fuel lamp. If

lamp is good, LOCATE and REPAIR
open in YEL/BLK (508) wire
between water in fuel sensor
connector C130 and water in
fuel indicator.
The Fuel Heater is operated by a built-in thermostatic

switch. When the switch is closed, battery voltage is
applied to the heater from the ALT Fuse.
An electric fuel pum p delivers diesel fuel from the tank

1.

position. Disconnect water in
fuel sensor connector C130.

reservoir in the filter. When fuel flows from the Fuel Filter
Assembly to the injection pump, it is clean and free of
water.
The Fuel Filter Assembly consists of the following

main parts: Fuel Heater, the Water In Fuel Sensor, the
Fuel Pressure Switch, and a Filter. The Filter contains
the "coalescer" (the device that combines small droplets
TEST
1.
RESULT
3.

PNK/BLK (39) to BLK (150) wire
at water in fuel sensor
connector C130.

YEL/BLK (508) wire at water in
fuel sensor connect or C130 to
ground.
ALT
20 AMP
I 39-. 8 PNK/BLK
FAST IDLE
SOLENOID
C135
12004267
39-.8 PNK/BLK
GENERATOR
(SEE PAGE 41)
WATER IN
FUEL SENSOR
FUEL
HEATER
508-.8 YEL
WATER IN
FUEL LAMP
(SEE PAGE 70;
I ----------------
FUEL SHUT
OFF VALVE
ENGINE
GROUND
G102
S208
(SEE PAGE 70)
3 9 ,8 PNK/BLK *
l/P CLUSTER
(SEE PAGE 69)
FUEL CONTROLS
DIESEL ENGINE
RPO CODES
M Tt - AUTO TRANS, HD, 4-SPD., WITH OVERDRIVE
ECM-CRNK
10 AMP
$
I 439-1.0 PNK/BLK I
S203
CO
DRAC
D
_i
O
_/
<
z
o
B
1
HiHl
11226 2
11223!
Ii23a ' 3
1224) 4
14 2 2 1
IZZI
5
o
Ui
uu
o
X
>
?!
(SEE PAGE 18)
1222'
ECM/PCM
CONNECTOR
5
6
C251
12052175
n
rrm
(l2 2 8
fisa 9 CZ3
1123-f 10 C=J
< 4 3 7 ] 11 LbJ
CZI 12 [4 2 0 ]
11229
x
tU
>
GT100
437-.8 BRN
12020107 (UPPER)
12020108 (LOWER)
1233-.8 DK GRN/YEL
vss
ENGINE
150-.8 BLK
(MT8)
439-.S PNK/BLK
1232-.8 LT BLU
824-.8 LT BLU/BLK
W/YEL
1233-.8 DK GRN/YEL
1232-.8 LT BLU
OUTPUT
SPEED
SENSOR
(MT1)
64
" i
mS
j:
T
a r
1233-.8 DK GRN/YEL I
____________ i
12020183
1232-.8 LT B L U ^ ^ ^ M M B M
DIGITAL RATIO ADAPTER CONTROLLER (DRAC)

GASOLINE ENGINES W/MAN OR AUTO TRANS AND DIESEL ENGINES W/AUTO TRANS
l/P
GROUND
G200
ALT
20 AMP
39-.8 PNK/BLK
39-.S PNK/BLK
\
\
I
f
_\_L
ll
M:
t
I!
30
24
18
19
68
3.
1233
505
), r
DRAC
11
VEHICLE SPEED SIGNAL CLUSTER

9
15
14
S24-.8 LT BLU/BLK
12
29
1232 VEHICLE SPEED INPUT
1232-.8 LT BLU
CC
I _______
C100
12020184
39>.8 PNK/BLK V
150-.8 BLK
39
12 VOLT (IGNITION)
150
GROUND
1233 VEHICLE SPEED SIGNAL INPUT
SPEEDOMETER
(SEE PAGE 71)
C292
12066130
S203
(SEE PAGE 19)
VSS
1233-.8 DK GRN/YEL 1232-.8 LT BLU
*1232
C185
12020600
GE3
C100
12020183
l/P
GROUND
G200

DIESEL ENGINE W/MAN TRANS
B-65
CIRCUIT OPERATION
TEMPERATURE GAGE
PRELIMINARY CHECKS:
Check condition of GAUGES and INST LPS fuses. If
fuses are in good condition use the following diagnostic
procedures.
Battery voltage is applied to the Park Brake Warning

Lamp when the Ignition Switch is in RUN or START. The
Park Brake Switch provides a ground when the Park
Brake is applied.
The Park Brake Warning Lamp
illuminates to alert the driver.

127c (260F) (hot coolant) and its resistance becomes
greater at lower temperatures. It is approximately 1400
temperature increases. This m oves the pointer.
SERVICE BRAKES WARNING LAMP
LOW COOLANT INDICATOR (DIESEL)
Battery voltage is applied to the Service Brakes

Warning Lamp when the Ignition Switch is in RUN or
START. The Brake Pressure Switch closes to provide a
ground and illuminate the lamp when there is a loss of
brake fluid pressure in one of the two brake systems.
This could be caused by a leak in one of the brake lines.

The operation of an individual Indicator is described

along with its circuit. Refer to the schematic and text for
the circuit that is indicated below each of the Indicators.
PARK BRAKE WARNING LAMP
FUEL GAGE
scale.

and closes. It has a very high resistance to ground,
more than 50,000 ohms, when the engine coolant level
is low. This causes the Low Coolant Module to light the
Low Coolant Indicator. With more of the Sensor covered
by coolant, its resistance decreases. When the fluid level
is good, the resistance will be less than 10,000 ohms.
With the Sensor resistance between 10,000 and 50,000
ohms, the Sensor is partly covered and the fluid is not
low enough to cause the warning to be displayed.
FUEL GAGE INDICATES FULL OR BEYOND AT ALL TIMES

TEST
1.
2.

Gage.
TEST
1.
B-66
INSTRUMENT PANEL

(30) wire between fuel pump
connector C400 and fuel gage. If
no open is found, REPLACE fuel
gage-
GO to step 2.

(150) wire between fuel pump
connector C400 and ground G400.
If no open is found, REPLACE fuel
pump.
REPAIR/REPLACE fuel pump.
Disconnect fuel pump and place

RESULT
Refer to Light Duty Truck Fuel, Driveability and

Emissions Service Manual, Section 3.
LOCATE and REPAIR an open in

PNK (30) wire between fuel pump
connector C400 and fuel gage. If
no open is found, REPLACE fuel
gage.
FUEL GAUGE IS INACCURATE

TEST
WATER IN FUEL WARNING INDICATOR

Refer to Fuel Controls (Diesel), Page 62
1.
Refer to Glow Plugs (Diesel), Page 59
RH/LH TURN SIGNAL INDICATORS

Refer to Front Exterior Lamps, Page 33
Refer to Headlamps, Page 22
Disconnect fuel pump connector

C400. Connect one RED lead of J
34029-A Multimeter to PNK (30)
wire and other to ground. Set
resistance dials to 0 ohms and
then to 90 ohms. Fuel gage
should indicate empty and then
full. (Allow time for gage to reach
full due to anti-slosh device.)
RESULT
ACTION
CHECK BLK (150) wire for high

resistance. If wire is good,
Gage does not respond correctly.
CHECK for high resistance in PNK

(30) wire. If wire is good, REPLACE
fuel gage.
TEMPERATURE INDICATOR STAYS ON AT ALL TIMES WITH IGNITION SWITCH IN RUN

TEST
RESULT
ACTION
DRL INDICATOR
Refer to Headlamps with Canadian Daytime Running
Lamps, Page 25
ACTION
CHECK ENGINE (GASOLINE) INDICATOR
HIGH BEAM INDICATOR

current flow through coils. The magnetic fields of the
Connect fused jumper form PNK

(30) wire to BLK (150) wire at fuel
pump connector C400.
ACTION
GLOW PLUG INDICATOR

OIL PRESSURE GAGE

C400 and place ignition switch to
from PNK (30) wire at fuel pump
RESULT
1.

C106 (Diesel) and place ignition
switch to RUN. Observe
temperature indicator.
Indicator stays on.
LOCATE and REPAIR short in DK

REPLACE instrument cluster.
Indicator goes off.

TEST
RESULT
1. Disconnect temperature sender

C106 (Diesel). Ground the OK
sender connector C108 (Gasoline)
or C106 (Diesel).
ACTION
Temperature gage indicates hot.
REPAIR/REPLACE temperature
sender.

indicate hot.
lOCATE and REPAIR open in DK

GRN (35) wire between
temperature sender connector
C108 (Gasoline) or C106 (Diesel)
and temperature gage. If wire is
good, REPLACE temperature
gage.

TEST
RESULT

C106 (Diesel). Connect RED lead
from J 34029-A Multimeter to DK
GRN (35) wire and other lead to
ground. Adjust resistance dials to
1400 ohms and then to 55 ohms.
cold then hot.
ACTION
Gage indicate correctly.
lOCATE and REPAIR open in DK

GRN (35) wire between
C108 (Gasoline) or C1 06 (Diesel)
and temperature gage. If wire is
good, REPLACE temperature
gage.

TEST
RESULT

switch to RUN.
ACTION

indicate cold.
lOCATE and REPAIR an open in

OK GRN (35) wire between
C108 (Gasoline) and 106 (Diesel)
and temperature gage. If no open
is found, PERFORM diagnostic
"Temperature Gage Is Not
Accurate.
TEST
Disconnect oil pressure sender
switch to RUN. Connect a fused
jumper from TAN (31) wire at oil
pressure sender connector C118
to ground.
RESULT
Oil pressure gage indicates low
pressure or indicator lights.
1. Disconnect oil pressure sender

connector C118. Connect one
RED lead of J 34029-A Multimeter
to TAN (31) wire at oil pressure
sender connector C118 and other
lead to ground. Set resistance
dials to 0 ohms and then to 90
ohms. The oil pressure gage
should indicate low pressure and
then high pressure.
RESULT
ACTION

correctly.
Oil pressure gage does not

indicate correctly.
lOCATE and REPAIR open in TAN

(31) wire between oil pressure
sender connector C118 and oil
pressure gage. If wire is good,
Oil pressure gage indicates high

pressure or indicator does not
light.
lOCATE and REPAIR open in

TAN (31) wire and bUlb. If wire and
bulb are good, REPLACE oil
pressure gage.
OIL PRESSURE GAGE INDICATES LOW PRESSURE WHEN OIL PRESSURE IS GOOD
RESULT
TEST
switch to RUN.
ACTION

pressure or indicator light goes
out.
Oil pressure gage indicates no or

low pressure or indicator light
stays on.
lOCATE and REPAIR open in TAN

(31) wire between oil pressure
sender connector C118 and oil
pressure gage. If wire is good,
LOW COOLANT INDICATOR DOES NOT LIGHT WITH COOLANT LEVEL LOW (DIESEL ONLy)
RESULT
TEST
ACTION
1. Disconnect low coolant warning

switch connector C150 and place
ignition switch to RUN. Observe
low coolant indicator light.
low coolant indicator lights.
REPLACE low coolant warning

switch.

light.
GO to step 2.

module connector C236. Connect
at low coolant warning module
Battery voltage.
GO to step 3.
No voltage.
lOCATE and REPAIR open in

BlK/ORN (550) wire. If no open is
found, CHECK condition of
GAUGES fuse.
3. Connect voltmeter from BlK/ORN

(550) wire to BlK (150) wire at low
coolant warning module connector
C236.
Battery voltage.
GO to step 4.
No voltage.
lOCATE and REPAIR open in BlK

(150) wire between low coolant
warning module connector C236
and ground G200.
4. Connect voltmeter from GRA (69)

wire at low coolant warning
ground.
Battery Voltage.
GO to step 5.
No voltage.
lOCATE and REPAIR open or

short to ground in GRA (69) wire
from low coolant warning module
connector C236 to low coolant
warning lamp.
5. Connect voltmeter from BlK/ORN

(550) wire to YEL/BlK (68) at low
C236.
Battery Voltage.

VEL/BlK (68) wire from low coolant
warning module connector C236 to
low coolant warning switch
connector C1 50.
No voltage.

module.
OIL PRESSURE GAGE IS NOT ACCURATE

TEST
ACTION
INSTRUMENT PANEL
8-67
TEST
Connect a fused jumper from low
coolant warning switch connector
C150 to ground. Place ignition
switch to RUN and observe low
8-68
INSTRUMENT PANEL
RESULT
ACTION

YELlBLK (68) wire. If wire is good,
under symptom "Low Coolant
Coolant Level Low."
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
ILLUM
ILLUM
ILLUM
ILLUM
ILLUM
ILIUM
ILLUM
-150
r------f---,
,CANADIAN
~:;
HIGH
BEAM
LEFT
TURN
(....
f--
RIGHT
14
TURN
11
~~~II~~Er-~v~
50
:
,LAMP
150
1,5
593:
:
'I
L _ _ _ _ _ _ _ _ .J
SERVICE
TRANSMISSION
(629W/DRL)
G--:[)-
1234
r-
508
'f-""'"
WATER
IN
FUEL
(DIESEL
ONLy)
39
39
39
t--
f--
419
68
-'-
LOW
COOLANT
'-~
SERVICE
ENGINE
SOON
SERVICE
BRAKE
PARK
BRAKE
GLOW
PLUG
(DIESEL
ONLY)
SPEEDOMETER
VOLT
/,
..--~------------~~----------------~---------------t----------~--+-t1~
.~
c::::
"'" g
p
= .",
~.
.~
_30 --_IHtt_IIfft..
.=
824 - ......__;t+t-.:iS ....
39 --...t-i=:::::ttt-e",
'"
- F==
F== .M .."'.
~ ..
F=
TEMP
C205
12040746
508 -
68-----~
:<S '" .;j'i-"",*~-!iiJ7---+-""'"
.~ CDO
~fF=HI-15O----I--.J
- ~
_-+----+--39
"
OIL
FUEL
_=
9:==t===t:S~r'
... :::; '"

co"'--+tF=H-41~1
.l!l
15O - _ ~ .~ ~
--------+---------__11_--------+---__1t--+--+33
~8
~ ~~~--~--~3---__11_---_+~
O~ ~.
-----35--~--~1t_e::::
:::.
r--
31
_~1_--15O
'"
~
~. F
~
~
~fF=I-fI-15O - - - f - - - - '
CDe..fIfF=I-fI-15 ----1----""1
---------~~--------+----~I__+--+-i_llro29--~E:~~~~~~;~
... ~::11~14-----1~
1""'"1234
co
,.....
l\.""t" JJ
'-----'\....::J....r="\"-.......-.J
'-..
INSTRUMENT PANEL
8-69
B-69
W 'A W W W W W V /
% HOT IN STAR T O R RUN <
GAUGES
20 AMP
m vw vw w vm
ALT
20 AMP L
_______
39-.8 PNK/BLK 1
I 550-.8 BLK/ORN |
FROM SWITCH
TO LAMP
GROUND
-1 5 0
IGNITION
-5 5 0
LOW COOLANT
WARNING
MODULE
LOW COOLANT
WARNING
SENSOR
PARK
BRAKE
SWITCH
(DIESEL ONLY)
(CLOSED WHEN
PARK BRAKE
IS APPLIED)
(DIESEL ONLY)
H I 5 5 0 - . 8 BLK/ORN
68-.S YEL/BLK
508-.8 YEL/BLK a m
508
120
: 450
111
68
31
439
35
2
: 440
6
906
| 120
[C
n ,7
505
30
24
18
19
11
12
15
593
14
29
CT
l/P CLUSTER
CONNECTOR
GLOW PLUGS ]
(SEE PAGE 61)
(SEE PAGE 69)
PCM
(SEE PAGE 53) 1
ENGINE
BRAKE PRESSURE
WARNING SWITCH
(SEE PAGE 74)
68-. 8 YEL7BLK
1234-.8 GRA/RED
RH TURN SIGNAL
(SEE PAGE 32)
TCM
(SEE PAGE 57)
LH TURN SIGNAL
(SEE PAGE 32)
WATER
IN FUEL
SENSOR
I 508-.8 YEL/BLK I
(DIESEL ONLY)
C205
12040744
C130
12015793
B-70
INDICATOR LAMPS
~
GROUND
G200
HEADLAMP
DIMMER SWITCH
(SEE PAGE 23)
HOT IN START
OR RUN
ALT
I
20 AMP
_______
39*.8 PNK/BLK I
ENGINE
TEMPERATURE
COOLANT
SWITCH
TEMPERATURE
CLOSES W HEN ENGINE
TEMPERATURE EXCEEDS
OIL PRESSURE
SENSOR
(DIESEL)
FUEL PUMP
OIL PRESSURE
SENSOR & SWITCH
FUEL PUMP
260F
REAR BODY
J CONNECTOR
k
30-.5 PPL
31-.5 TAN
35-.5 DK GRN
FRAME
GROUND
CO)
_
,/p
GROUND
G200
INSTRUMENT PANEL GAGES
B-71
PANEL DIMMER
SWITCH
A
"S i
9 [1 5 0 (1 5 6 44
INST LPS
5 AMPS
I T
44-1.0 DK G R N *
PROVISIONS FOR
DOME LAMPS
(SEE PAGE 38)
I1 5 6 -.8 WHT
i 8-.5 GRA
zi
q
IJ
m
o
9 n
d>
TURN
SIGNAL
SWITCH
8-.5 GRA I
44
LIGHT
SWITCH
A
39
*
30
,s .
150-
DOME
I
OFF
156
l/P CLUSTER
CONNECTOR
(SEE PAGE 69)
CIRCUIT
BREAKER'
25 AMP
----/ I
150
824
419
39
33
11,1
|1 5 0 -.8 B L K |
f _
35
HEAD
40-
150
'PARK
31
OFF
1S0
' PARK
15
I':
HEAD
14
.150
11
S203
(SEEPAG E 18)
LIGHT'
SWITCH
150-3.0 BLK I
l/P
GROUND
G200
B-72
ALARM W ILL NOT SOUND
CIRCUIT OPERATION
TEST
Vehicles equipped with the Hydro-Boost Brake system
have an optional warning harness that plugs into the l/P
harness. Refer to Section 5A1 of the 1991 R/V, P Light
Truck Service Manual for further description and
operation of the Hydro-Boost System.
1.
DIAGNOSIS - BRAKE WARNING SYSTEM
2.
PRELIMINARY CHECKS:
1.
2.
3.
3.
Check condition of GAUGES fuse. Replace if

needed.
Place Ignition Switch in RUN.
For vehicles equipped with Hydro-Boost Brake
system, verify hydraulics as described in Section

5A1 of the 1991 R/V, P Light Truck Service
Manual. If alarm continues to malfunction, use
the following procedures.
BRAKE INDICATOR REMAINS ON WITH IGNITION SWITCH IN RUN AND PARK BRAKE OFF
TEST
1.
2.

connector C204.

RESULT
ACTION

out.
GO to step 2.

corrected, REPLACE park brake
switch.

out.

ground in BLK (111) wire between
brake pressure switch connector
C105 and indicator lamp.
4.
RESULT
ACTION

PNK/BLK (39) wire at alarm
Test lamp lights.
GO to step 2.

PNK/BLK (39) wire between
alarm connector C217 and fuse
block.
Connect test jum per from BLK
Alarm sounds.
GO to step 3.
C217 to ground.
Alarm does not sound.
REPLACE alarm.
Connect test jum per from BLK

(11) wire at delay module
Alarm sounds.
GO to step 4.

(11) wire between alarm
connector C217 and delay
Connect test jum per from TAN

(966) wire at hydro-boost
pressure switch connector
C148 to ground.
Alarm sounds.
REFER to Section 5A1 of the

1991 R/V, P Light Truck Service
Manual.

(966) wire between hydro-boost
pressure switch connector C148
and delay module connector
C216. If no open is found,
REPLACE delay module.
ALARM WILL NOT SHUT OFF

TEST
1.
CHECK for a possible leak or loss

of brake fluid.
2.
3.

warning switch connector
C105.
Disconnect delay module
connector C216.
Disconnect hydro-boost
TAN (996) wire at hydro-boost
C148 to positive battery
terminal.
RESULT
ACTION
Alarm stops.
GO to step 2.
Alarm continues to sound.
CHECK for possible leak or loss

of fluid in the brake system.
Test lamp lights.
GO to step 3.

ground in BLK (11) wire between
delay module connector C216
and alarm connector C217.
Alarm continues to sound.

ground in TAN (996) wire
between hydro-boost pressure
delay module connector C216.
If no short is found, REFER to
Section 5A1 of the 1991 R/V, P
Alarm stops.
REPLACE delay module.

SCHOOL BUS
B-73
C218
12004888
~BA~
_ _ _ 39-.8PNK/BLK_ -
- -
I
L I
[iJpUJ
lEI 0
S
1.5 OHM
RESISTOR
[iJ~ill
lID lID 00
rID lID [ru 0 ill

ACC
GAUGES
u0
ALARM
GAUGES
20 AMP
Ou
. ._ _ _ _ _ _ _ _ _ 966-.8 TAN _ _ _ _ _ _ _ _ _..
TRANS
ECM-BAT
HTR
ACC-RADIO
(SEE
(SEE PAGE
PAGE 69)
C217
8905825
PWR
~[AJ~~
HORN/OM INSTR-LPS
liP
l/P CLUSTER
CONNECTOR
lEI 0
~DO~OO
TAIL LPS
INJ
~OODD[)]
~P-HAZ E~r [jUXO
WIPER
Jib Pu::g
FUSE BLOCK
FRONT
REAR
HYDRO IOGST SWITCH
HI
AlARM
111
...J
12089776
C216
8900655
FLASHER
UNIT
::s<D
..
<Xl
...-_......:;
0
HYDRO
HYDROBOOST
PRESSURE
SWITCH
f1~~~....---- 860-.8 YEL - - - - - -..

HI
(CLOSED
(CLOSED
WITH LOSS
OF PRESSURE)
C205
12040744
r;tiil!"'~---- 966-,8 TAN - - - - - -
C255
C148
12004827
GT100
12015987
12020107 (UPPER)
12020108 (LOWER)
C298
12010966
12015952
C299
6294841
A
::s<D
..
<Xl
...J
4iiM-------
FLOW
SWITCH
(CLOSED
WITH LOSS
OF FLUID
FLOW)
--
860-.8 YEL - - - - - -. .
. ._ _ _ _ _ _ 111-.8 BLK _ _ _ _ _ _ _. . .
lIP
C149
6288440
ENGINE
=
(CLOSES WHEN
UNEQUAL PRESSURE
EXISTS BETWEEN
340
450
39
419
31
439
35
J
K
F
G
440
~1
STA
123
B-74

SCHOOL
SCHOOL BUS
BUS
C100
12020184
OFF
ACC
L
0
C100
12020183
RUN
LOC
111-.8 BLK
IGNITION
SWITCH
SWITCH
CIRCUIT OPERATION
BACKUP LAMPS
PARK, TAIL, MARKER, AND LICENSE LAMPS

the gear selector lever is shifted to REVERSE the
the lamps turn on.
Voltage is applied through the PARK LP Fuse to the

License Lamps.
TEST
1.
2.
Place transmission in reverse.

(24) wire at rear lamp harness
Connect test lamp from DK BLU
connector C214 (auto) or C146
(man) to ground.
RESULT
Test lamp lights.

installed wiring.
GO to step 2.
Test lamp lights.
GO to step 3.

(man) to fuse block and DK BLU
(38) wire.
Test lamp lights.

switch connector C214 (auto) or
C146 (man) to connector C408.

switch.
DIAGNOSIS -- REAR EXTERIOR LAMPS

PRELIMINARY CHECKS:
3.
The rear lamp systems taillamps, backup lamps, and

license plate lamp(s) all receive voltage from same wire
circuit (BRN 9) and are grounded at the bulb socket(s).
If only one system is not working, LOCATE and REPAIR
an open in the wiring and/or bulbs that pertain to that
system.
NONE OF THE REAR LAMP SYSTEMS OPERATE

TEST
RESULT
ACTION
1. Connect test lamp from ORN (40)

C209 to ground.
Test lamp lights.
GO to step 2.
CHECK condition of TAIL LPS fuse.

REPAIR open in RED (2) wire from
light switch connector C209 to
battery junction block and/or ORN
connector C209 to fuse block.
2.
Place light switch to PARK

BRN (9) wire at light switch
Test lamp lights.
GO to step 3.

wire at rear lamp harness
Test lamp lights.

(150) wire.

connector C402 to light switch
connector C209.
3.

(man) to ground.
ACTION
REAR EXTERIOR LAMPS
B-75
1 24-.8 LTG R N I
RH
BACKUP
LAMP
PROVISIONS FOR
RH SIDE MARKER
F ~ ) l - . 8 BLK
C408
C406
2977107
RH TAIL STOP AND

TURN LAMP
M 8blK'
U I I t V - S BLK.
19-.8 DK G R N l
C404
2984855
d>
Q D
A
S402
yf ia i
9-.8 BRN w a rn
19
c4oo
|kg)
RH LICENSE
LAMP
I9 -.8 BRN I
S400
2977107
24-.8 LT G RNa

12034342
9-.S BRN
<
S401
C150
- .8 BLK-=
LH LICENSE
LAMP
I 1 5 0 - .8 BLK |
S404
.8 BLK*
I 18-.8 YEL
M b it * .8 b l k -
LH
BACKUP
LAMP
C403
2984855
LH TAIL, STOP AND

TURN LAMP
^ B
C405
2977107
PROVISIONS FOR
LH SIDE
MARKER
24-.8 LT GRN
B-76
REAR LAMP HARNESS
^ - S BLK ^
RPO CODES
TRANSMISSION
BACKUP
LAMP SWITCH
(AUTO TRANS ONLY)

C214
2973407
REAR
JD)H l a m p
24-1.0 LT GRN
HARNESS
BACKUP
LAMP SWITCH
(4 SPEED MAN
TRANS ONLY)
>
1
1C
1
O
C100
12020183
BACKUP LAMPS
B-77
yÂVW V'W W Vf
S
HOT AT ALL TIMES <
i^VWVVVWVV^T
LIGHT
SWITCH
TAIL LPS
20 AMP
44
140-1.0 ORN
150-
PANEL DIMMER
SWITCH
,x
156
DOME
LIGHT
SWITCH
I l S l r i 11 so 11 se I 4 4 lC ^
CIRCUIT
BREAKER
25 AMP
.PARK
HEAD
OFF
r -.
* PARK
HEAD
REAR
BODY
CONNECTOR
9-2.0 BRNI
jj
12065158
340
: 450
120
39
419
31
439
35
2
440
6
94
906
33
30
24
I9
18
19
[C )
n
93
434
11
12
15
593
14
29
N
P
o
o
B-78
TAILLAMPS, REAR MARKER AND LICENSE LAMPS
REAR
LAMP
HARNESS
C402
CIRCUIT OPERATION
VACUUM SYSTEMS
pressure of a partial vacuum to operate the component.
The vacuum created within the inlet manifold when the
engine is running is stored in a vacuum tank in the
engine compartment. A check valve in the line feeding
vacuum to the tank keeps the stored vacuum from
weakening when inlet manifold vacuum drops during
high speed or high power operation.
Vacuum is routed through hoses (and in some cases,
tubing) to a mechanical or electric valve that provides a
means of controlling the vacuum-operated component.
When the valve is open, it allows vacuum to go to an
actuator that actually operates the component. When
the component is to be returned to its original position,
the valve cuts off the vacuum to the actuator hose and
vents the hose to normal air pressure.
A typical actuator is a metal shell with a movable shaft
that retracts and extends to mechanically operate the
component. A flexible diaphragm separates the interior
of the shell into two chambers - a sealed chamber to
which vacuum can be admitted, and an open chamber
exposed to normal air pressure. The movable shaft is
attached to the center of the diaphragm and extends
from the open chamber.
When the vacuum is directed to the sealed chamber,
shaft.
positions. This extends the shaft.
EXHAUST GAS RECIRCULATION

VACUUM SYSTEM
All 1991 P-Truck gasoline engines are equipped with
an exhaust gas recirculation (EGR) system. The EGR
system allows a small amount of exhaust gas to flow
from the exhaust manifold into the inlet manifold when
the throttle is opened beyond idle and inlet manifold

vacuum is normal.
This reduces combustion
temperatures in the engine to control oxides of nitrogen
emissions.
the pintle to open, allowing a measured flow of exhaust
The EGR system remains closed during periods of
engine idle and deceleration to prevent rough idle from
excessive dilution of the fuel-air mixture. It also remains
closed at wide-open throttle to prevent voltage loss. At
other times, it rapidly cycles open and closed to
modulate the flow of exhaust gas as required. Under
certain circumstances, it may remain fully open to
provide the maximum EGR.
A manifold absolute pressure (MAP) sensor measures
the strength of the vacuum in the EGR vacuum circuit
and sends a signal back to the electronic control module
(ECM). If actual vacuum differs from the preferred
of exhaust gas into the cylinders. This provides the
required control of oxides of nitrogen emissions while
retaining engine performance under all operating
conditions. The ECM also uses the signal from the MAP
sensor to control fuel delivery and ignition timing.
Vacuum for the EGR system is taken from the throttle
body and routed through a hose to the electronic
vacuum regulator valve (EVRV) solenoid (V8 engine) or
to the EGR valve solenoid (V6 engine). The solenoid is
controlled by the 435 circuit from the ECM. When the
solenoid opens the electronic vacuum regulator valve or
the EGR valve, vacuum reaches the EGR actuator
through another vacuum hose and opens the EGR pintle
valve to allow exhaust gas to flow into the inlet manifold.
When the EVRV solenoid or the EGR valve solenoid is
released, the valve vents the EGR actuator to outside air
to close the EGR pintle valve.

exhaust gas recirculation and adversely affect engine
cruise can result in the engine stalling after closed
throttle deceleration, surging during steady throttle
cruising, or a rough idle. Too little exhaust gas flow
allows combustion temperatures to become too high and
bring about detonation ("spark knock") or an overheated
engine. In addition, nitrous oxide emissions may be high
enough to cause the vehicle to fail an emissions test.
Because the source of an EGR system symptom
might be traced to a mechanical or electrical condition
as well as a faulty vacuum system, an effective
systematic diagnosis procedure should examine all three
categories of components - not just the vacuum system
alone. Therefore, no exclusive vacuum system diagnosis
the EGR system, refer to the 1991 "Fuel and Emissions
Service Manual."
DIAGNOSIS
Condition most likely to cause vacuum system
binding components.
A vacuum pum p can be used as a vacuum source to
operate com ponents and test the system. The built-in
On vacuum systems that are controlled by electrical
or electronic switches, check for a blown fuse, wiring that
is cracked, frayed or burned, and high resistance in
connectors of the control circuit(s) before checking for a
S102
(SEE PAGES 42, 52)
I 45O-.0 BLK/W HT
S 111 (SEE PAGE 46)

P39-.8 PNK/BLK I
ENGINE
GROUND
G100
B-80
EXHAUST GAS RECIRCULATION (EGR)
39-.8 PNK/BLK I
PCM
(SEE PAGE 51)
C 134
C 135
12H-25
12A3
12A5
1.
2.
3.
4.
5.
6.
1. RH Batteries
2. LH Battery
3. Starter Motor
Figure 1 - Batteries and Cables (6.2L V8 HD Diesel Engine)
Cold Advance Control

Fast idle Solenoid
Fuel Shut-Off Valve
Generator
Glow Plug (RH)
Cold Advance and Fast Idle
Temperature Switch
Figure 2 - Engine Wiring Harness - RH Side (6.2L V8 HD Engine)
B-81
FRONT
OF VEHICLE
S116
VIEW [ a ]
1.
2.
3.
4.
5.
6.
C106

Fuel Heater
Back Up Lamp Switch
Speed Sensor
Oil Pressure Switch
Figure 4 - Engine Wiring Harness - Rear (6.2L V8 HD Diesel Engine)

FRONT
OF
VEHICLE
C195
C100
C116
1. Glow Plug (LH)

2. Coolant Temperature Sender
1.
2.
3.

Map Sensor
Low Coolant Sensor
12H24
Figure 3 - Engine Wiring Harness - LH Side (6.2L V8 HD Diesel Engine)
B-82
Figure 5 - Engine Wiring Harness to Cowl/Radiator (6.2L V8 HD Diesel Engine)
C117
FRONT
OF VEHICLE
4 SPD., MAN TRANS
1.
2.
3.
4.
5.
6.
Ignition Coil
Distributor
Electronic Spark Module
Transmission
Engine Temperature Switch
Transmission Backup Lamp Switch
1.
2.
3.
4.
5.
6.
8.
9.

Injectors
EVRV
Starter Motor
Knock Sensor
TP Sensor
Generator
Map Sensor
12H22
Figure 6 - Engine Wiring Harness, LH Side (7.4L V8 Gas Engine)
Figure 7 - Engine Wiring Harness, RH Side (7.4L V8 Gas Engine)
B-83
FRONT
OF VEHICLE
VIEW
1.
2.
3.
4.
5.
6.
7.
8.
Map Sensor
Idle Air Controller
TP Sensor
Injectors
ESC Hybrid
Knock Sensor
Starter Motor
EVRV
C118
C174
C108
C146
C185
4 SPD., MAN TRANS

Coil
Distributor
Oil Pressure Sender
Output Speed Sensor
Transmission
Input Speed Sensor
Vehicle Speed Sensor
Backup Lamp Switch
12
Figure 8 - Engine Wiring Harness, LH Side (5.7 V8 Gas Engine)
B-84
1.
2.
3.
4.
5.
6.
7.
8.
Distributor
Oil Pressure Sender
Output Speed Sensor
Transmission
Input Speed Sensor
Knock Sensor
C174
Figure 10 - Engine Wiring Harness to Cowl (7.4L V8 Gas Engine)
12H16
C110
cm
C 112
GT101
S189
S190
1.
2.
3.
4.
5.
6.
7.
8.
EGR Solenoid
TP Sensor
Injectors
Starter Motor
Map Sensor
Coil
Idle Air Control
C206
C224
12C2
Figure 12 - Steering Column Switches
S199
12H17
GlgO
G101
FRONT
OF VEHICLE
FRONT
OF VEHICLE
G111
C116
C121
C115
VIEW B
VIEW A
B-85
C100
4.3L ENGINE
S197
1.
2.
3.
4.

Fuel Pump Relay
ESC Hybrid Function
[ ]
C113
(MAN TRANS ONLY)
GT100
12H4
S109
G110
Figure 15 - Battery and Leads (4.3L V6 and 5.7L V8 Gas Engines W/ School Bus Equipment)
G110
S101
G111
(5.7L ENGINE)
VIEW
(7.4L ENGINE)
1.
2.

Fuel Pump Relay
GT100
12H6
FRONT
OF VEHICLE
Battery
Starter Motor
(4.3L ENGINE)
VIEW B
Figure 14 - Engine Wiring Harness to Cowl (4.3L V6, 5.7L and 7.4L V8 Gas Engines
B-86
1.
2.
Figure 16 - Battery and Leads (4.3L V6, 5.7L and 7.4L V8 Gas Engines)
COMPONENT LOCATION
Backup Lamp S w itc h ....................... . . Top LH front of tra nsm issio n .............................................
Battery, L H .......................................... . . LH front behind radiator s u p p o rt......................................

Battery, RH ........................................ . . RH front behind radiator support ................ ...................
Battery Junction B lo c k ..................... . . RH side of shipping panel

Brake Pressure Warning Switch . . . . .
Cold Advance Control ..................... . .
Cold Advance Fast Idle
Temperature Switch ..................... . .
(G asoline)........................................ . .
(D ie s e l)............................................ , . .
Distributor .......................................... . .
.......................... ...................
Near master cylinder .........................................................

Top front of e n g in e .......................................... ...................
RH rear of e n g in e ........................................... ...................
81
Top front of e n g in e ........................................ ...................
83
Top RH front of e n g in e ................................. ...................

Top rear of e n g in e ........................................ ...................
84
83
84
84
85
83
84
84
84
86
83
84
84
83
84
81
85
82
86
81
83
84
85
81
81
81
81
81
81
81
81
81
82
83
84
8
6
8
10
11
6
8
10
9
14
6
8
10
7
9
2
13
4
14
2
7
9
11
2
3
2
3
2
3
2
3
2
4
7
9
EGR Solenoid ..................................., . . Top RH side of e n g in e ................................. ...................

Engine Temperature S w itc h ........... . . . LH side of e n g in e ........................................... ...................
ESC H y b r id ....................................... . . . Top RH side of e n g in e ................................. ...................

ESC Module
Page - Figure
4
82
6
83
8
84
1
81
1
81
15
86
16
86
5
82
14
86
14
86
2
81
..................................... . . . Top of engine at d istrib u to r.......................... ...................
E V R V ................................................... , . . Top RH front of e n g in e ................................. ...................

Fast Idle Solenoid ............................. . .
Fuel Gage S e n d e r ............................. . .
Fuel Heater ....................................... . . .
Fuel Pump R e la y .............................. , . .
Fuel Shut Off Valve ......................... . . .
Generator (Diesel) ............................. . .
Top LH side of engine .................................

In fuel t a n k ......................................................
Top rear of e n g in e ........................................
Top LH side of shipping panel ...................
Top front of e n g in e ........................................
Front of e n g in e ...............................................
...................
...................
...................
...................
...................
...................
Generator (Gasoline) ........................ . .

Glow Plug #1 ................................. . . .
Glow Plug # 2 ................................. . . .
Glow Plug # 3 .................................... . .
Glow Plug # 4 ................................. . . .
Glow Plug # 5 ................................. . . .
Glow Plug # 6 ................................. . . .
Glow Plug # 7 ................................. . . .
Glow Plug # 8 ................................. . . .
Glow Plug Controller ..................... . . .
Idle Air Control A c tu a to r................ . . .
Front of e n g in e ...............................................
LH side of e n g in e ...........................................
RH side of e n g in e ...........................................
LH side of e n g in e ...........................................
RH side of e n g in e ...........................................
LH side of e n g in e ...........................................
RH side of e n g in e ...........................................
LH side of e n g in e ...........................................
RH side of e n g in e ...........................................
Top LH rear of engine .................................
Top rear of e n g in e ........................................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
...................
COMPONENT LOCATION
Page - Figure
Ignition C o i l ...................................... . . . Top of engine near d is trib u to r........................ ................. 83

84
85
. . . Top center of engine ...................................... ................. 83
84
85
. . . Top center of engine ...................................... ................. 83
84
85
Input Speed S e n s o r........................ . . . LH side of transmission ................................. ................. 84
84
. . . RH side of e n g in e ............................................. ................. 83
84
85
Low Coolant Sensor (Diesel) . . . . . . . RH side of ra d ia to r........................................... ................. 82
MAP Sensor (Diesel) ..................... . . . LH side of shipping p a n e l............................... ................. 82
MAP Sensor (Gasoline) ................. . . . Top rear of e n g in e ........................................... ................. 83
84
85
Oil Pressure Sender (D iesel)......... . . . Top rear of e n g in e ........................................... ................. 84
84
Oil Pressure Switch (Gasoline) . . . . . . Top LH side of tra n sm is sio n .......................... ................. 82
84
Output Speed Sensor ................... . . . LH side of transmission ................................. ................. 84
84
.................
81
Starter M o t o r .................................... . . . Lower RH side of engine ...............................
83
84
85
86
86
TP Sensor ......................................... . . . Top RH side of e n g in e .................................... ................. 83
84
85
.................
85
.
.
.
LH
side
of
steering
c
o
lu
m
n
............................
Turn Signal S w itc h ..........................
V S S .................................................... . . . Top LH side of tra n sm issio n .......................... ................. 82
84
Water in Fuel S e n s o r ..................... . . . Top rear of e n g in e ........................................... ................. 82
. . . LH side of steering c o lu m n ............................ ................. 85
Connectors:
C100 ............................................. . . . Top left side of left cowl ................................. ................. 82
86
C102 ............................................. . . . Top left side of left cowl ................................. ................. 82
86
C103 ............................................. . . . At fuel pump relay ........................................... ................. 86
C105 ............................................. . . . At brake pressure warning s w itc h ................. ................. 86
C106 ............................................. . . . At coolant temperature sensor ..................... ................. 81
................. 81
C107 .............................................
83
84
85
COMPONENT LOCATER INDEX
6
8
11
7
9
11
7
9
11
8
10
7
9
11
5
5
7
9
11
8
10
4
8
8
10
1
7
9
11
15
16
7
9
11
12
4
8
4
12
5
14
5
14
14
14
3
2
7
9
11
B-87
COMPONENT LOCATION
..........................
C108
................................................
C109
........................ ..........................
C110
........................
.....................................................
cm ................
.....................................................
C112
........................ ..........................
C113
........................ ..........................
C115
........................ ..........................
C116
........................ ..........................
C117
........................ ..........................
C118
........................ ..........................
C199
C120
C121
C125
........................ ..........................
................................................ .....................................................
.................................................... .....................................................
.................................................... ....................................................
C127
C128
C129
C130
C131
C132
C134
C135
C146
.........................................................................................................
C150
.........................................................................................................
B-88
..........................
......................................................
; .....................
....................................................
.........................................................................................................
.................................................... ....................................................
.........................................................................................................
..........................................................................................................
.................................................... ....................................................
Page - Figure
82
83
84
84
At coolant temperature sensor ............................... ___ 83
84
84
At throttle position s e n s o r ................................................................................. ______ 83
84
85
At RH in je c to r.............................................................. ___ 83
84
85
At LH in je c to r.............................................................. ___ 83
84
85
At ESC hybrid ........................................................... . . . . 84
86
At idle air control a c tu a to r......................................... ___ 83
84
85
At MAP s e n s o r ........................................................... ___ 82
83
84
85
At knock s e n s o r ......................................................... ___ 83
84
84
At oil pressure sender (gasoline) .......................... ___ 84
84
At oil pressure switch (d ie s e l)................................. ___ 82
At electronic spark m o d u le ............................................................................. ______ 83
84
84
At ignition coil ........................................................................................................................ ______ 83
84
85
LH side of distributor ................................................................................................ ______ 83
84
84
. . . .
85
At glow plug c o n tro lle r............................................. ___ 82
______
81
At water in fuel sensor ........................................................................................... ______ 82
At cold advance fast idle temperature switch . . . ______ 81
At fuel h e a te r ............................................................................................................................ ______ 82
Top of cold advance c o n tro l ........................................................................ . . . . 82
Fast idle s o le n o id .............................................................................................................. ______ 81
At backup lamp s w itc h ........................................................................................... ______ 82
83
84
At low coolant s e n s o r ................................................................................................ ______ 82
At engine temperature s w itc h .................................
. . . .
5
6
8
10
7
8
10
7
9
11
7
9
11
7
9
11
9
14
7
9
11
5
7
9
11
7
9
10
10
4
6
10
6
8
11
COMPONENT LOCATION
Page - Figure
83
84
84
83
84
84
83
84
84
83
84
82
84
86
81
81
81
81
81
81
81
81
85
85
85
85
85
6
8
10
6
8
10
6
8
10
7
9
4
8
14
3
3
3
3
2
2
2
2
12
12
13
13
13
LH lower side of c o w l............................................ .........

Center of injector b o d y .......................................... .........
86
83
84
85
14
7
9
11
Top LH rear of engine
83
84
85
84
85
81
81
86
86
84
86
81
81
85
7
8
11
9
11
2
1
15
16
11
16
1
1
13
84
85
86
86
9
11
14
14
C172
............................ ........................ LH center of transm ission..................................... .........
C173
............................ ........................ Input speed sensor ............................................... .........
C174
............................ .......................
Output speed s e n s o r ............................................ .........
C175
............................ .......................
EVRV ........................................................................ .........
C185
............................
C186 ............................ .....................

C192 ............................ .....................
C193 ............................
C194 ............................ .....................
C195 ............................
C196 ............................ .....................
C197 ............................ .....................
C198 ............................
C199 ............................ .......................
C206 ............................ .....................
C224 ............................ .....................
C400 ............................ .......................
C401 ............................ .......................
C402 ............................ .......................
Grommets:
GT100 .......................... .......................
GT101 .......................... .....................
Grounds:
G100 ............................. .....................
G101
.........
LH top of LH cowl (near support) ........................ .........
#1 glow p l u g .......................................................... .........
.........
# 5 glow p l u g .......................................................... .........
.........
# 2 glow p l u g .......................................................... .........
# 4 glow p l u g .......................................................... .........
.........
# 8 glow p l u g .......................................................... .........
Base of serving column ........................................ .........
Base of serving column ........................................ .........
At fuel t a n k ............................................................... .........
At fuel level s e n d e r................................................. .........
At rear lamp harness ............................................ .........
.......................................... .........
............................ .....................
At alternator b ra c k e t............................................... .........
G102 ............................. .....................

G110 ............................ .....................
RH front top of engine .......................................... .........

RH side of radiator support above b a tte ry .......... .........
8
10
11
4
G111
............................
.........
G112 .............................
G113 ............................
G402 .............................
Splices:
S 1 0 1 ...............................
.........
.........
.........
S 1 0 2 ...............................
.........
4
4
2
4
6
.........
COMPONENT LOCATION
S 1 0 4 ..........................................
S 1 0 9 ..........................................
5 11 1
511 2
511 3
511 4
511 5
511 6
511 7
S 1 8 9 ..........................................
5190
5191
5195
5196
5197
5198
S199
Page -- Figure
Top LH side of c o w l...........................................................
Top LH side of LH cowl ....................................................
Front RH top of e n g in e .......................................................
RH top corner of e n g in e ....................................................
RH top center of e n g in e ....................................................
LH top rear of e n g in e .........................................................
RH top rear of e n g in e .........................................................
Top LH center of e n g in e ....................................................
86
86
86
86
81
81
81
81
81
83
84
84
85
Top LH side of engine ....................................................... 85
LH side of transmission .................................................... 83
84
LH side of cowl .................................................................. 82
86
LH side of cowl .................................................................. 82
86
LH side of cowl .................................................................. 82
86
Lower RH side of engine .................................................. 83
84
85
Lower RH side of engine .................................................. 83
84
85
14
14
14
14
2
2
2
3
2
6
8
9
11
11
6
8
5
14
5
14
5
14
7
9
11
7
9
11
B-89
SECTION C
P MODEL
(MOTORHOME)
SECTION C - P-MOTORHOME
C-1
DRL RELAY
(SEE PAGE 18)
STEERING
COLUMN
SWITCHES
FUEL PUMP
SENDER
(SEE PAGE 38)
l/P CONNECTOR
(SEE PAGES 4
BATTERY
(SEE PAGES 4
REAR LAMPS
HARNESS
(SEE PAGE 61)
PROVISIONS FOR
WIPER/WASHER
(SEE PAGE 28)
REAR BODY
CONNECTOR
(SEE PAGE 38)
C-2
PHANTOM VIEW
SYMPTOMS INDEX
SYMPTOM
PAGE

Auxiliary cooling fan does not r u n ................................................................................................................... C-48
Auxiliary cooling fan runs c o n tin u o u s ly .......................................................................................................... C-48
CRUISE CONTROL
Cruise control does not disengage when brake pedal is depressed ...................................................... C-51
Cruise control does not operate ......................................................................................................................C-51
DIESEL ENGINE FUEL CONTROLS
Service fuel filter indicator does not light briefly with ignition switch turned to RUN ............................ C-46
Fuel heater does not operate .......................................................................................................................... C-46
Water in fuel indicator lights with no water in fuel ....................................................................................... C-46
Fuel gage indicates full or beyond at all tim e s .............................................................................................. C-53
Fuel gage indicates empty when there is fuel in the ta n k ............................................................................C-53
Fuel gage is inaccurate ................................................................................................................................... C-53
Oil pressure gage indicates low pressure when oil pressure is g o o d ...................................................... C-53
Oil pressure gage indicates high pressure at all tim e s ................................................................................ C-54
Temperature gage indicates hot with engine coolant below operating temperature and ignition
switch in R U N ................................................................................................................................................. C-54
Temperature gage indicates cold all the time .............................................................................................. C-54
Temperature gage is in a c c u ra te ..................................................................................................................... C-54
Low coolant indicator is lit when coolant level is g o o d ................................................................................ C-54
Low coolant indicator does not light with coolant level low (diesel o n ly ) ..................................................C-54
REAR EXTERIOR LAMPS

None of the rear lamps operate ...................................................................................................................... C-60
Backup lamps do not o p e ra te ........................................................................................................................... C-60
START AND CHARGE
Battery is undercharged or o v e rc h a rg e d ........................................................................................................ C-29
Engine does not crank and starter solenoid does not click ....................................................................... C-29
Starter solenoid clicks, engine does not crank or cranks s lo w ly ................................................................ C-29
TURN LAMPS
Turn signals do not work on one s id e ............................................................................................................. C-23
Turn signals do not operate ..............................................................................................................................C-23
Turn signal lamps flash r a p id ly .........................................................................................................................C-23
WIPER/WASHER
Wipers do not operate in any mode ............................................................................................................... C-27
Wipers do not operate in HI ..............................................................................................................................C-27
Wipers do not operate in L O ..............................................................................................................................C-27
GLOW PLUGS
Wait indicator does not flash or flashes for the incorrect amount of time when engine is
below normal operating te m p e ra tu re .......................................................................................................... C-43
HEADLAMPS
Headlamps do not illuminate high or low beams - both sides .................................................................. C-13
Low beam lamp(s) do not operate .................................................................................................................C-13
High beam lamp(s) do not o p e ra te .................................................................................................................C-13
HEADLAMPS (WITH DRL)
Headlamps do not illuminate high or low beams - both sides .................................................................. C-16
Low beam lamp(s) do not operate .................................................................................................................C-16
High beam lamp(s) do not o p e ra te .................................................................................................................C-17
Canadian daytime running lamps do not operate ....................................................................................... C-17
HORNS
Horn will not operate ........................................................................................................................................C-25
Horn sounds continuously without depressing horn switch .......................................................................C-25
PARK, MARKER AND HAZARD LAMPS
Park lamps do not o p e ra te ...............................................................................................................................C-21
Side marker lamp(s) do not o p e ra te ...............................................................................................................C-21
Hazard warning lamps do not operate .......................................................................................................... C-21
SYMPTOM INDEX
C-3
_ _ _ _ _ _ _ 2-5.0 RED _ _ _ _. .
P.iJ::'
2_
ow
sr
BAlTERY
a::
o
44
START
~
0
RUN
OFF
lOCK
. ._ _ _ _ _ _ 1-50.0 BlK
_L
f-
C201 I
6294641 ~
C200
12010966
ACC
;::
IGNITION
COil
(SEE PAGE 32)
-'
(L
(L
aw
Hi
>::
a::
(L
'9
'"
S205
AUTO APPLY
PARK BRAKE
SWITCH _ ..._ __
IGNITION
SWITCH
i'"'"' ' _::::"
156
150
DOME
2
OFF
CIRCUIT
BREAKER
25 AMP
LIGHT
SWITCH
HEAD
10
PPNK
STARTER
MOTOR
--
S100
.S103
I~
~~
a::rn
S101
40
_2-5.0 RED_
HEAD
DIESEL
2-3.0 RED
aw
C202
12020029
a::
I~
PANEL DIMMER
SWITCH
om
"'::J
NbS
51
a::
o
M
GT100
12085003 (UPPER)
12085002 (lOWER)
a::
aw
.o
a::
S102
2-2.0 R S T _
(FUSIBLE LINK)
COOLING FAN
RELAY
(SEE PAGE 49)
-----JF i
V yT
I
;r
11
I----- fcl-----*---- kH i
~BA~ ~
[g
~ ill
rn:J rn:J
ill ~ ill
[ill
~
~
AOCC
0 ~R jW:
PWR
r'i5flrstlnotl~
~ ECM-BAT
f""";;;-{l
f10tl ~ ~ ~
L...r;J
TAIL
LPS
~
HTR
r::::l
INJ
C!
a::
rn
ACC-RADIO
r';;;;-;l
M -
~K
ALT
nsr.t
G110
T~
DD
n 0
CRNK
k/S/PLR
STOP-HAl
15AMP
AlT
20 AMP
^TURN/BU
TURN/BU
* 115AMP
5 AMP
~n-otl~~
l.J.=W ~ AUX
WIPER
STOP-HAZ
GASOLINE ENGINE
OA
GAUGES
LL"~-
o
I
L.r;j INSTR-LPS
L..r;J ~
HORN/OM
POWER DISTRIBUTION
ORN
I ~
[ill
Fsjn m
C-4
2-5.0 RED _ _ _ __
~~-I-I
C106
12045896
4i
-m
.1 ___
-.r-. =~OO-5.0
rn:Jrn:J~DillDD
GENERATOR
" ___11_ 9-1.0 BRN
.300-5.0 ORN1
S201
10AMP
WIPER
25 AMP
INJ
7.5 AMP
2-5.0 RED
4
'Jj~'.
_6-5.0PPL
C201
o
S200
44
START
_2-5.0 RED
RUN
LH
BATTERY
RH
BATTERY
. .-..
.
-'
8:
~
w
0.
0.
'"
to
W
S150
_L
4-5.0BRN_
a:
CD
0
p----------
a:
o
t
-= -:
-=
~1~ENG1NE
ENGINE
GROUND
LH CYLINDER
HEAD
G113
ENGINE
GROUND
RH CYLINDER
HEAD
G112
D 9 508 331
E 35 8 397
3001301 sol
G 39 1234 31 59 50
1
2
3
4
5
;(;
12085003 (UPPER)
12085002 (LOWER)
MI
10
OFF
,PARK
-----.....--
(])
o
o
[!!J
S~5 -
lID lID @ ill ~ CD [ill D
C203
12020030
PANEL DIMMER
SWITCH
a:
o
to
L,....
2-5.0 RED
~~i-i=r~~"o~
0.
0.
:b0
C202
12020029
---.,
a:
2-3.0 RED
12015764
-'
9-1.0BRN
----~-
GAUGES
20AMP
i_
TRANS
10AMP
INSTR-LPS
5AMP
.l.BAT.l
l!!J @ !IJ ~ CD [ffi D

L
3-3.0 P N K - ,
D~
ACC
ow
a:
o
..;
N
'~J
IGN
D~
HTR PWR
~OO~G
~OO~~
~~~~
GAUGES
PWR
TRANS
ECM-BAT
INJ
HTR
ACC-RADIO
l~~]K
OAUXO
WIPER
HORN/OM INSTR-LPS
TAIL LPS
'"
a:
Z
0.
CD
lID@@DOJDDO
FUEL SHUT
OFF VALVE
(SEE PAGE 47)
GENERATOR
593 11 K
68 2501419 L 481
10 505
W/GASOLINE
901 93 75 NJ-l0 W/DiESEL
l 1 /824T 141 4 p
10 9
8
7
6
12015964
a: q
0
..;
LIGHT
SWITCH
to
6
AJ- 2 150 24011111

439 17
2
~~~~~~ID41-~==~~I[I:~~-~!~/P~--16 350
420 440 592 J
[-J- J
3-3.0 PNK
SHEET
./ METAL
0 , GROUND
G110
:~:.:;E~RN-------.
.~-II-------3-5.0PNK-------. .
~, .
'""-Z "-'"Z
tri
.., ..,tri
oj
Ir------------
.S100
'-PARK
HEAD
GT100
CIRCUIT
BREAKER
25 AMP
.,
C 140 15 120
GLOW PLUG
CONTROLLER
40-+-.......- .
"~l
ow
DOME
...to
300-5.00RN
156
150
C!
(])~
(FUSIBLE LINK)
ACC
HEAD
2-5.0 RED
2-1.0 RST _ _ _ __
IGNITION
SWITCH
Z
0.
0.
S101
OFF
[[
L..
.@::z' :;r.,
2-2.0 RST
(FUSIBLE LINK)
-'
LOCK
C200
12010966
906-.5 RST ----z~

(FUSIBLE LINK)
...tri
a:
..,tri
a:
HORN/DM
15AMP
to
HTR
Lb.~11.1
ECM-CRNK
10AMP
~~~OO
ST P-
.T U R N /B U
15 A M P
ALT
CRNK
~ PuS/P~
10AMP
WIPER
25 AMP
POWER DISTRIBUTION
DIESEL ENGINE
C-5
< 0)
1-50.0 BLK
d.
I
I
/n
.--------
y
If
[
GT100
12085003 (UPPER)
12085002 (LOWER)
COOLING
FAN RELAY
(SEE PAGE 48)
SHEET
METAL
GROUND
G110
C-6
POWER DISTRIBUTION
GASOLINE DRIVEAWAY
INJECTORS
7.5 AMP
ECM
10 AMP
IGN
20 AMP
I 6-5.0 PPL
1-32.0 BLK I
J" r^3
+
RH
BATTERY
[ b e
[M o
LH
BATTERY
IGNITION
SWITCH
-^=r
300*5.0 ORN |
DIESEL ONLY
E ONLY |
G ASO LINE ONLY
3-3.0 PNK
3 9 | 1 4 3 1 1Y59 ! 50 I
! 300 30 P 50 I
35
397-j*----- !--------9 508
140 15 120j-----j--------7
1 4i-
fl
33
481 W /G ASOLINE
o
(
|1 5 0 | 2 4 0 |1 1 1 |/
G ASO LINE O NLY
250 419
.... 593 11
|4 2 0 |4 4 0 | 592
I 439 f 17 I 2
DIESEL ONLY
10 W /DIESEL
2
3
140
9
35
! 150 | 240 |111|

I
14 3 9 1 17 I 2
| 16 |3 5 0 |
|
I
14 2 0 1440 I 592
15 120
593 11
I
/"-\
L _
68 250 419
508 33
O
i
8 397 ^
10
505
^
I
19011 93
75
[300 30 | 50 I
|
|824| 14
4
39 11234 3 1 1 59 | 50 | |
5
10
l/P
-481 W /G ASO LINE

10 W /D IESEL
12015964
I 3-3.0 PNK
VAM AW W W VVV^
% HOT IN START OR RUN ?
V W W W W V W A ^C
ECM
10 AMP
REAR
__
r in h
f| o
r h
d h
c ]
[ ]
c ]
t ]
S I
CD-
DS on
FUSE BLOCK
12052472
BOT
5
ENGINE
GROUND
LH CYLINDER
HEAD
G113
ENGINE
GROUND
RH CYLINDER
HEAD
G112
POWER DISTRIBUTION
DIESEL DRIVEAWAY
C-7
WE:lu ED u
fB
GO HI
ACC
IGN
CD O
KC>
r BAT
11
8-1.0 GRA-
1 1
350-.8 PNK/WHT - FUEL CYC MDL
HTR PW R
0 GXA UI
1PW
30,R1 1
G ES
tK ] I
_ Xi
_ K 1
d c
TRANS
E C M -B A T
K l'
INJ3
KHTR]
30A~1
B ] K l
S T O P -H A Z E C M -C R N K
20A
ALT
K ]
TURNm i
AUX
SHUNT 12041235
8-1.0 GRA---------------------------------------------
H O RN /D M IN S T R -L P S
TA IL L P S
250-1.0 BRN - TRANSMISSION

440-1.0 ORN - ECM
2-5.0 RED - BATTERY
- 50-3.0 BRN

-141-1.0 BRN/WHT
4-5.0 BRN - IGN SW
K l
A C C -R A D IO
DW IPd
ER

76-3.0 PNK - AUXILIARY
0C R N K0
16-.? PPL - TURN SIGNAL SW

FU S/PLR

FRONT
-38-.8 DK BLU - TURN SIGNAL
C-8
COLOR
MALE CONN
BRN
12004887
BLK
12004886
GRN
12004885
NAT
12004888
BLU
12004884
FUSE BLOCK
GASOLINE ENGINE
FU SE
L O C A T IO N
FU SE
P A R T NO.
COLOR
AND
AM PERE
HOT
C O N D IT IO N
R A D IO A C C E S S O R IE S
HTR
12004010
W H IT E
25 A M P
H O T IN
RUN
H O T IN R U N
O R START
ALTERNATO R
IN J
12004006
BRN
7.5 A M P
HO T IN R U N
O R START
GRN
30 A M P
H O T IN R U N
O R STA RT
B O D Y B U IL D E R
IN S T A L L E D A C C E S S O R IE S
IN S T R -L P S
12004005
TA N
5 AMP
H O T W/ H E A D L A M P IN
PARK O R HEAD
12004007
RED
10 A M P
HO T AT
A L L T IM E S
E L E C T R O N IC C O N T R O L M O D U L E
S T O P -H A Z
12004008
LT B L U E
15 A M P
H O T AT
A L L T IM E S
STOP LAM PS
HAZARD FLA SH ER
E C M -C R N K
12004007
RED
10 A M P
H O T IN R U N
O R STA RT
PW R
C IR C U IT
BREAKER
GRN
30 A M P
H O T AT
A L L T IM E S
B O D Y B U IL D E R
IN S T A L L E D A C C E S S O R IE S
G AUGES
12004009
YELLO W
20 A M P
H O T IN
RUN
P R O V IS IO N S F O R G A G E S
T A IL L P S
12004009
YELLO W
20 A M P
H O T AT
A L L T IM E S
TA IL L A M P S
H O R N -D M
12004008
LT B L U E
15 A M P
H O T AT
A L L T IM E S
P R O V IS IO N S F O R
HORN AND DOME LAM PS
TRANS
12004007
RED
10 A M P
HOT IN R U N
O R ST A R T
T R A N S M IS S IO N
TURN-B/U
12004008
LT B L U E
15 A M P
HOT IN R U N
O R START
T U R N S IG N A L S
B A C K -U P L A M P S
W IP E R
12004010
W H IT E
25 A M P
HO T IN
A CC O R RUN
FU SE
L O C A T IO N
FU SE
P A R T NO.
COLO R
AND
AM PERE
HOT
C O N D IT IO N
A C C - R A D IO
12004007
RED
10 A M P
H O T IN A C C
O R RUN
ALT
12004009
YELLO W
20 A M P
AUX
C IR C U IT
BREAKER
E C M -B A T
D E S C R IP T IO N
E L E C T R O N IC C O N T R O L
M O D U L E IG N IT IO N 1
D E S C R IP T IO N
H EATER
IN J E C T O R S
IN S T R U M E N T P A N E L L A M P S
W IN D S H IE L D W IP E R S
8-1.0 G RAI
x c >
iT A
[L ]P tD
W i i
m
IG N

HTR PW R
[] @]
ACC
IshV n t ]
II
r s i
K l
E l
K ]
0 [jd
KTRANSl
25A
INJ
u]
STOP-HAZ ECM-CRNK
| 30A

ECM-BAT
D 3
HTR
ACC-RADIO
30A
DWIPER
]
AUX
ALT
D d

SHUNT 12041235
8-1.0 G R A ---------------------------------------------
G AUG ES
HORN/DM INSTR-LPS
TAIL LPS

'439-1.0 PNK/BLK - ECM (FUSED)
CRNK
TURN-B7U FUS/PLR
FRONT
COLOR
MALE CONN
BRN
12004887
BLK
12004886
GRN
12004885
NAT
12004888
BLU
12004884
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
HTR
12004010
WHITE
25 AMP
HOT IN
RUN
ALTERNATOR
INSTR-LPS
12004005
TAN
5 AMP
HOT W/ HEADLAMP IN
PARK OR HEAD
BODY BUILDER
INSTALLED ACCESSORIES
STOP-HAZ
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
STOP LAMPS
HAZARD FLASHER
PWR
CIRCUIT
BREAKER
GRN
30 AMP
HOT AT
ALL TIMES
BODY BUILDER
INSTALLED ACCESSORIES
TAIL LPS
12004009
YELLOW
20 AMP
HOT AT
ALL TIMES
TAIL LAMPS
TRANS
12004007
RED
10 AMP
HOT IN RUN
OR START
TRANSMISSION
PROVISIONS FOR
HORN AND DOME LAMPS
TURN-B/U
12004008
LT BLUE
15 AMP
HOT IN RUN
OR START
TURN SIGNALS
BACK-UP LAMPS
WIPER
12004010
WHITE
25 AMP
HOT IN
ACC OR RUN
FUSE
LOCATION
FUSE
PART NO.
COLOR
AND
AMPERE
HOT
CONDITION
ACC-RADIO
12004007
RED
10 AMP
HOT IN ACC
OR RUN
RADIO ACCESSORIES
ALT
12004009
YELLOW
20 AMP
HOT IN RUN
OR START
AUX
CIRCUIT
BREAKER
GRN
30 AMP
HOT IN RUN
OR START
ECM-BAT
12004007
RED
10 AMP
HOT AT
ALL TIMES
ECM-CRNK
12004007
RED
10 AMP
HOT IN RUN
OR START
GAUGES
12004009
YELLOW
20 AMP
HOT IN
RUN
HORN-DM
12004008
LT BLUE
15 AMP
HOT AT
ALL TIMES
DESCRIPTION

ELECTRONIC CONTROL
MODULE IGNITION 1
DESCRIPTION
HEATER
WINDSHIELD WIPERS
FUSE BLOCK
DIESEL ENGINE
C-9
LAMP BULB DATA

Lamp Usage
Headlamp1
Quantity
2
Trade
No.
Power Rating
at 12V, Watts
6014
50/60 W
Candle Power
LAMP BULB DATA
2057
32-2
Tail and Stoplamp3 (Union City Body Co.)
1157
32-3
Tail and Stoplamp2 (Except Union City Body Co.)
2057
32-2
Front Side Marker Lamp
194
Rear Side Marker Lamp
194
License Lamp
67
Backup Lamp4
Instrument Cluster Illumination Lamp
PC194
PC194
Headlamp High Beam Indicator Lamp
PC74
.7
Service Brake Warning Indicator Lamp
PC74
.7
Park Brake Warning Indicator Lamp
PC74
.7
Transmission Control Illumination Lamp
73
.3
Low Coolant Indicator Lamp5
PC74
.7
Glow Plug Indicator Lamp5
PC74
.7
Water in Fuel Indicator Lamp5
PC74
.7
Service Engine Soon Indicator Lamp
PC74
.7
Trans Indicator Lamp5
PC74
.7
Fasten Safety Belts Indicator Lamp6
PC74
.7
Door Ajar Indicator Lamp
PC74
.7
Daytime Running Lights Indicator Lamp7
PC118
.7
1.
2.
3.
4.
5.
6.
7.
C-10
Park and Signal Lamp2
Double filament sealed beam: 50W low beam, 60W high beam.
Refer to body manufacturers specifications.
Diesel only.
When used by body manufacturer.
Canada only.
RPO CODES
p
I 4 3 9 1 17 I
2 1150 I 240 11111
A
I
|
16 350|
B 3
14 2 0 1440
C 140 15 120
593
250
D 9 508 33
8 397 ^
10 505
E 35
w
19011 93
F
1300 30 I 50 I
I
|
59
|
50
|
|
14
G 39 11234 31
1
2
3
4
5
10 9
7
J
N J--------
-J
S113
A/C COMPRESSOR
I 413-. 8 TAN I
__
68
1454-.8 BLK/WHT I
PCM
(SEE PAGE 34)
COOLING FAN
PRESSURE SWITCH
(SEE PAGE 49)
L
n
CM
CO
(SEE PAGE 50)
PCM
(SEE PAGE 34) _
/~N
ALDL
(SEE PAGES 35, 37)
450-.8 BLK/WHT )
PCM
450-.8 BLK/WHT I
(SEE PAGE 34)
2
592
11
419
75
4
H l/P
J
K
L .481 W /G ASOLINE
M
10 W /D IESEL
N'
P
12015964
DIESEL ONLY
G ASO LINE ONLY
-G A j ? LINE ONLY
,481 W /G ASOLINE
10 W /D IESEL
----------------1
/ti
rrs:::
S 112
l/P CLUSTER
(SEE PAGE 56)
150-1.0 BLK
PANEL DIMMER
SWITCH
150-3.0 BLK
(SEE PAGE 58)
GT 100
CD
CO
12085003 (UPPER)
12085002 (LOWER)
CD
CO
DRL MODULE
(T61 ONLY
(SEE PAGE 18)
WIPER SWITCH
L _____-
(SEE PAGE 28)
DRL RELAY
(T61 ONLY)
(SEE PAGE 18)
DRAC
(SEE PAGE 42)
ENGINE
GROUND
G102
ENGINE
GROUND
G100
ALTERNATOR
BRACKET
GROUND
G103
l/P
GROUND
G200
FRAME
GROUND
G400
GROUND DISTRIBUTION
GASOLINE ENGINE
C-11
150-.8 BLK
ALDL
(SEE PAGE 41)
DRAC
(SEE PAGE 42)
150-.8 BLK I
WIPER SWITCH
(SEE PAGE 28)
1150-.8 BLK I
GLOW PLUG
CONTROLLER
(SEE PAGE 47)
PANEL DIMMER
DRL RELAY
(SEE PAGE 18)
GT100
1150-. 8 BLK I
WATER IN FUEL
SENSOR
12085003
(UPPER)
12085002
(LOWER)
(SEE PAGE 47)
EF71
1150-.8 BLK I
FUEL
HEATER
(SEE PAGE 47)
551-1.0 TAN/WHT
TCM
(SEE PAGE 41)
I 450-1.0 BLK/WHT r
150-.8 BLK
1150-.8 BLK I
p
i i
.
i
i
2 115 0 I 240 11111
A
J439 i 1 7 I
|
B 3 I 16 |350|
|
|
14 2 0 1440
C 140 15 120
593
- J
L _
D 9 508 33
68 250
E 35 8 397 ^
10
505
^
F
1300 30 | 50 |
|
{901| 93
G 39 1234 3 1 1 59 | 50 | |
| 824) 14
1
2
3
4
5
10
9
8
7
------- v --------
4 i 5
1
2
3
G 3 9 | 1234
F
30 P 50
E 35
D
C 140
B
16 I3 5 0 f
2 ^ 150 I 24011111,
311^591501
C-12
GROUND DISTRIBUTION
DIESEL ENGINE
G108
ENGINE
GROUND
, |824| 14
ENGINE
481 W /G ASOLINE
G ASO LINE ONLY
9*
G109
SHEET
METAL
GROUND O
75
4
6
r\
H l/P
J
K
L .481 W /G ASOLINE
M
N | 10 W /DIESEL
P
12015964
DIESEL ONLY
G ASO LINE ONLY |
GASO LINE ONLY
G101
ENGINE
GROUND
2
592
11
419
I
I 10.
*1iA
,-----^ Z Z 1 > 8 250 419 L
593 11 K
|420| 440 | 592 J
t 4 3 9 1 17 I 2
H
"T T
10 W /D IESEL
DIESEL ONLY
G200
l/p
GROUND
CIRCUIT OPERATION
TEST
Breaker. The Circuit Breaker opens when the Headlamp
circuit draws too much current.
When the Circuit
current flow, the Circuit Breaker cools off and resets

Headlamp Dimmer Switch directs voltage to either the
Low Beams or the High Beams. The Hi Beam Indicator
also receives voltage along with the High Beams.
1.
2.
RESULT
TEST
3.
Test lamp lights.
GO to step 2.

C202 to battery junction block.
2. With the light switch on and the

headlamp dimmer switch to HIGH
BEAM, connect a test lamp from
Test lamp lights.
GO to step 3.
3.
Test lamp lights.
REPAIR open LT GRN (11) wire

C101.

switch.
ACTION
GO to step 2.
Test lamp lights.

installed wiring.
Place headlamp dimmer switch in

HIGH BEAM position. Connect a
test lamp from LT GRN (11) wire
at headlamp dimmer switch
GO to step 3.
Test lamp lights.

GRN (11) wire from headlamp
dimmer switch connector C215 to
connector C101.


Test lamp lights.

switch.

lamp from LT GRN (1.1) wire at
ACTION
1. Connect a test lamp from RED (2)

C202 to ground.

RESULT

TEST
RESULT
ACTION
1. Turn the light switch to ON and

GO to step 2.
Test lamp lights.

installed wiring.
2.

GO to step 3.
Test lamp lights.

connector C101.


Test lamp lights.

switch.
3.
HEADLAMPS
BASE
C-13
RH
SIDE MARKER
LAMP
HORN
C137
12004267
1 15-.5 DK BLU
S121
I 11-1.0 LTGRN
S122
LH
HIGH-LOW
HEADLAMP
NOTE: THIS H A R N E SS IS
SHIPPED ALONG WITH THE
VEHICLE AND IS INSTALLED
BY THE BODY BUILDER.
LH
SIDE MARKER
LAMP
G107
C-14
G106
SHEET
METAL
GROUND
G105
FRAME
Q j GROUND
G104
BATTERY JUNCTION
BLOCK
C101
12059472
FORWARD
LAMP
HARNESS
REAR LAMP
HARNESS
(SEE PAGE 62)
l/P CLUSTER
111-1.0 LT GRN I
(SEE PAGE 56)
I 11-1.0 LT GRN
C203
14(M 15 120 _ J
9 # 5 0 8 33
n
35 [ 8 397 ^
L_
39 11234 3 1 1 59 j 50 |
5
593
11T
68 250 419
10 505
[82 4 j 14
12020030
W /G ASOLINE
PANEL DIMMER SWITCH
10 W /DIESEL
2015964
10
DIESEL ONLY
G ASO LINE ONLY |
^GASO LINE ONLY
ENGINE
9 I 50 |
50 |
T \ i 824i 14
I
o 1
3
HEADLAMP
DIMMER
SWITCH
| 16 13501
150 I 2 4 0 11 T l]/
G ASO LINE ONLY
481 W /G AS O U N E
1
[59
|4 2 0 |440
1439) 1 7 j
DIESEL ONLY
150-
I I P . 505L
use
iil
10 W /D IESEL
OFF
156
DOME
CIRCUIT
BREAKER
25 AMP
12015113
PARK
HEAD
I 10-1.0 YEL I
I 11-1.0 LT GRN I
LIGHT
SWITCH
OFF
'PARK
40'
HEAD
LIGHT
SWITCH
HEADLAMPS
BASE
C-15
CIRCUIT OPERATION

TEST

Relay. When energized, the DRL Relay disconnects the
DK BLU/WHT (593) wire from ground and internally
connects it to the ORN (240) wire, causing it to be 12
volts.
Battery voltage is applied to the Daytime Running

Lamps (DRL) Relay Switch at all times through the BRN
(50) wire and the HTR fuse.
With the Headlamps on, the DRL Relay is not
energized and the LT BLU/ORN (593) wire is grounded
to BLK (150) wire inside of the relay. This serves as
ground for the LH Headlamp.
With Ignition in RUN, headlamps off and Park Brake
released, the DRL Module applies battery voltage to the
LT GRN/BLK (592) wire. This action illuminates the DRL
Indicator in the Instrument Panel and energizes the DRL
The DK BLU/WHT (593) wire feeds the LH High

Beams which are connected in series to the RH
Headlamp through the LT GRN (11) wire. Grounding of
the entire DRL circuit is accomplished through the BLK
(151) wire at the RH Headlamp. This result in High
Beam headlamps that are less intense for daytime
driving and should provide longer service.
(WITH DRL)
RESULT

GO to step 4.
Test lamp lights.
GO to step 2.
2.

BLU/WHT (593) wire at connector
C101 to DRL relay connector
C208.
Test lamp lights.
GO to step 3.
REPLACE DRL relay.
Test lamp lights.


GO to step 5.
Test lamp lights.



Test lamp lights.

switch.
3.
4.
Connect a test lamp from DK

BLK/WHT (593) wire at DRL relay

C208 to ground.
PRELIMINARY CHECKS:
HIGH BEAM LAMP(S) DO NOT OPERATE test
procedures.
If the High Beam Lamp(s) are operative, use the
following diagnostic procedures, after placing the
Light Switch to OFF position.
Before checking the DRL system, do the following:

Switch to HIGH BEAM position.
If the High Beam Lamp(s) are inoperative, refer to the

TEST
RESULT
Test lamp lights.
GO to step 2.

C202 to fuse block.
2. With the light switch on and the

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

C101.

switch.

C-16
HEADLAMPS
W/DRL
5.
ACTION

C202 to ground.
1.
ACTION
CANADIAN DAYTIME RUNNING LAMPC I

TEST
Turn light switch ON and
iamp from TAN (12) wire at
GO to step 4.
Test lamp lights.
GO to step 2.

BLK/WHT (593) wire at DRL relay

C101 to DRL relay connector
C208.

C208 to ground.


TEST
ACTION
RESULT
Test lamp lights.
GO to step 3.
REPLACE DRL relay.
Test lamp lights.

GO to step 5.
Test lamp lights.


Test lamp lights.

switch.
2,
3.
With ignition in RUN, headlamps

off and park brake released,
connect a test lamp from ORN
C208 to ground.
Measure voltage.

connector C208 to BLK (150) wire
at each component connector.
Measure voltage.

C101.
NOT OPERATE
RESULT
ACTION

(240) wire between DRL relay
connector C208 and fuse block or
REPLACE HORN/DM fuse.
Test lamp lights.
GO to step 2.
Battery voltage at only one

connector.

connector with missing voltage.
No battery voltage at eithc

connector.

fuse block or REPLACE HTR fuse.
Battery voltage at both

connectors.
GO to step 3.
No voltage.

(150) wire between suspect
connector and ground G102 or
G200.
Battery voltage.
GO to step 4.
No voltage.

GRN/BLK (592) wire between DRL
relay connector C208 and DRL
open is found, REPLACE DRL
module.
Battery voltage.
GO to step 5.

BLU/WHT (593) wire between DRL
relay connector C208 and
Test lamp lights.
DRL are operating.
HEADLAMPS
W/DRL
C -1 7
y W M A /W W v /
BATTERY
JUNCTION
BLOCK
<
V A A M /W W V W 'M
HOT A T A L L TIMES C
<
>vWVVWVVV\N
HOT IN START OR RUN Z
W /M A M W V W 'C
HTR
15528797
25 AMP
. . . ._ _ _ _ _ _ _ _
502.0 BRN _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
o o o o
~.2.1.0RST
(FUSIBLE LINK)
. ._ _. . . . . ._ _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240.1.00RN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . .
S100
I
0
a:
0
Iri
l>ClJocm."c;>
_ _ _ _ _ _ _ _ _ _ _ 2-5.0 REO _ _ _ _ _ _ _ _ _ _ _~N eN
CQ ~
~
'"
...L .....
.....
~~Q~Lj~------- 23.0 RED _ _ _ _ _ _ _ _. , .
U;~Q)~NN
(II 0)
~t:-:-
~~
~~l.o-
)"1
:111
1_
. ._ _ _ _ _ _ l"'.OLTGRN . . . . . . . . . . . ._
. . . . . . . . . 111.0LTGRN _ . . . . . . . . . . . .
_________________ WNt1~www
:g 0t- ...
~~-----. 24O1.00RN _ _ _ _ _ _ _ ~
~~SL~LINE
",1$ '"
0
GASOLINE ONLY !:::::::.
'-::
_1 ......._ .. 503.0 BRN -----~~~~y~~;:~t GASOLINE

0
DIESEL ONLY
.1
..._ _ _ _ 101.0YEL _ _ _ _
, ,_ _ 101.0YEL _
.1_
,/~
-.J
"""11_ _ _ _ _. . 24O.1.00RN
f- DIESEL ONLY
:g1en
-
....-
_ _ _ _ 50.3.0BRN _ _ _ _ _ _ __
I,.. ONLY
____
- .... ....- --....-...
f-
593.8 DK BLU/WHT
I--' -
....
~f i
593-.8 DK BLU/WHT
,,~;7=~ ..-__..
...
150.1.0BLK. . . . . . . . . . . .
_:=-
'"
_1S2.1.S_ _ _ _.11.1.0LTGRN
~ _ _ _ _. . . ._ _ _ _
'"
12-.8 TAN
til
l>
C-18
l.QJ
~Oh
W/DRL
Cl0l
,""Mn
G102
t- ::
_ _ _ _ _ _ _ 11-1.0 LT GRN _ _ _ _ _ _ _. .
HEADLAMPS
-FORWARD LAMP
HARNESS
ENGINE
GROUND
_ _ _ _.150. 8BLK . ._ _ _ _ _ _ _ _ _. .
, -_ _ _
r11
24O.1.00RN
24O2.0 0RN
. . . . 24O-1.00RN _ .
'"
50-3.0BRN _ _ _. .
C208
12052287
592-.8LTGRN/BLK
HORN RELAY
(SEE PAGE 26)
240-1.0 ORN _ _. . . ._
....-... _ _ _
593-.8DKBLU/WHT _ _ _ _
........J
/~rr~I?~r'~
. ._ _
S214
(SEE PAGE 18)
_ _......
_ _ _ _ _ _ _ _ _ _ _ _ _ _ 12. 8TAN _ _ _ _ _.........
_______
~,-
... 593-.8 DK BLU/wHTr
L,. _ _ _ .. 592.. 8LTGRN/BLK _
_ _ _ _ _ _ _. :
(SEE PAGE 11)

,
l 1 . 0 L T G R N - - - - - - -. . . . .
,_____________________ ::::::~:~R.N
S204
i ..___________________~I~------.I-,,
1_________
1_._ .
_12 . 8TAN _ _ _ _ _ _ _ _ _ _ _ _ _ _
...~
......+~ ................................
ffi
,~
S112
(SEE PAGE 11)
. _. ._ _ _ _ 150.2.0BLK-,
....-... _
:......_ _ _ 10-1.0YEL _ _ _ _ _ _ _ __
ENG
12015113
33-.5 TAN/WHT _
2 4 0 + - -_ _-,
50 ....._ _--.
593
592
DRL
RELAY
150-+-----....
l/P CLUSTER
CONNECTOR
(SEE PAGE 55)
DOME LAMP
(SEE PAGE 59)
DRL
MODULE
I 2*3.0 RED i
I 240-1.0 ORN I
I 50-3.0 BRN I
I 33-. 5 TAN/WHT I
110-1.0 YEL I
' 593-.S DK BLU/WHT ,
i n - 1.0 l t g r n m am
* 592-.0 LT GRN/BLKI
1 12-.8 TAN |
LIGHT
SWITCH
LIGHT
SWITCH
IQ)
l/P GROUND
G200
HEADLAMPS
C-19,
W/DRL
RH
SIDE MARKER
LAMP
HORN
151
12077765
11-1.0 LT G R N *
RH
HIGH-LOW
HEADLAMP
C137
12004267
12-.8 TAN I
ID
_J
CO
15-.5 DK BLU
15-.8 DK BLU *
29-1.0 DK GRN
RH PARK AND
TURN LAMP
S121
593-.S DK BLU/WHT
14-.5 LT BLU
I1 2 -.8 TAN
9-.8 BRN
LH PARK AND
TURN LAMP
I 11-1.0 LTG RN
S122
11-1.0 LT GRN |
12-.8 TAN
LH
HIGH-LOW
HEADLAMP
593-.8 DK BLU/WHT
151-3.0 BLK
14 L
0
C141
12077765
C-20

W/DRL
NOTE: THIS HARNESS IS

VEHICLE AND IS INSTALLED
LH
SIDE MARKER
LAMP
G105
SHEET
METAL
GROUND
G104
FRAME
Q ) GROUND
SIDE MARKER LAMP(S) DO NOT OPERATE
CIRCUIT OPERATION
RESULT
TEST
1.

License Lamps. The Front Marker Lamps are grounded
through the LH and RH Park and Turn Lamps.
HAZARD LAMPS
Voltage is applied at all times through the STOP-HAZ
contact of the Hazard Switch in the Turn Signal Switch.
With the Hazard Switch in HAZARD FLASH, voltage is
applied to both Front and Rear Turn Lamps. All of the
Turn Lamps and both Turn Indicators flash on and off.

as they did in TURN RIGHT and TURN LEFT, if the Lamp
switch is in OFF, they flash on when the Hazard Lamps
are on. If the Lamp Switch is in either PARK or HEAD,
they flash on when the Hazard Lamps are off, and off
In HAZARD, the circuit is always open, and the
Hazard Flasher Controls the Lamps.
DIAGNOSIS - PARK, MARKER AND HAZARD LAMPS

PRELIMINARY CHECKS:
If only one lamp is inoperative, inspect wire(s) to
affected lamp socket, check bulb-to-socket fit or replace
bulb.

ground. (See page 15 for wiring of
marker lamp circuit.)
ACTION
Test lamp lights.

installed wiring.

HAZARD SIGNAL LAMPS DO NOT OPERATE

RESULT
TEST
1.

making a turn.

hazard warning lamps ON.
ACTION
GO to step 2.
REFER to "Turn Signals Do Not

Test lamp lights.
CHECK condition of STOP/HAZ

fuse and for an open in ORN (140)
wire and BRN (27) wire. If fuse and
wiring are good, REPLACE hazard
flasher.
PARK LAMPS DO NOT OPERATE

TEST
RESULT
ACTION
1. Place light switch in PARK

ORN (40) wire at light switch
connector C202 to ground. (See
page 15 for wiring of park lamp
circuit)
Test lamp lights.
GO to step 3.
GO to step 2.
2.
Test lamp lights.

REPAIR open in ORN (40) wire.

(2) wire from fuse block to battery
junction block.

C202 to ground.
Test lamp lights.
GO to step 4.

wire at connector C101 to ground.
Test lamp lights.

installed wiring.

3.
4.

wire at fuse block to ground.
PARK, MARKER AND HAZARD SIGNAL LAMPS
C-21
STOPLAMP
SWITCH
(CLOSES WHEN
WHEN
(CLOSES
BRAKE PEDAL
PEDAL
BRAKE
IS DEPRESSED)
DEPRESSED)
IS
<
140
liP CLUSTER
CONNECTOR
HOT A T A L L TIMES C
m vw w w w s
STOP-HAZ
15 AMP
(SEE PAGE 55)

C218
12040744
(STEERING COL SWITCHES)
C216
2984235
17-1.0WHT
a:
0
C!
- - --,..
_ _ _ _ _ _ _ 140-.100RN _ _ _ _ _ _ _ _
18-1.0YEL
--~~~;F=n
17
16-.8 PPL _ _ _ _~~~Iy~
19
27-1.0 BRN _ _ _~
18
16
S210
14-.5 LT BLU
HAZARD
FLASHER
. ._ _ 17-1.0 WHT _ _- '
C212
2973385
__ ___ 27-1.0 BRN

W~--..- - . 140-1.0 OR N
a:
---~W:!rLJ
27
27-1.0 BRN
15
15-.5 DK BLU
14-.5 DK BLU
28-.5 BLK
;::
12004147
.8 LT GR N -
t-~c>:L
-s.
'KEvT
p _____________________ 15-.5DKB
2
11
1~.J.:;4""'2::J0'T'4"'4"&'~59::"'2,..l J
0
I
I I
10
110
901
824
9
8
5
9
14
7
liP
LU
WIGASOLINE
~ MI
75 NTlO WIDIESEL
46
P 12015964
. ._ _ _ _ _ _ _ _ 15-.5 D( B
LU
. ._ _ _ _ _ _ 14-.5 LT B
..________.1_ _ _____ 16-.8 PPL LU
Cl00
12015113
10 '\9
I r T\
D 9 508 331
C 140 15 12~~5QL:::t-1
B
A
r1W,ollll]1
-]
'r
---=::;Z68 25.19
5931111
420 440 IS
I
439 17
2Il
H
~
8
7
6
824 14
4
901 9:l1 75
10 50
-- -
P ENG
N
481
MIIU)W/GASOLINE
L
K
--
~10WIDIESEL
12015113
~\
,~
_ _ _ __
g C
(!l
_ _ _ _ _ _.19-1.0 DK
GRN
--- ----- -
E
_ _ _ _ _ _ _ 140-1.0 OR
~ 17-1.0WHT
B
A
---II-
12020926
. ._ _ _ _ _ _ _ _ _ _ _ 14-.5 LT BLU _ _ _ _ _ _ _ _ _ _ _ _. .
A B
_ _ _ _ _ _ _ _ _ 140-1.00RN _ _ _ _ _ _ _ _ __
1GT100
12085003
12085003 (UPPER)
(UPPER)
12085002 (LOWER)
(LOWER)
12085002
HAZARD SIGNAL LAMPS
12020786
C400
12065158
. .- - - - - - - - - - - - 15-.5 DK BLU
C-22
REAR LAMP
HARNESS
19-1.0 DK GRN
17-1.0 WHT _
_ _ _ _ _ _ _ _ 16-.8 PPL _ _ _ _ _ _ _ _ _ _
. ._ _ _ _ _ 15-.5 DK BLU _ _ _ _ _
~~
---------:~~iiC~D~
FORWARD LAMP
HARNESS
Cl0l
12059472
~fi!;'S
PRNDL LAMP
(SEE PAGE 58) .......
- - - 8-.5 GRA
_ . _ _ _ _ _ _ _ 18-1.0 YEL
DIESEL ONLY
GASOLINE ONLy'l
GAS~LlNE ONLY
1
2
3 \. 4 l5
G 39 1234 311159 50
300 30 50
F
E 35 8 397
LU
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 14-.5 LTB
~+6:;842;11+4",1..:;9LL::..!-481
TURN SIGNAL
SWITCH
.1
-=
12004148
. ._ _ _ _ _.14-.5 LT BLU _ _ _ _ _ _
439
I-
I
~,
HORN
A
1
240 111
B 3
11 350
C 140 15 120
D 9 508 33
E 35 8 397
F
300 30 I 50 I
G 39 12341 311 59 I 50
1
2
3
4
5
S2
a:
I
I
_ _ _ _ _ _.15-.5 DK BLU _ _ _ _
~~~~~~~~~~~~~~-
t;:
NORMALLY
OPEN
SWITCHES
112~.
0
C!
.rr-I
18-1.0YEL
16-.8 PPL
F
E
0
14-.5 LT BLU
~~rl
17-1.0WHT
19-1.0 DK G RN
CIRCUIT OPERATION
TEST
TURN SIGNAL LAMPS
1.

applied through the TURN/BU Fuse and Turn Flasher to
the normally closed contact of the Hazard Flasher Switch
in the Turn Signal Switch.
LH Front Park and Turn Lamp LT BLU (14) wires.
Voltage is applied to the LH Tail, Stop and Turn Lamp
YEL (18) wire.'
when the current flow heats up the Timing Element in the
Flasher and it repeatedly opens and closes the circuit.
The voltage applied to the LH Park and Turn Lamp
will also be applied to the LH Side Marker Lamp. If the
Lamp Switch is in the OFF position, the LH Side Marker
Lamp will find a path to ground through Splice S123 and

the Park and Turn Lamp to ground. This Lamp provides
low resistance paths to ground. The Marker Lamps will
flash with the Turn Lamps.
voltage is applied through the TAIL LPS Fuse, Lamp
Switch, and Splice S122 to the Marker and Park Lamps.
If the Turn Signal Switch is in TURN LEFT, the LH Side
will go out. When the Flasher removes voltage to the
the Turn Lamp and will go on. In this way, the LH Side
Marker Lamp will flash on when the LH Park and Turn
Lamp goes off, and off when the Turn Lamp goes on.

ON position.
2 . Connect a test lamp from PPL (16)

wire at turn signal switch
DIAGNOSIS - TURN LAMPS
ACTION
GO to step 2 .
REFER to "Hazard Lamps Do No

Operate" symptom.
Test lamp lights.
CHECK condition of TURN/BU fuse

and for an open in PPL (16) wire
or DK BLU (38) wire. If fuse and
wiring are good, REPLACE turn
signal flasher.
TURN SIGNAL LAMPS FLASH RAPIDLY

TEST
1 . Turn hazard lamp switch to ON

With the Turn Signal Switch in TURN RIGHT, voltage
will be applied to the RH Lamps in the same way.
RESULT
position. Check from turn signal

lamps and rear taillamps.
RESULT
ACTION
One side of turn signal lamps

flash rapidly.

bulb.
Only one side of turn signals

light but do not flash rapidly.
REFER to Turn Signals Do Not


TEST
RESULT
ACTION
Lights flash.

GO to step 2.
2. Turn hazard warning system off.

turn signal to side that does not
work. Connect a test lamp from LT
BLU (14) or DK BLU (15) wire
(depending upon which side does
not work) at turn signal switch
Test lamps lights.
GO to step 4.
GO to step 3.
3.

Test lamp lights.

(depending on which side did not
work) at connector C101 to
ground.
Test lamp lights.

installed wiring.

either LT BLU (14) or DK BLU (15)
wire(s) between turn signal switch
C101.
1. Turn hazard warning system on.

4.
TURN SIGNAL LAMPS
C-23
~BA~ ~
I1l ~ [0 [ffi 0
L
lID lID ~ ill ~ [0
[ffi
[ID[ID~D[oOD
ACC
liP CLUSTER
CONNECTOR
(SEE PAGE 55)
IGN HTR PWR
C218
12040744
~DD~EJ
GAUGES
TURN
SIGNAL
SWITCH
PWR
[}DOO[}D~
TRANS
ECM-BAT
HORN/OM INSTR-LPS
OODDOO~
TAIL LPS
INJ
HTR
ACC-RADIO
1 I 00
0000 0
[}J [}J
30A
STOP-HAZ ECM-CRNK
ALT
AUX
WIPER
CRNK
T~ ~spQ
19-1.0DKGRN
17-1.0WHT
-----~If19]iB
_ ....-:;:-1.....,
r-~-+-16
18-1.0 YEL
16-.8 PPL
L
K
------t--+---t.....
+-_....J
. - - -_ _
27-1.0 BRN
...J
p----_____________
>~
16-.8 PPL
L-...._+-38
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ 15-.5 DK BLU _ _ _ _ _
t-....1...f'=Cr'JlI:o'-r""2'='! H
592 J
3 11 K
0419 L
5
MI
75 N
4
P
6
_ _ _ _ _ _ _ _ _ _ _ _ 14-.5 LT BLU _ _ _ _ _
liP
15-.5 DK BLU
481 W/GASOLINE
14-.5 LT BLU
10 W/DIESEL
12015964
Cl00
F
E
15-.5 DK BLU _ __
_ _ _ _ _ _ _ _ _ _ 14-.5 LT BLU _ _ _ _. .
TURN
FLASHER
JIIlII'I"":::"+rr"
16-.8 PPL
1_
12004147
C211
12004148
OPEN
SWITCHES
1_ -
----
PRNDLLAMP
(SEE PAGE 58) . . - 8-.5 GRA
19-1.0DKGRN
18-1.0YEL
C
~
42
439
7
6
4
4
3 75
50 5
25 0419
59 3 11
4 o 592
7
2
ENG
481 W/GASOUNE
Mild)
~Vl0 W/DIESEL
J
H
L"'l
12015113
I~
DIESEL ONLY
_ _ _ 15-.5 DK
BLU
. ._ _ _ _ _ _ _ _ _ 16-.8 PPL
C-24
TURN SIGNAL LAMPS
c:::s::::
r~
J[
14-.5 LT BLU
1-
.18-1.0 Y E L r
A
Cl02
"" 19-1.0 DK GRN_
C400
12065158
12020786
14-.5 LT BLU _ _ _ _ _ _ _ _ _ _ _ _ _- .
15-.5 DK BLU _ _ _ _ _ _ _ _ _ _ _ _ _. .
GT100
12085003 (UPPER)
12085002 (LOWER)
FORWARD LAMP
HARNESS
Cl0l
12059472
CIRCUIT OPERATION
Horn Relay coil is grounded. The relay is energized. Its
contacts close and battery voltage is applied to the
Horns.
DIAGNOSIS - HORNS
PRELIMINARY CHECKS:
Check to see that the HORN/DM fuse is not blown.
REPLACE if blown.
HORN W ILL NOT OPERATE
TEST
3.
4.
ACTION
Test lamp lights.

installed wiring.
GO to step 2 .
Test lamp lights.
GO to step 3.

connector C207 and fuse block or
REPLACE HORN/DM fuse
Reinsert horn relay. Disconnect

turn signal switch connector C211.
Connect a jumper wire to BLK (28)
GO to step 4.
Horn sounds.
Disconnect horn relay. Install a

jumper wire from ORN (240)
terminal to DK GRN (29) terminal
at horn relay connector C207.
Horn sounds.
REPLACE horn relay.

GRN (29) wire from horn relay
connector C207 to horn. If no
open is found, ISOLATE problem
in body builders installed wiring.

ground. Press horn switch.
2.
RESULT
Remove horn relay. Connect a test

lamp from ORN (240) wire at horn
relay connector C207 to ground.
HORN SOUNDS CONTINUOUSLY WITHOUT DEPRESSIN G HORN SWITCH

RESULT
TEST
1 . Disconnect turn signal switch
ACTION
Horn stops.
GO to step 2.
No shorts found.
REPLACE relay.
Short(s) found.
REPAIR or REPLACE as required.
connector C211.
2.
Disconnect horn relay connector

C207. Check for a short to ground
in BLK (28) wire.
HORN
C-25
y v w /w w v w
>
HOT AT ALL TIMES C
> V W W V V \V \A T A
HORN/DM }
15 AMP *
HORN
RELAY
C 207
12065169
G
C
o
I 240-1.0 ORN I
17
PROVISIONS FOR
DOME LAMP
(SEE PAGE 59)
19
17-1.0 WHT
19-1.0 D K GRN
18
18-1.0 YEL
16
- 16-.8 PPL
27
^ 27-1,0 BRN
15-.5 DK BLU
15
X
- 14-.5 LT BLU
14
HAZARD
- 28-. 5 BLK
I
I
8
3 | 16 13 5 0 1
140 15 120
9 508 33
n
35 8 397 ^
1300 30 | 50
39 11234 3 1 1 59 |
2
3
|
O
|
50 ]
5
|420[ 4 4 0 !
593
L _
68 250
r
10 505
|
|901| 93
|
(8 2 4 |1 4
592
11
419
75
4
12004147
C211
12004148
.481 W /G ASO LINE
TURN
SIGNAL
SWITCH
10 W /D IESEL
10
12015964
8-.5 g r a
prndl
LAMP
(SEE PAGE 58)
C100
12015113
DIESEL ONLY
I
n==r'
o
G
C
O
DRL RELAY
I ^
GT100
240-1.0 ORN
S214
HORN
lr
240-1.0 ORN
(SEE PAGE 18)
C-26
12085003
(UPPER)
12085002
(LOWER)
29-1.0 DK GRN
FORWARD
LAMP
HARNESS
WIPERS DO NOT OPERATE IN LO
CIRCUIT OPERATION
TEST
WIPER
circuit is through the PPL (92) wire, the Wiper/Washer
Switch and the BLK (150) wire to ground.
The W iper Motor is supplied battery voltage with the

Ignition Switch in START or RUN, with ground supplied
by the Wiper/Washer Switch.

to LO. Connect a fused jumper
from GRA (91) wire at wiper switch
RESULT
LOCATE and REPAIR open in GRN

Wiper motor runs.
WASHER
When the Wiper Motor is in LO, battery voltage is
supplied to the motor through the WHT (93) wire and the
ground circuit is through the GRA (91) wire.
Battery voltage is applied to the washer pump

through the WHT (93) wire, to the switch and to ground
through the BLK (150) wire. The washers are operational
as long as the paddle switch on the Wiper Switch arm is
on.
When the wiper is in HI, battery voltage is supplied to

the motor through the WHT (93) wire and the ground
ACTION
DIAGNOSIS - WIPER/WASHER
PRELIMINARY CHECKS:
Check condition of WIPER and INST LPS fuses. If
fuses are in good condition, use the following diagnostic
procedures.
TEST
1. Place ignition in RUN and turn
wipers to HI. Connect a test lamp
from WHT (93) wire at wiper motor
2.

RESULT
ACTION

block.
Test lamp lights.
GO to step 2.
Wiper motor runs.

and ground G102 (Gasoline) or
G101 (Diesel).

TEST
1.

to HI. Connect a fused jumper
from PPL (92) wire at wiper switch
RESULT
ACTION

Wiper motor runs.
C-27
HOT IN A C C Y O R RUN
WIPER
25 AMP
93-3.0 WHT I
A
2
150 124011111
B 3 i 16 1350}
|
C 140 15 120
^
D 9 508 33 r
n
E 35 8 397 ^
^
F
1300 30 | 50 |
G 39 1234 31 ! 59 | 50 |
|
|
11
17 i
I' BOI 440
\
1593
L _
% 250
^
1505
n
|
|9 0 ir 9 3
|
|824f 14
10 9
2
H
592 J
11 K
419 L
75
4
6
l/P
.481 W/GASOUNE
M
Nl 10 W/DIESEL
P
12015964
C100
194*1.0 PNK I
WIPER MOTOR
(BODY BUILDER
INSTALLED)
192-1.0 PPL*
97-1.0 LT BLU I
91-1.0 GRAh
12015113
DIESEL ONLY
GASOUNE ONLY I
GASOLINE ONLY
H \
10
3911234 31 | iT 5 0 l
35 8 397J
9 508 33
140 15 120
2 [150 I 240|111|/
GASOUNE ONLY
93-3.0 WHT l
DIESEL
ONLY
|^H150-.8 BLK*
15Q-.8 B LK *
M 150-1.0 BLK
S112
(SEE PAGE 12)
150-1.0. BLK
PULSE WIPER
CONTROL MODULE
S204
(SEE PAGE 11)
97
GT100
12085003
(UPPER)
12085002
(LOWER)
ENGINE
GROUND
G102 (GAS)
G101 (DIESEL)
C-28
1150-.8 BLKI
94
B= i . J
C207
12020492
C204
PULSE WIPER,
WASHER SWITCH
(COLUMN MOUNTED)
ENGINE
481 W/GASOLINE
.. 1824114
I
I 1flW 505

419
I
Jr
1593 11
An i
# 3 9 1
17
D IE9fl ONLY
m>
10 W/DIESEL
CIRCUIT OPERATION
RESULT
TEST
START
contacts to open simultaneously. As soon as the


position, battery voltage is applied to the Starter
Solenoid. Both solenoid windings are energized. The
circuit through the Pull-In Winding is completed to
ground through the Starter Motor. The windings work
together magnetically to pull in and hold in the Plunger.
The Plunger moves the Shift Lever. This action causes
the Starter Drive Assembly to rotate as it engages the
Flywheel ring gear on the engine. At the same time, the
Plunger also closes the solenoid switch contacts in the
Starter Solenoid. Full battery voltage is applied directly
to the Starter Motor and it cranks the engine.
CHARGE
The AC voltage is converted to DC by the rectifier bridge
terminal.

contacts in place to continue cranking the engine.
voltage applied to the Pull-In Winding is now opposing

supply to Rotor current and thereby control the output
voltage. The Rotor current is proportional to t h e width of
magnetic field.
Regulator senses Generator rotation by detecting AC
by controlling the pulse width. This regulates the
The digital regulator controls the VOLTS Indicator light
with a solid-state light driver. The light driver turns on
the light whenever undervoltage, overvoltage or a
stopped Generator is detected.
ACTION
1. Place transmission in PARK.

wire at starter solenoid to ground.
Turn ignition switch to START
position.
Battery voltage.
GO to step 2.
No voltage.
GO to step 3.
2. Connect a voltmeter from PPL (6)

Battery voltage.
REPLACE starter solenoid.

surface.
Battery voltage.
No voltage.

(2) wires and fusible link between
ignition switch connector C200
and battery junction block.
3. With ignition switch in OFF

position, connect a voltmeter from
RED (2) wire at ignition switch

TEST
RESULT
ACTION
1. Connect a voltmeter to positive
and negative battery terminals.
Turn ignition switch to START.
2. Connect a voltmeter from negative

3. Connect a voltmeter from positive
terminal to BLK (2) wire.

GO to step 2.
Voltage less than 9.5 volts after

15 seconds cranking.

Less than .5 volts.
GO to step 3.
More than .5 volts.
Less than .5 volts.
More than .5 volts.

BATTERY IS UNDERCHARGED OR OVERCHARGED
RESULT
TEST
1. Connect a voltmeter from RED (2)
wire at generator to ground.
2. Connect generator connector

accessories turned off and engine
running at fast idle. Connect
voltmeter from battery terminal on
generator to ground.
ACTION
Battery voltage.
GO to step 2.
No voltage.

generator to battery junction block.

Reading of less than or greater

than 13-16 volts.
REPAIR generator.
STARTING/CHARGING
C-29
idd oQ-9
I
I
i qbu
o'9-z
ECM-BAT
1 0 AMP
------*4X -----k-ai.
ki p*
k. im
yC I h .....L
i
/ 1|
'-----J t
-a
-a
-a
g s a - l
CRUISE
CONTROL
MODULE
(SEE PAGE 52)
G110
C-30
STARTING/CHARGING
GASOLINE ENGINE
4 4 0 -.8 O R N I
TCM
(SEE PAGE 40)
l/P CLUSTER
(SEE PAGE 56)
ENGINE
GROUND
LH CYLINDER
HEAD
G113
ENGINE
GROUND
RH CYLINDER
HEAD
G112
FUSE BLO C K
(SEE PAGE 4)
STARTING/CHARGING
DIESEL ENGINE
C-31
ECM-CRNK
10 AMP
I
1439-1.0 PNK/BLK
I 439-1.0 PNK/BLK
I423-.8 WHT,
I430-.8 PPiyW HT
1424-.8 TAN/W HT
--------------
453-.S BLK/RED '

C125
12015791
12010996
P424-.8 T A N /W H T I
! L i.
I
-.8 W H T i
Lr
^!4 2 4 -.8 TAN/W HT
4 4 5 3 -.8 BLK/RED
C121
12040705
J430-.8 PPL/WHT
1 3-5.0 PNK |
GT100
DISTRIBUTOR
12085003
(UPPER)
12085002
(LOWER)
I1 2 1 -.8 W H T |
wmmmm S205
I i i -
(SEE PAGE 4)
\ f
f a r
jm m r
^ i 4 3 9 - . s p n k / b lk m h t
I 3-5.0 P N K i
(SEE PAGE 4)
SPLICE S202
(SEE PAGE 19)
439-1.0 PNK/BLK I
-1
GE]
o
oo
fO cn
Ul (0
o
ti <D
fe\r *
o
Ul
o
Ul
C122
2977253
TACHOMETER
10 W /D IE SEL
10 W /D IESEL
-32
IGNITION
r-
481 W /G ASOLINE
ro <o
o
o
Ul to
(0
fo
e- I
481 W /G ASOLINE
IGNITION
- SWITCH
CIRCUIT WIRE
SIZE
NO.
COLOR
465
1223
1222
422
.8
.8
.8
.8
DK G RN/W HT
YEL/BLK
LTG R N
TAN/BLK
419
.8
BRN/WHT
435
420
.8
.8
GRA
PPL
1226
1225
1224
1229
1228
1230
1231
437
59
.8
.8
.8
.8
.8
.8
.8
.8
.8
RED
DK BLU
PNK
LT BLU/WHT
BLK/RED
DK BLU/WHT
GRA/RED
BRN
DK GRN
CAVITY
. DESCRIPTION
CIRCUIT WIRE
SIZE
NO.
COLOR
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12

SOLENOID B DRIVER
SOLENOID A DRIVER
TCC DRIVER
NOT USED
NOT USED
NO T USED
NO T USED
NOT USED
EVRV SOLENOID
BRAKE SIGNAL
439
450
551
416
417
441
442
444
443
432
1061
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
PNK/BLK
BLK/WHT
TAN/W HT
GRA
DK BLU
LT BLU/WHT
LT BLU/BLK
LT GRN/BLK
LT G RN/W HT
LTG RN
ORN/BLK
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
NO T USED
NOT USED
NOT USED
FORCE MOTOR LOW
FORCE M OTOR HIGH
INPUT SPEED HIGH
INPUT SPEED LOW
DRAC MODULE
AIR CO NDITIO NING
413
412
468
467
.8
.8
.8
.8
440
455
452
474
496
451
120
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
.8
DESCRIPTION
TAN
PPL
DK GRN
DK BLU
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
12V IGNITION FUSED

SYSTEM GROUND
SYSTEM GROUND
5V SENSOR REFERENCE
TPS
STEPPER COIL A HIGH
STEPPER CO IL A LOW
STEPPER CO IL B LOW
STEPPER CO IL B HIGH
MAP
SERIAL DATA
NO T USED
OXYGEN SENSOR GROUND
OXYGEN SENSOR
INJECTOR B (2) DRIVER
INJECTOR A (1) DRIVER
ORN
PPL
BLK
GRA
DK BLU
W HT/BLK
TAN/W HT
D1
D2
D3
D4
D5
D6
D7
W HT
TAN/BLK
BLK/RED
PPL/WHT
BLK/YEL
YEL
D8
D9
D10
D11
D12
D13
D14
D15
D16
12V BATTERY FUSED

SENSOR GROUND
SENSOR GROUND
5V SENSOR REFERENCE
KNOCK SIGNAL
ALDL
ELECTRIC FUEL PUMP FEED
FUSED
NOT USED
NOT USED
NO T USED
HEI SPARK TIM ING
HEI BYPASS
DISTRIBUTOR REFERENCE LOW
DISTRIBUTOR REFERENCE HIGH
TRANSMISSION TEMPERATURE
COOLANT TEMPERATURE
POWERTRAIN CONTROL MODULE CONNECTOR

423
424
453
430
1227
410
CAVITY
POW ERTRAIN CONTROL MODULE CO NNECTOR

GASOLINE W/HD 4-SPD., AUTO TRANS W/OVERDRIVE
C-33
ECM-CRNK'
ECM-BAT ~
10AMP J...
10 AMP ~.'_ _ _ _ _ _ _ _ _ _ _
439-.8 PNKlBlK
~ ~ ~
44O-.80RN
44O-.80RN
S111
(SEE
PAGE
_
_4)
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 450-.8 BIK
.r..
417-.8DKBLU _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
417-.8 DK BLU
TP
SENSOR
I-~t__-..
452
417 C
416
Jl
416-.8GRA
416_-'6GRA
432-.8 LTGRN
. . . . . - - - - - - - - 432-.8lTGRN - - - - - - - - - - - - - - - - - - - - - - - - - - - 474-.8GRA - - - - - - - -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
474-.8 GRA
496-.8 DK BLU
. .- - - - - - 496-.8 DK BlU -
Cll0
12078090
________
1
--:1
____
S107
455-.8 PPl _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
452-.8 BlK _ _ _ _ _ _ _ _ _ _ _..._ __
S106
410-.8VEl _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
- - - - - - - 410-.8 VEL -
MAP
SENSOR
1tI~-
496
Cl17
12015375
~------------412-.8
PPl _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
OXYGEN
SENSOR
INPUT
SPEED
SENSOR
C-34
I
~
si
~
?---------
1230
o
123
--=
~
~
123
1231
"""",,,'W_. -
_1231-.8GRA/RED
,,
,,
,,
,,
,,
I,
,,
,,
C173
12078084
----t-
~ ~ ..... 1227-.8 BLK/YEL ..
...-.,
1226-.8 RED
-I.~
_ _ _ _ _ _ _ 412-.8 PPL _ _ _ _. . . . .
~ ~ ~
~~
_ _ _ _ _ _ _ 410-.8 VEL _ _ _ _
-'
"""'" 1230-.8DKBlU/WHT . . . . . .
_ _ _ _ _ _ _ 1225-.8 DK BlU _ _ _ _....
---
1231-.8 GRA/AED _
_ _ _ _ _ _ _ 1224-.8 PNK
. ._ _ _ 455-.8 PPl
J , ENGINE
_ _ _ _ _ _ _ _ _ _ _ _ ...-..
_____ r-=
- - -_ _ _ _ 452-.8 BLK - - - -. . .~
,, ,.--" - - - -
452-.8 BLK - - - - .
Cl0e
12078084
- -_ _ _ _ 455-.8 BLK - - - -....
r ..........
ESC KNOCK
SENSOR
COOLANT
TEMPERATURE
SENSOR
--------------
ENGINE
GROUND
G100
TRANSMISSION
CONNECTOR
ALTERNATOR BRACKET
GROUND
G103
. - . . . - 439-.&
439-.S PNK/BLK ~
...
,-
..
..
440-.& ORN _
450-.8 BLKlWHT,.
l- - - - - - -
454-.& BLKlWHT'"
417-.&DKBLU
432-.&LTGRN
. . . , - 474-.8GRA
... ,
120&5003
(UPPER)
120B5002
(LOWER)
_~_
-l.
l
416-.& GRA
416-.&GRA
432-.& LTGRN
432-.& LTGRN
496-.& OK BLU
. ._ _ _ _ _ 440-.& ORN _ _ _ _ _
_,_
. . , _ 452-.&BLK _ , _
. . ~ _ _ 1227-.& BLK/YEL - , -
~._41o-.&YEL_
,,'_412-.&PPL
...
455-.8 PPL
----_
452-.& BLK
....,.
-l.
1230-.8DKBLU/WHT
_ . - 1231-.& GRNRED . . . _
i r
l
m
'22'5-.8 OK BlU _ , .
,,'_1224-.&PNK
413-.8 PPL
I_
---~--
~"
g;
..
~
<XI
1231-.& GRNRED
413-.& PPL
.......
.J
W
U>
W
::;
,.
..............
CD
~ '"
e ~
-- ............................
, ,,
- - - - - - - ...,
,.-- -
w
Z
~~
~~+...:::.=--,
.Je"
w
U>
w
i5
,-,-, ...
>J~
~r
~ ,.
c
1
2450,..
440
.455
3~"'~
452
474
496
451
4~
@Q]
417
00
rngJ
OB~
[ffi]
010~
~1100
.i=
-=
~I..
~120
@ID 13 413
@Q] 14 f.illl
..
,. .
1-
~15[@
'. --
~,
2:J
C250
12052177
412-.& PPL
PCM
CONNECTORS
413-.BPPL _
_ _ _ _ _ 439-.&PNKlBLK ... ~
c::::J
1226 2
1225 3
1 24
@Q]
~7
~e
1230
---....,.--
It)
L
- -- -- I
_----- ,
..
'"
'lllll1IGIQJ 16 [1J
..,.-~
-_... ,
1.225-.8 OK BLU
_ _ _ _ _ 413-.& PPL
U>
...,-.
...
'II1II
,- "1-
1224-.& PNK
44O-.BORN
::;
~,
1230-.& OK BLU/wHT ..........
. ._ _ _ _ 440-.& ORN _ _- .
439-.B PNK/BLK -
,
I
_~_
-_
... ,
.......
1227-.& BLK/YEL
1226-.8 RED
. .,
.........- F
. - 451-.&WHT/BLK _ _ _ _
4~~~::::L ............... 1
_1226-.8RED_,_
~,.
45O-.BBLKlWHT _
_
_ _ _ _ _ _ _ _ _ _ ..-454-.&BLKlWHT _ _
417-.& OK BLU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 &DKBLU
44O-.&ORN
",'_455-.BPPL
474-.8 GRA
496-.&DKBLU _ , _
... -
GT100
416-.&GRA _ . _
,~
454-.& BLKlWHT
..
-l-
,-,-
45Q-.& BLKlWHT
z
::;
C251
12052175
U>
ALDL
C204
12020043
-c
...
. .- - 59-.& OK GRN - - - -...
AIR CONDITIONING
(SEE PAGE 50)

C-35
I-::::::::::::::::::::::::::::::::::::::::::::::::~~:~::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::---""":
r" ,....,
~
~
----.
,....,
a.
....
442
,. . , ,. . ,
,...., ,...., , . . . . , , . . . . , . . . " , . . . . , , . . . . , . . . . . ,
~ ~
,. . , .-., . ." 1
,....,
~ ~
~ ~
442-.8DKGRN/BLK -
,...."
.... ~ ... 441-.8 DK GRN/WHT ... ~

B
,...., ... 443-.8DKBLU/WHT ~ . . " , ... ,.
=- -
..."
_ Slll
~
~ -","
....
..."
~ 450-.8 BLK/WHTF
,'~ ~ ~ ~
'I. ,
, , .. ..
444-.8 DK BLU/BLK
12047951
. .- - - - - - - - - - - - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
..."
. . . " ,...., -
~~
~ ~
~-
IIiIo
......
...--.....
~ _
......
..
. . 439-.8 PNK/BLK . . . . . .
---
" ' I F - - . . . . ."
C
C
C
44O-.80RN
120-.8 GRA
. - 423-.8WHT
- - 453-.8BLK/AED ........
424-.8TAN/WHT
I-,~
439
....,
:J
---I
..... _
,....,
.....,,....,
,....,
,....,
.--.....
...-.....
,
.
...--t
.
.
.......... ,....,' ....
___
....,,....,,....,.........
,
....
-I ... ,. . _ . .
_
...... ,rr ~--,.
;- - - -t:.:~:.:,.:,:..::~:,:. : ='::~~""--:
,-,, ' ,-, ___________________
..."
.-.,
.
.
.
.
....
1'I - .... - . -..-- - .-1,...., ...... r
, "--1-I - - . - ......-,:,-...... ~ - ..." ---...... .... ....1,. - ..."
~, :c
.
-1-1-. .-1_,_:-,',.
r.'=-:'::t':!r _:1- __ ""G"_,_
c
435
~,....,,....,
450-.8BLK/WHT ___ ,....,
~ ~ ~
. , IDLE AIR
CONTROL
III
ACTUATOR
EVRV
. .- - - - - - - - - - - - - - 44O-1.00RN _ _ _ _ _ _ _ _ _ _ _ _. . .
450
..." ..." ,....,,....,
rir..." ...". .",....,,....,

- ,...., ...,. . ,
250-1.0BRN
,....,,....,
,....,
~
~
439-1.0PNK/BLK
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 44O-1.00RN
43O-.8PPL/WHT
--C
..-..c
C120
12078082
",F
.-~ ... ~ ,...., ,.
....
_465-.8DKGRN/WHT ..........
1228-.8BLK/AED
ELECTRONIC
SPARK
TIMING
423
EST SIGNAL
430
EST REFERENCE PULSE HI
424
453
EST BYPASS
EST REFERENCE PULSE LO
~-,,..,-,-,
_
430-.8 PPL/WHT_
. _
424-.8 TAN/WHT_
,422-.8TAN/BLK
...
_467-.8DKBLU-l . .
453-.8 BLK/RED... ....
r--
GROMMET
0112
12020549
101
12084618
INJ-2@:~~~
INJ-1 @~:
..._ _ _ _ 468-.8 DK GRN _ _ _ _I
INJ-2
INJ-1
I
I
I
S109
r.~:r71rn~~~------120-'8
GRA - - _ . _
itIII---44O-80RN-----L..-_ _ _- - '
Cl18
-44O-.80RN-
111.. ....., -
to
.-- ,
...,

_ _
l'"
~_
..J
:'~tr
12~90
~
"'442-.8DKGAN/BLKF . . ......
441-.8DKGRN/WHT_k .....
1222-.8LTGAN_ ......
,"'_.,,.,, ,_1=
... 443-.8DKBLU/WHT . . . . . . .
_ . - . , .... 444-.8 DK BLU/BLK . . . ......
~.
,III- - -.-- -,...., .

T - - - - -, - - ~ :':""-'=:
1- , - -
ffi
t-____ 467-.8DKBLU-::-1
t-____ 461-.8AED
.,-.-.-.-~
,
..
L.... .....
,.
......,--- ....
I,
---------.-
'F.-----1
-.,_"'' 0_'
..._ _ _ _ 462 8 WHT

-.
--,
~~ I
120
120-.8GRA
i~
~:o!~
~
':J
8153
_ -250-.8
BRN.' _ _ _ _ _ 250-.8 BRN _ , _ _ _ _ _ _ _ 250-.8 BRN
_.~
440
. .12065401
_ _ _ _ _ _ _ _ _ _ _ 440-.80RN _ _ _ _ _. .
. ._ _ _ _ _ _ _ _ 490-.8 RED _ _ _ _ _ _ _ __
~ ~
FUEL
PUMP
RELAY
~
;
C-36
. . . , . . . , ... 465-.8 OK GRN/WHT .... ,...., . . - , .... ...
......
~=~

OUTPUTS GASOLINE
GASOUNE ENGINE
ENGINE
OUTPUTS
120-.8 GRA
F . . . " .......... 450-.8BLK/WHT.-- ,...., ~ . . . . . . . . .
Cl03
12052287
-1'
,....--
..J
_ _ ,...., ...... _
,
I
~
..." ,....,,....,,....,...... ......
,
&\
G~;r~~D (Q)
SHEET
G100
ALTERNATOR
BRACKET
GROUND
G103
~~~~~
I
A
e
_
,,
-"481-1.0 RED
~250-1.00RN
'-439-1.0 PNK/B LKr~""'~~

~440-1.0 ORN
- . . 450-.8 BLKJWHT_
,..- - -- -- -.- -,.- --,--,-.- -,- -- --..--.- -,-,-,- --,......,- ---_ .. - - - ..

--,--I--- . .. - -,-r'"
----..-- - -..... r_- --,...,....--- - - -i:11..-
.-..-- .-
~ 450-.8 BLKIWHT r
~ 439-.8 PNK/BLK_
"-423-.8WHT
. . 424-.8 TAN/WHT...
"-453-.8 BLK/RED.,.
"-430-.8 PPL/WHT_
,...,
-......, 11"-
~,-...
j[5Jf
1-
~1228-.8 BLK!RED_
.-...
HT _ _ _ _ ..-
. . . 454-.8 BLKJW
BLK ___
"'487-.8DKBLU
"488-.8DKG RN
-~--..-
," ......,
~,..--
7n .,.
1- ~ c:s::::
-"444-.8DKB LU/BLK'
-"442-.8LTB LU/BLK'
""441-.8LTBLU/BLK.
GRN
. . . 1223-.8 YEllBLK.,.
"'490-.8 RED
.- ,..
.- "
...
...
- . - ,.
-"440-1.0 OR N
....
-,
c:::J
250
I-
,......-
i-
-~
_440-1.00RN_ : ,
A 2 150 240 111

16 350
B 3
C 140 15 120
o 9
I H
7
E 35 8
F
300 O[ 50 I
1 59
G 39 .
4
5
1
2
(OPENS WHEN
BRAKE PEDAL IS
DEPRESSED)
-r---.
t
S207
250-1.0 BRN
10
I
J
"-419-.8
12015113
SERVICE
ENGINE
SOON
LAMP
(SEEPAGE)
FUEL
CYCLE
MODULE
(SEEPAGE)
G "
0 ~
35
~ 1~0
311~
300 30 50
8 397
~
33 ~ (
15 120,.
16 350
10
12015964
2
439 1.
420 440 592
593 11
250 419
10 505 481
901 93 75
1824114 4
9
8
6
7
1250-1.0 BRNI
~~-
~~
II-
~_,,,J
.120-.8GRA
I-
....
.481-.8 RED
i-
"
-_
......- -,
;h: -
12085003 (UPPER)
12085002 (LOWER)
..-
..- ,.......,
..-
,,~
GT100
I-
..- ,..
-~
-.
_430-.8PPL/WHT _ _ ...
... 1229-.8 LT BLU/WHT"
435-.8GRA
_
465-.8 OK GRN/WHT,..
~1228-.8BLK/RED
.-- ...
__
...
_454-.8 BLKJWHT _
~
422-.8 TAN/BLK ___

467-.8 OK BLU
468-.8 OK GRN
I-
~443-.8DKB LU/WHT
~-~--
..-
r..-
~
~
1-
423-.8 WHT
_424-.8TAN/WHT _
_ _ _ _ 453-.8BLKlRED _ _
-- -
I-
. . 485-.8DKG RN/WHT
[g:
44O-.80RN
-----
i~
" ......,
. - 439-.8 PNK/BLK _
120-.8GRA
c-
II
"-435-.8GRA
SWITCH
450-.8 BLKJWHT ,...,. ... 450-.8 BLKJWHT ~ _
---
1..-
,...,- .-
-.-...
"'1229-.8LTBLU/WHT _
TCC
I-
-"120-.8GRA,
~1222-.8LT
___
I-
~440-.80RN
. . . 422-.8 TANI
r~
:~I
N
P
a:
<Xl
BRN/wHT~
8
7
6
824 14 4 P
901 93 75 N
L,J.l0 505481
'\
250419 ... ..::'
593 11 K
420 440
120-.8GRA
.
-.- ...
_443-.8 OK BLU/WHTr ....

..- 444-.8 OK BLU/BLK r
_442-.8 LT BLU/BLK,..
_441-.8 LT BLU/WHT"
..
...
1222-.8 LT GRN _
_
1223-.8 YELlBLK _
.... .......
-...
.,.
,, ,"'-1 0,, ,,
,,
490 422
1061
Ir
436
451
450
,.
1-

C-37
FUEL CYCLE MODULE

~O
GROUND
--
Cl
1-..- - - 150-.8 BLK
481-1.0 RED
350-.8
439-1.0 PNK/BLK - - - ~
AI
A
2 150 240 111
B 3
16 50
C 140 15 120
0950833
E358397
F
300 30 50
G 39 1234 31 59 50
1
2
3
4
5
350-.8 PNKlWHT
_ _ _ _ _
r ,..." =.._.
8218
II1II
e...._..I....
3.5.0.-.8.P.N.KIW_.HT
___.....
r,
C219
<t
12047886
PNKlWHT~'
- , . . . " ..
...
120-.8 GRA . _. . . . . .. .
I/P
r--t-;'~~r-::.L.,::;+-481 W/GASOLINE
120-.8TAN/WHT
, . . . " . . . . 439-.8 PNK/BLK
_ _ ,..." ...-
824 14
8
7
C
B
A
..III
Cl02
12020786
_ _ _ _ .....
12020827
_ , . . . " _ _ _ ,..." . . . - _
--- <B
12015964
_
... 450-.8 BLKlWHT _ , . . . " , . . . " , . . . "
11-________ 417-.8 DK BLU
GASOLINE ONLY
DIESEL
~
"
NlY
... , . .
___
1-__
120-.8TAN/WHT...-....
A.~439-.8 PNK/BLK _ _ _
lIIi _
1-___
12015113
GT101
..-i~
_ _ _ _ 467-.8 DK B
LU
~---_412-.8
PPL
t..... ...-...- .... ...
____ 452-.8 BLK
.J
~
:t::
~
5111
.-a
~ 3 @!l
~ ~ 416
~ 5 417
THROTTLE BODY INJECTION

GASOLINE ENGINE
..- ....... ...

~
[ID]
[ill]
~11~
12
[!jQJ
16
1=1
~13~1........1
~14 412
~15 46B
467
loy,
.InnI
C250
12052177
. ._ _ _ _ _ _ _ _ 150-1.0 BLK _ _ _ _ _. .
452
r---r-
416
C
..38
C-38
10
[!W
-('
i4'1'2l
~.=~
D
D
. ._ _. ._ ._ _ _ _ _ _ _ _ 412-.8 PPL _ _ _ __
TP
SENSOR
L.---r-
rID ... I- ...
7 ~
DB~
E
t:::
~ (SEE PAGE 11)
t"'-- 450-2.0 BLKlWHT
...
[Ig[J
467-.8 DK BLU _ _ _ _ _ _ _ _. ._ _. .
,..." ...-
~2~
--
c~
482-.8 WHT _ _ _ _ _ _. .
e_
....
PCM
CONNECTOR
INJ-2
INJ-l
1-___~----416-.8 GRA
5109
,..." ,..."
-----e
12084615
u.L..--'rl,I----~---- 488-.8 DK GRN
-.
... '~ ~ ,...,,"--i!.1---.
Cl00
12015113
g:~~~===~
12020829
C400
481 W/GASOUNE
10 W/OIESEL
10
,..."
IIIIIIIII
,..."
'"c
_ ..
. ._ _ _ _ _ _ 481-1.0 RED _ _ _ _ _ _ _ _ _ _ _ _
. . . . . , . . . " ...... _
...
INJ
'7.5 AMP
GAUGES
20AMP
<
120
ECM-CRNK
10AMP
..2!0
....
(SEE PAGE 11)
ISO
()
IGNITION _ 2:!0
ELEC. FUEL PUMP
.e 5206
___
30
, r: ,. ." -
12010996
C136
12015791
liP
l/P
, %
GROUND (Q )
G200
~
--
FRAME
GROUND
G400
CIRCUIT WIRE
SIZE
NO.
COLOR
1224
1225
1226
1223
1222
451
.8
.8
.8
.8
.8
.8
PNK
DK BLU
RED
YEL/BLK
L TG R N
WHT/BLK
440
.8
ORN
420
422
1234
1061
1233
1232
.8
.8
.8
.8
.8
.8
PPL/BLK
TAN/BLK
GRA/RED
ORN/BLK
DK GRN/YEL
LT BLU
CAVITY
DESCRIPTION
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
NOT USED
NOT USED
SOLENOID B DRIVER
SOLENOID A DRIVER
ALDL
NOT USED
NOT USED
NOT USED
12V BATTERY FUSED
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
NOT USED
NOT USED
NOT USED
BRAKE SIGNAL
TCC
NOT USED
NOT USED
NOT USED
SYSTEM CHECK LAMP
SERIAL DATA
OUTPUT SPEED SENSOR LOW
OUTPUT SPEED SENSOR HIGH
CIRCUIT WIRE
SIZE
NO.
COLOR
450
551
452
416
.8
.8
.8
.8
BLK/WHT
TAN/W HT
BLK
GRA
1228
439
.8
.8
RED/BLK
PNK/BLK
437
1231
1230
.8
.8
.8
BRN
DK BLU/WHT
GRA/RED
121
476
417
.8
.8
.8
W HT
BLK/PNK
DK BLU
1227
433
.8
.8
BLK/YEL
GRA/BLK
1229
.8
LT BLU/W HT
TRANSMISSION CONTROL MODULE CO NNECTO R
CAVITY
DESCRIPTION
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
SYSTEM GROUND
SYSTEM GROUND
SENSOR GROUND
5V SENSOR REFERENCE
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
FORCE M OTOR LOW
12V IGNITION FUSED
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
NOT USED
DRAC MODULE
INPUT SPEED LOW
INPUT SPEED HIGH
NOT USED
ENGINE SPEED
SENSOR GROUND
TPS
NOT USED
NO T USED
NOT USED
NOT USED
TRANSMISSION TEMPERATURE
MAP
NO T USED
FORCE M OTOR HIGH
TRANSM ISSION CONTROL MODULE CO NNECTOR
TRANSMISSION CONTROL MODULE (TCM) PINOUTS

DIESEL ENGINE
C-39
l V A M V M /W W \M
S
j )
HOT AT A L L TIMES ^
HOT IN START OR RUN ! ?
H
^
nvMwwvvwA |
WvVVWVWVV^T
ECM B
10 AMP
TRANS
10 AMP ^
ECM-CRNK ^
10 AMP
439-.S PNK/BLK
1250-1.0 ORN I
-4 H T |
1440-1.0 ORN I
1250-1.0 ORN I
1 440-1.0 ORN I
11226- 8 RED I
P SENSOR
439-.8 PNK/BLK fl
11225-.8 DK BLU I
-4 5 2
-417
11224-.8 P N K M
I 476-.8 PNK/BLK I
121-.8 W H T l
1417-.8 DK BLU I
1416-.8 GRA I
-4 1 6
1420-.8 PPUBLK m
422-.8 TAN/BLK r
417- 8 DK BLU
1229-.8 LT BLU/WHT I
455
r D
I4 5 5 -.8 PPL I
C135
\
12020403
I 433-.S G R A /B LK I
I4 3 3 -.8 G R A/BLK I
416-.8 G R A *
I 1222-.8 LT GRN I
416 )
450-1.0 BLK/WHT ^
1227-.8 BLK/YEL
INPUT
SPEED
SENSOR
1230-.8 DK BLU/WHT <
C173
12078084
A 1231-.8 DK BLU/WHT
11230-.8 GRA/RED W T
1231-.8 G R A / R E D ^
452
)
1228-.8 RED/BLK
I4 5 2 -.8 BLK I
FT
C175
12015792
1121-.8 W H T l
1150-1.0 BLK |
450-1.0 B L K /W H Ti
CUD
ENGINE
SPEED
SENSOR
TRANSMISSION
CONNECTOR
to
4k
O
C172
12084690
1
2
3
7
6
4
5
10
9
4 | 14
391
31 I 59 I 50 | |
4
93
75
I 300 30 I 50 I
n> 4
35
8 397
i
~
L _
33
250pH i
9
,
o
593] 11
140 15 120
1
14201
440
tm m
3 I 16 |350{
i
I 4 3 9 1 17 I 2
2
150
______ i
C-40

DIESEL ENGINE
I 250-.8 BRN I
I 250-.8 BRN I
ENGINE
GROUND
G109
_ _ _ 439-1.0PNK/BlK _ _ _
..
250-1.0 OR N
L ,..,. ....
- ..
-- --
...-1223-.BYEL/BlK_
"""439-.B PNK/BlKr
..
1226-.B RED
..
1225-.BDK BlU
..
1224-.B PNK
..
121-.BWHT
r- -
--- ---1 "L", 439-1.0PNK/BlK _ _ _ . . -
- - - - - - - ...,., -,-...,.,
1223-.BYEL/BlK ......
",. . WH._'
PNK/BlK~
_
--
...,., "-476-.B PNK/BlK_~_~'"
-- - ...
...-42O-.B PPL/B l K _
..-
. . . . _ _ 422-.B TAN/BlK ...

".~----_417-.B DK BLU'
. . . . . ...,., ..-1229-.BlT BlU/WHT
....._ _ _ _ _ 440-1.0 OR
476-.8
....
--
_.
'".."'OCUlWH'_
-.,
417-.BOKBLU
- -...,., -~-...,.,~=...,., - . .,.,.
........ ...,., -
422-.BTAN/BlK
.-
-.....
-I
,_ -,
c:J
::>
c::J
qCJ 2 CJ
,--,
':::r-'till3Jill..-
"
, __
', -,,
~~ -, ....
... -
_~
1225
_~
1226
CJ6 ~ . "
CJ 7 1222
CJ B TsfI. ~
~~9CJ
11061110 @Bl1
L....
,,
1,
112331 11
(12321 12
...,.,
......
~ ~
CJ
440
lIP
l/P CLUSTER
(SEE
(SEE PAGE 56)
56)
C216
12059125
. .t. .
..I1061-.B ORN/BLK -
I,
,~ - ,-r
'" -, .- - ~ ~,,.
_::J
--t
::: :=r. ='--,=....c,. :t:=:
:,----.
.
.
. . - _.......... -, ........,...,.............1
."".,.,"""'"'--,- _.,--.-,......................, I
.
_1223-.BYEL/BlK_...,.,
---------~ ~~
1226-.BRED_.
1225-.BDKBLU_. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ,
1224-.8 P N K _ I _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1234-.8 GRA/RED
1234-.8GRNRED
-
44O-1.00RN
...- 451-,B WHT/BLK _
..-433-.B GRA/BlKr
...,., ...,., . . -
.... 433-.B GRA/BlK
........._ _ _ _.1222-.B IT GRN
1222-.BLTGRN
~.~-----41B-.B GRA
GT100
120B5003 (UPPER)
120B5002 (lOWER)
....._ _ _ _ _.452-.B BlK
r __
....
~,
551-1.0TAN/WHT _ _ . . . . . . . . . . . .
_ _ "'-1227-.B BLK/YEl_~_
"'-1231-.B OK BlU/WHT
--_
-~
. . . - . _ _ 1230-.BGRNREO_
~ .. ,
..-122B-.B RE D/BlK,. ~ ~
1:,~
i
~
~
iii
-- .
~ "450-1.0BlKIWHT--~ ~'"
~ ~ _
~-
44O-1.00RN
~
...,.,
2
A 2 150 240 111
439 1
16 350
420 440 592
B 3
C 140 15 120
593 11
0 9 SOB 33
1 j250
E 35 8 397
10
F
300 30 50
901 93 75
1311591 1 1 1 TS24 14 4
G 39
1
3
10 9 8 7
2
4 5
6
'"
....
...
.. .,--
,..,.
....,
ENGINE
GROUND
G108
G10a
~ . . . ~., ... " . . .
C10D
H
J
K
M
N
...,.,
-,-,-
TRANSMISSION
CONTROL
MODULE
CONNECTORS
-,-~--,---
,-
1231-.BOKBLU/WHT_
.'=."'."""- -"
~,,,.
-,-~
_551-1.0TAN/WHT _ _ _
1227-.BBLK/YEL,.
.. , r . .
. . . . ,.
, _ _ ,_
-"
-,~
. .---,. . -, 1,
...."
-,-~
-,-.' -
-"
..
- ' - ' - ,-,- -
~~t_'_I
:-r;
~ ~ :~
0
, ' - .......
..., - -
__~I_
..
;--~I-
i
i
i,
'f!:.. -]1
mZJ
I ", Lr' ~ - - ~~
"I, __ ':.r===.,-==
~,'
!!
!
~.
Iw _ _ ",.. _
...a
,
,
:
J ! !Lre,
,ALDL
~ I _ _ _ _ .~w---------.
1_,...1
,,
1t----.L---,,_~ _____ J ,~!,

.... _
~ ~ ...,., ...,., .. 451-.BWHT/BlK _ _ ~ -
...,., ...,., _ . . . , . , ,422-.BTAN/BlK _
_.
~ ~ ~
.......

ENGINE
DIESEL ENGINE
C-41
"39-.8 PNK/BLKI
ECM-CRNK
10 AMP
l/P CLUSTER
CONNECTOR
39-1.0 PNK/BLK
S209
(SEE. PAGE 56)
DRAC MODULE
39-.8 PNK/BLK
(Z D i
12261
5225] 3
11224 4
f 4~6fil
(1223)
824-.S LT BLU/BLK -
3JSS21
SPEEDOMETER
(SEE PAGE 57)
f 4221
CZD 6 c m ]
ff22t 7 DPI
fi228l 8 HZ]
9 a
H a s il 10 [ZD
( p z l 11 [ 435 ]
r s n 12 rwi
z
A
B
C
D
E
F
G
2
3
140
9
35
1150 I 240 11111

1439! 17 I
[ 16 13501
1
T
14201440
15 120
593
I
68 250
508 33
j
w
r * 10 505
8 397
[300 30
1
19*1 93
50 1
50
|
|
[824(14
39 11234 31
1
2
3
4 5
10 9
8
7
/-\ V , O X
.1
1 591 j
2
592
11
419
-r
H l/P
J
K
L .481 W/GASOLINE
75
4
6
-10 W/DIESEL
P
12015964
12015964
12015113
DIESEL ONLY
GASOLINE ONLY I
GASOLINE ONLY
S213 (GASOLINE)
(SEE PAGE 30)
39-.S PNK/BLK
1
2
7
10 \ 9
8
6
t 5
G 39|1234 3 1 |^ 5 9 |5 0 | I
I \ | 8 2 4 | 14
4 P
F
I 300 30 P 50 1
93 75 N
E 35 8 397-J*-----!---------1
505
D 9 508 33
=T2T68 250 419
140 15 12!593 11
3 I 16
14201 4401 592 j
|B
2 1150 ^ 0 1 1 1 1 1 /
1439 j 17 I 2
3\ *
L, m\
f y -- l 10i
\\
CRUISE
CONTROL
MODULE
(SEE PAGE 52)
SOLINE ONLY
139-.8 PNK/BLK
824-.8 LT BLU/BLK
S152
(DIESEL)
(SEE PAGE 47)
150-.8 BLKI
S112
(SEE PAGES 11, 12)
3Q-.8 PNK/BLK
GT100
12085003
12085002
vss
1232-.8 LT BLUI
ENGINE
(Q ) GROUND
G102
C-42
DIESEL ONLY
ENGINE
m
q
K
481 W/GASOLINE
10 W/DIESEL
12015113
CIRCUIT OPERATION

(2) wire from Junction Block. The relay is operated by a
Solid-State Controller. The Controller responds to engine
temperature and also to an Ignition Switch Start Input.
After the initial time period the relay will be de-energized

for five seconds then will cycle ON/OFF for approximately
10 seconds.
TEST
1.

ON/OFF after the Ignition Switch is returned to RUN,
stops.
2.
3.
PRELIMINARY CHECKS:
A check of the glow plug system should
performed before doing diagnostic procedures.
be

ignition switch to RUN. The WAIT Indicator should light.
After approximately 10 seconds, the WAIT Indicator must
out.

START and return to RUN position. The WAIT Indicator
out.
4.
With engine at normal operating temperature, turn

ignition switch to RUN. The WAIT Indicator should flash
for a 6.2L engine.
5.
ACTION

ground.
Test lamp lights.
GO to step 2.

Connect a test lamp from PNK (3)

Test lamp lights.
GO to step 3.

(3) wire from glow plug controller
connector C113 to fuel shutoff
valve connector C129.
Test lamp lights.
GO to step 4.

ground G101.

(906) wire at glow plug controller
connector C113 to ground. Place
ignition switch in START position.
Test lamp lights.
GO to step 5.

or RST (906) wire from glow plug
starter motor.
Place ignition in OFF position.

(503) and ORN/BLK (509) wires at
C191 to ground.
Test lamp lights.
GO to step 6.
GO to step 7.

controller connector C113 to glow
plug harness splice S154.

goes off.
GO to step 8.


(503) and ORN/BLK (509) wires
and fusible links from glow plug to
C190.

more glow plugs.

lamp did not light.
Connect a test lamp from PNK (3)

wire to BLK (150) wire at glow
plug controller connector C113.
6. Disconnect glow plug controller

polarity ohmmeter. Check
continuity between ORN (503) and
BLK (150) wires.
7.
RESULT
Connect glow plug controller

connector. Connect a test lamp
from ORN (503) and ORN/BLK
(509) wires at glow plug controller
connector C191 to ground. Turn
ignition switch momentarily to
START and then release to RUN
position.
8. Remove all connectors from glow

GLOW PLUGS
C-43
1906-1.0 PPL |
2-8.0 R E D M
1
m
_____ n
+
LH
BATTERY
1906-1.0 PPL I
11-32.0 BLKI
RH
BATTERY
a
m
509-5.0 ORN/BLK I
503-5.0 ORN I
503-1.0 ORN I
906-.5 R S T B M B
(FUSIBLE LINK)
E Ô |
S150
6-5.0 PPL I
503-1.0 ORN I
STARTER MOTOR
2-3.0 R S T
(FUSIBLE LINK)
6-5.0 PPL I
S158
S101
2-2.0 R S T I
(FUSIBLE LINK)
RH CYLINDER
/ \
HEAD GROUND O
/A
O
G112 G110
C-44
GLOW PLUGS
SHEET
METAL
GROUND
LH
CYLINDER
HEAD
GROUND
2-5.0 RED I
G113
C190
3-5.0 PNK I
FUEL
SHUTOFF
VALVE
S
GLOW PLUG
CONTROLLER
1 2-5.0 RED 4 G
1C
[m L
C298
6294641
D
C113
12015982
16-5.0 PPL
1509-5.0 ORN/BLK I
503-5.0 o r n m a m
503-1.0 ORN
13-5.0 PNK I
13-5.0 PNK
S200
S105
(SEE PAGE 5)
13-5.0 PNK I
13-5.0 PNK I
1503-1.0 ORN I
503-1.0 o r n m m m m m 9
12-5.0 RED I
12-5.0 RED I
12-5.0 RED
S 250
2 1150 I 2 4 0 11111
A
16 3 5 0 1
B 3
C 140 15 120
D 9 508 33
E 35 8 397 ^
F
1 300 30
G 39 (1234 31 | 59 | 50 |
I
|
I 4 3 9 1 17 I
14 2 0 1440
593
68 250
10 505
i9 01| 9 |
[ 824}
J ^ -\ L_
w
i son
r
|
2 H l/P
592 J
11 K
419 L .481 W /G ASO LINE
M
75 n ' 10 W/D1ESEL
4
P
12015964
S112
(SEE PAGE 1.2)
IGNITION
SWITCH
12015964
0100
6-5.0 PPL I
5-5.0 PPL I
12015113
L r
m m r
y e l/b lk w
DIESEL ONLY
G ASO LINE O NLY
GASOLINE ONLY
GT100
ENGINE
12085003
12085002
j b
I 33
I 111
481 W /G ASOLINE
CO
300
10 W /D IESEL
START
12015113
RUN
OFF
LOCK
l/P CLUSTER
__/.
(SEE PAGE 56)
J B T
ACC
^ H 5 0 5 -.8 YEL/BLK
IQ)
1 2-5.0 RED I
1 6-5.0 PPL I
= - ENGINE
G101 GROUND
GLOW PLUGS
C-45
FUEL HEATER DOES NOT OPERATE
CIRCUIT OPERATION
TEST
The Diesel Fuel Filter System combines six functions
1. It heats diesel fuel to prevent wax-plugging of the
filter;
2. It combines very small droplets of water in the fuel
into larger drops and separates the water from the
fuel;
3. It filters the diesel fuel;
4. It detects an excessive pressure drop indicating filter
plugging; (Vacuum Switch)
5. It detects the presence of excess water in the fuel;
and
6. It provides a means to drain the water it has
separated.
thermostatic switch. The switch opens or closes, to turn

the fuel.
reservoir in the filter. When fuel flows from the Fuel Filter
Assembly to the injection pump, it is clean and free of
water.
A time delay circuit in the Water In Fuel Module

grounds the Indicator bulb briefly to test the bulb each
An electric fuel pump delivers diesel fuel from the tank

The Fuel Heater is operated by a built-in thermostatic

switch. When the switch is closed, battery voltage is
applied to the heater from the GAGES Fuse.
DIAGNOSIS - DIESEL ENGINE FUEL CONTROLS

SERVICE FUEL FILTER INDICATOR DOES NOT LIGHT BRIEFLY WITH
IGNITION SWITCH TURNED TO RUN
1.
RESULT
2.
3.
ACTION
Battery voltage.
GO to step 2.
No voltage reading.

C127 to fuse block.

PNK/BLK (39) to BLK (150) wire at
C127.
Battery voltage.
GO to step 2.
No voltage.

(150) wire from water in fuel
sensor connector C 127 to ground
G102.
Connect a voltmeter from YEL/BLK

(508) wire at water in fuel sensor
Battery voltage.
No voltage.
CHECK water in fuel lamp. If lamp

is good, LOCATE and REPAIR
open in YEL/BLK (508) wire.
Disconnect water in fuel sensor

switch in RUN position. Connect a
at water in fuel sensor connector
C127 to ground.
C-46
FUEL CONTROLS
DIESEL ENGINE
2.

light the SERVICE FUEL FILTER Indicator.
The Fuel Filter Assembly consists of the following

main parts: Fuel Heater, the Water In Fuel Sensor, the
Fuel Pressure Switch, and a Filter. The Filter contains
the coalescer (the device that combines small droplets
TEST
1.
RESULT
Disconnect fuel heater connector

C128. Place ignition switch to RUN
position. Connect a voltmeter from
PNK/BLK (39) wire at fuel heater

C128.
ACTION
Battery voltage.
GO to step 2.
No voltage.

fuel heater connector C128 to fuse
block.
Battery voltage.
REPLACE fuel heater.
N o voltage.

(150) wire from fuel heater
connector C128 to ground G 102 .
WATER IN FUEL INDICATOR LIGHTS WITH NO WATER IN FUEL

TEST
1.

position. Disconnect water in fuel
sensor connector C127.
RESULT
ACTION
Water in fuel indicator stays on.

ground in YEL/BLK (508) wire.
Water in fuel indicator goes out.
W V W /W W W V V /
<
HOT IN STAR T OR RUN ^
>WWVVWVWV'vrA
Vm
S209
(SEE PAGE 42)
ALT
20 AMP
FAST IDLE
SOLENOID
c
s
531
COLD
ADVANCE
CONTROL
C
*_l
m
S
531
C129
12004267
WATER IN FUEL LAMP

(SEE PAGE 56)
I 508-.8 YEL I
-M
r\
I
. ---------------------- ---------------------A
A
I 439| 17 | 2
H l/P
h s q | 2 4 0 I111j
P50|
|
B 3
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C 140 5 | 20 _ J
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250 419 L
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O
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300 30 I 50 |
G 39 I
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1
2
3
4
5
10 9
8
7
6
J r 6J
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C100
7
1
2
3
4
5
10
9
6
8
391
31 I 5911111 |
18 2 4 114 4
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1
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E 35
8 397 _ J
_
L _ 10
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.
O
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Cj 140
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120
3 \ % |350i.
|
|4 2 0 | 4401 592
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I
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M
L
K
J
H
.................................... ~ V I
I
3
UJ
>
-
_____J
ENGINE
GROUND
G102
FUEL SOLENOID
FUEL CONTROLS
DIESEL ENGINE
C-47
AUXILIARY COOLING FAN DOES NOT RUN
CIRCUIT OPERATION
TEST
Battery voltage is applied to the Auxiliary Cooling Fan
Relay at all times by the RED (2) wire and by the
PNk A/VHT (350) wire through the GAUGES fuse, when
the Ignition Switch is in RUN or START. When the
Auxiliary Cooling Fan Switch closes at 107C (225F), the
DK GRN (935) wire is grounded and the Auxiliary Cooling

Fan Relay energizes. Battery voltage is applied across
the Auxiliary Cooling Fan Motor and the Cooling Fan
runs.
DIAGNOSIS ~ AUXILIARY COOLING FAN
1.
2.
AUXILIARY COOLING FAN RUNS CONTINUOUSLY

RESULT
TEST
1.
2.
ACTION

position and with engine coolant
temperature below 107C (225F),
disconnect auxiliary cooling fan
C106.
GO to step 2.

temperature switch.
Disconnect auxiliary fan relay

connector C190. Connect a test
lamp from PNK/WHT (350) to DK
GRN (935) wires at auxiliary
Test lamp lights.
CHECK for short in DK GRN (935)

wire from auxiliary cooling fan relay
connector C138 to auxiliary cooling
C106.
3.
4.

relay.
5.
6.
7.
C-48

GASOLINE ENGINE
ACTION
RESULT

from DK GRN (935) wire at
auxiliary cooling fan temperature
GO to step 2.

temperature switch.

relay connector C138. Connect a
test lamp from PNK/WHT (350)
Test lamp lights.
GO to step 3.
CHECK condition of GAUGES fuse

and/or LOCATE and REPAIR open
in PNK/WHT (350) wire from
auxiliary cooling fan relay to fuse
block.
Connect fused jumper from DK

GRN (935) wire at auxiliary cooling
C106 to ground. Connect a test
lamp from PNK/WHT (350) wire to
DK GRN (935) at auxiliary cooling
Test lamp lights.
GO to step 4.

GRN (935) wire between auxiliary
cooling fan temperature switch
connector C106 and auxiliary

Test lamp lights.
GO to step 5.

(2) wire and fusible link between
auxiliary cooling fan relay
connector C138 and battery
junction block.
Connect 30 amp fused jumper

from RED (2) wire to BLK/RED
(702) wire at the auxiliary cooling
GO to step 6.

relay.
Leave 30 amp fused jumper

connected. Disconnect auxiliary
cooling fan connector C152.
BLK/RED (702) at auxiliary cooling
fan connector C 152 to ground.
Test lamp lights.
GO to step 7.

BLK/RED (702) wires from auxiliary
cooling fan connector C152 to
auxiliary cooling fan relay
connector C138.

BLK/RED (702) to BLK (150) wires
at auxiliary cooling fan connector
C152.
Test lamp lights.
REPLACE auxiliary cooling fan.

(150) wire from auxiliary cooling
fan to ground G102.
GAGES
20 AMP
S218
I 350-.8 PNK/WHT I
(GASOLINE ONLY)
(SEE PAGE 38)
BATTERY JUNCTION
BLOCK
I 2-.8 RST
S104
p
(FUSIBLE LINK)
r\
150
-r
150-.8 BLK
I 2-2.0 RED i
I 4 3 9 1 17 I
2
592
593
11
L _
68 250 419
r
10 505
n
I
1901] 93
75
|
824| 14
4
10 9
8
7
6
3
*
o'
CM
2 |1 5 0 4 0 | 1 1 l |
A
B 3 I 16 13 5 0 1
|
C 140 15 120 _ J
^
D 9 508 33
n
O
8 397 ^
E 35
w
F
!3 0 0 I 30 I 50
G 39 11234! 31 | 59 | 50 |
1
2
3
4
5
H
J
K
l/P
L .481 W /G ASOLINE
M
N 10 W /DIESEL
P
12015964
k-
I 2-2.0 RED
C100
702-2.0 BLK/RED
DIESEL ONLY
G ASO LINE ONLY |
^GASOLINE ONLY
702
ENGINE
I 9 3 5 ,8 DK GRN
AUXILIARY
COOLING
FAN
481 W /G ASOLINE
10 W /D IESEL
12015113
150
/>
~)
12085003
(UPPER)
12085002
(LOWER)
150-.8 BLK
9 3 5 ,8 DK GRN I
AUXILIARY
COOLING
FAN
PRESSURE
SWITCH
GT 100
S 114
C153
12015792
I 150-.8 BLK I
I 935-.8 DK GRN
935-.8 DK GRN I
I 150-.8 BLK
;
|
S112
(SEE PAGE 11)
I v '
702-2.0 BLK/RED
I 2-2.0 RED
AUXILIARY
COOLING FAN
TEMPERATURE SWITCH
(CLOSED WHEN
COOLANT EXCEEDS
225F)
ENGINE
GROUND
COOLING
FAN
RELAY

GASOLINE ENGINE
C-49
PROVISIONS
FOR AIR
o m jo kg rn
CONDITIONING
r-
1*40 I 1 I.463J
f ia o l z
l * l
A 2 1150 I 24C
B 3 I 16 |350|
C 140 15 120
D 9 508 33
E 35 8 397
F
1300 30
G 39 11234 31 I
S3
C 14391 17 I 2
142014 4 0 1592
T
t
593 11
J
/~ \
L_
68 250 419
O
r 10 505
1
^
n
50
I l
X
5
!901| 93
f j
10
|824| 14
8 7
H l/P
J
K
L .481 W/GASOUNE
M
75
N'
4
6
-10 W/DIESEL
12015113
DIESEL ONLY
GASOUNE ONLY I
GASOUNE ONLY
481 W/GASOUNE
10 W/DIESEL
S123
zC
C
sO
Q
m
59-.8DKGRN|
150-.8 BLK I
S112
(SEE PAGE 11)
COMPRESSOR
sue
159- 8 DK GRN
59-.8 DK GRN
ENGINE
GROUND
G102
C-50
PROVISIONS FOR AIR CONDITIONING

GASOLINE ENGINE
GT100
12085003
(UPPER)
12085002
(LOWER)
C Z 3 4 I435I
rVsTl a
C Z I 6 I439]
c
E
POWERTRAIN
CONTROL
MODULE
D bb ] 7 t ia a l
I'ss '] B L.4B1]

C Z ] 9 UsTI
I 434 I 10 GUI
r~ ]u m i
C251
12052175
C100
IN-UNE
DIODE
C3
CO
\ 4B0I
12015964
S124
CIRCUIT OPERATION
TEST
The Cruise Control regulates the speed of the vehicle

in response to driver commands.
The Cruise Control Module contains electronic
circuitry and a stepper motor.
The other system
components are:
Cruise Control Switch

Brake Switch
Vehicle Speed Sensor (VSS)
The Cruise Control Module receives voltage from the

IGN Fuse in RUN or START. A speed signal is received
from the VSS. The driver gives his input to the Cruise
Control Module through the components listed above.
The Cruise Control Module circuitry receives the drivers
input and generates electrical pulses. These pulses
cause the stepper motor and its output reel to rotate.
The throttle is controlled by a cable wound on the output
reel. The Cruise Control Module also contains a clutch
which releases the cable when the Cruise Control
System must be shut off. This clutch will operate when
the Brake Pedal is depressed, the Cruise Control System
is turned off, or the Cruise Control System detects a
failure.
RESULT
Test lamp lights.
GO to step 6.

(397) wire from brake switch
connector C245 to splice S215.
Test lamp lights.
GO to step 7.

(901) wire from brake switch
connector C246 to cruise control
Test lamp lights.
GO to step 8.

switch. If properly adjusted,
REPLACE brake switch.
Test lamp lights.
GO to step 9.

switch. If properly adjusted,
REPLACE brake switch.

(84) wire at cruise control switch
Test lamp lights.
GO to step 10.
Test lamp lights.
GO to step 11.
Test lamp lights.
GO to step 12.

BLU (84) wire from cruise control
module connector C248 to cruise
control switch connector C244.
12. Depress and hold RESUME/

ACCEL switch. Connect test
lamp from DK GRN (83) wire at
cruise control switch connector
C248 to ground.
Test lamp lights.
GO to step 13.

(83) wire at cruise control module
Test lamp lights.
GO to step 14.

GRN (83) wire from cruise control
14. Raise vehicle so drive wheels can

be turned by hand. Connect
voltmeter from PNK/WHT (39) wire
to DK GRN (389) wire at cruise
Slowly turn drive wheels.
Pulses between 0 and battery

voltage as wheels are turned.
REPLACE cruise control module.
Does not pulse or no voltage

reading.
CHECK speed sensor circuit. Refer

to Fuel, Driveability and Emission
Manual (Gasoline).
5.
Connect a test lamp from GRA

6. Connect a test lamp from TAN

7.

DIAGNOSIS - CRUISE CONTROL

CRUISE CONTROL DOES NOT DISENGAGE WHEN BRAKE PEDAL IS DEPRESSED
1.
ACTION
RESULT
TEST
position and cruise control switch
to ON. Depress brake pedal.
wire at brake switch connectors
C245 and C246 to ground.
REPLACE control module.
Test lamp lights.

corrected, REPLACE brake switch.

9.
10 . Depress SET switch. Connect a

CRU ISE CONTROL DOES NOT OPERATE
TEST
RESULT
ACTION

cruise control switch to ON.
PNK/BLK (39) wire at cruise
control switch connector C244 to
ground and then cruise control
ground.
Test lamp lights.
GO to step 2.
CHECK condition of IGN fuse. If

C244 and cruise module connector
C248 to fuse block.

(397) wire at cruise control switch
Test lamp light.
GO to step 3.
3. Connect a test lamp from GRA

(397) at cruise control module
Test lamp lights.
GO to step 4.

(397) wire from cruise control
4.
Test lamp lights.
GO to step 5.

(150) wire from cruise control
module connector C248 to ground
G202.
1.
2.

(397) to BLK (150) wires at cruise
ACTION
test lamp from DK BLU (84) wire at

C244 to ground.
1 1 . Connect a test lamp from DK BLU

(84) wire at cruise control module
CRUISE CONTROL
C-51
yW W vW W vW V /
s
HOT IN START OR RUN Z
>VVV\M/VVVWW''*
ALT
20 AMP
IGNITION
- 39
ACCEL/RESERVE SW
CRUISE ENGLARGER SWITCH
GROUND
- 83
- 84
- 150
VEHICLE SPEED INPUT

ELECTRONIC CRUISE
- 389
- 397
_ 901
BRAKE SWITCH
CRUISE
CONTROL
MODULE
8209
09
(SEE PAGE 42) $
2'
4011111
A
161
l/P
>l 17 I
>01440 { 592
l/P
68 250 419
.481 W/GASOLINE
C
D
F
g
397
1300
551
10
505
1901J 9 3
31159 ( 50 | 1 | l824jT4
10 9 8
10 W/DIESEL
C100
12015113
DIESEL ONLY
GASOUNE ONLY
GASOLINE ONLY
ENGINE
I 150-.8 BLK I
S112
(SEE PAGES 11, 12)
481 W/GASOLINE
10 W/DIESEL
GASOLINE ONLY
DIESEL ONLY
GT 100
12085003
(UPPER)
12085002
(LOWER)
BRAKE
SWITCHES
(OPEN WHEN
BRAKE PEDAL
IS DEPRESSED)
d
>
co
co
m
*
I 3S9-.8 DK GRN I
Z
DRAC
(SEE PAGE 42)
CRUISE
CONTROL
ACTIVATOR
C245
12010649
' 39-.8 PNK/BLK I
139-.8 PNK/BLK
S213 (SEE PAGE 30)
I 397-.8 G R A B *
397-.8 G R A ^ H
S215
1 901 -.5 TAN
A
ENGINE
(Q ) GROUND
G102
C-52
CRUISE CONTROL
CIRCUIT OPERATION
The operation of an individual Indicator is described
along with its circuit. Refer to the schematic and text for
the circuit that is indicated below each of the Indicators.
PARK BRAKE WARNING LAMP

Battery voltage is applied to the Brake Indicator when
the Ignition Switch is in RUN, or START. Three Switches
are connected to the Brake Indicator. When any one of
these switches closes, a ground is provided and the
indicator lights.
The Park Brake Switch provides a ground when the
Park Brake is applied. The Brake Indicator lights to alert
the driver.
The Brake Pressure Switch closes to light the Brake
Indicator when there is low brake fluid pressure in one of
the two hydraulic brake systems. This could be caused
by a leak in one of the brake lines.
The Ignition Switch grounds the Brake Indicator when
the Ignition Switch is turned to START to provide a quick
check of the Brake Indicator Bulb and circuitry.
FUEL GAGE
scale.
TEMPERATURE GAGE
PRELIMINARY CHECKS:

127C (260F) (hot coolant) and its resistance becomes
greater at lower temperatures. It is approximately 1400
temperature increases. This moves the pointer.
Check the condition of GAGES and INST LPS fuses.

If fuses are in good condition, use the following
FUEL GAGE INDICATES FULL OR BEYOND AT ALL TIMES
TEST
1.
LOW COOLANT INDICATOR (DIESEL)

and closes. It has a very high resistance to ground,
more than 50,000 ohms, when the engine coolant level
is low. This causes the Low Coolant Module to light the
Low Coolant Indicator. With more of the Sensor covered
by coolant, its resistance decreases. When the fluid level
is good, the resistance between 10,000 and 50,000
ohms, the Sensor is partly covered and the fluid is not
low enough to cause the warning to be displayed.
CHECK ENGINE (GASOLINE) INDICATOR
2.
RESULT
ACTION

from PNK (30) wire at fuel pump

PNK (30) wire. If not short is found,
REPLACE fuel gage.
GO to step 2.

(30) wire to BLK (150) wire at fuel
pump connector C401.

(150) wire.

TEST
1.

RUN.
RESULT
ACTION

PNK (30) wire. If no short is found,
, REPLACE fuel gage.
FUEL GAGE IS INACCURATE

TEST
1.
Refer to Light Duty Truck Fuel, Driveability and

Emissions Service Manual, Section 3.
WATER IN FUEL WARNING INDICATOR

Refer to Fuel Controls (Diesel), Page B-38.
GLOW PLUG INDICATOR

C401. Connect one RED lead of J
34029-A Multimeter to PNK (30)
wire and other to ground. Set
resistance dials to 0 ohms and
then to 90 ohms. Fuel gage
should indicate empty and then
full. (Allow time for gage to reach
full due to anti-slosh device.)
RESULT
ACTION
CHECK BLK (150) wire for high

resistance. If wire is good,
Gage does not respond correctly.
CHECK for high resistance in PNK

fuel gage.
Refer to Glow Plugs (Diesel), Page B-11.

OIL PRESSURE GAGE INDICATES LOW PRESSURE WHEN OIL PRESSURE IS GOOD
RH/LH TURN SIGNAL INDICATORS
TEST
Refer to Front Exterior Lamps, Page B-24.

1.
OIL PRESSURE GAGE
HIGH BEAM INDICATOR

Gage.
DRL INDICATOR
Refer to Headlamps, Page
Refer to Headlamps with Canadian Daytime Running

Lamps, Page
Disconnect oil pressure sender

switch to RUN.
RESULT
ACTION

pressure or indicator light goes
out.
Oil pressure gage indicates no or

low pressure or indicator light
stays on.
LOCATE and REPAIR short in TAN

oil pressure gage.

current flow through the coils. The magnetic field of the
INSTRUMENT PANEL
C-53

TEST
RESULT

switch to RUN. Connect a fused
jumper from TAN (31) wire at oil
pressure sender connector C118
(Gasoline) or C119 (Diesel) to
ground.
ACTION
Oil pressure gage indicates low

pressure or indicator lights.
Oil pressure indicates high

pressure or indicator does not
light.

(31) wire. If wire bulb is good,

RESULT
TEST
switch to RUN.
ACTION

indicate cold.

DK GRN (35) wire. If no short is
found, PERFORM diagnostic
MTemperature Gage Is Not
Accurate.-

ACTION
RESULT
TEST
C108 (Diesel). Ground the DK
sender connector C1 04 (Gasoline)
or C108 (Diesel).
Temperature gage indicates hot.
REPAIR/REPLACE temperature
sender.

indicate hot.


TEST
C108 (Diesel). Connect RED lead
from J 34029-A Multimeter to DK
GRN (35) wire and other lead to
ground. Adjust resistance dials to
1400 ohms and then to 55 ohms.
cold then hot.
RESULT
ACTION
Gage indicates correctly.


TEST
1. Connect a fused jumper from low
coolant warning switch connector
C150 to ground. Place ignition
switch to RUN and observe low
C-S4
INSTRUMENT PANEL
RESULT
ACTION

YEl/BLK (68) wire. If wire is good,
under symptom -Low Coolant
Coolant Level Low.
LoWCO oLANT INDICTOR DOES NOT LIGHT WITH COOLANT LEVEL LOW (DIESEL ONLy)
TEST
switch connector C 126 and place
ignition switch to RUN. Observe
low coolant indicator light.
RESULT
ACTION
Low coolant indicator lights.

switch.

light.
GO to step 2.

module connector C223. Connect
voltmeter from BLKlORN (550)
ground.
Battery voltage.
GO to step 3.
No voltage.

BLU/ORN (550) wire. If wire is
good, REPLACE GAUGES fuse.
3. Con nect a voltmeter from

PNKlBLK (39) wire to BLK (150)
Battery voltage.
GO to step 4.
No voltage.

(150) wire.
4. Connect a voltmeter from GRA

(69) wire at low coolant warning
ground.
Battery voltage.
GO to step 5.
No voltage.

ground in GRA (69) wire from low
C223 to low coolant warning lamp.

PNKlBLK (39) wire to YEl/BLK
(68) at low coolant warning
Battery voltage.

ground in YEl/BLK (68) wire from
low coolant warning module
connector C223 to low coolant
No voltage.
REPLACE low coolant module.
ILLUM
ILLUM
ILLUM
--
ILLUM
ILLUM
ILLUM
:
v
r------r---,
I
LEFT
HIGH
BEAM
TURN
~5~Q)
'150
RIGHT
TURN
_1~
15
-,-
:
I
ORL
(C~~~~,AQ N
~ bi
150
r---
'-
593:
L ________
11
...J
(629W/DRL)
39
r--
419
WATER
IN
FUEL
(DIESEL
ONLy)
LOW
COOLANT
....
SERVICE
ENGINE
SOON
PARKING
BRAKE
SERVICE
BRAKE
GLOW
PLUG
(DIESEL
ONLy)
SPEEDOMETER
FUEL
VOLT
,,.. =
=
e~ -e F
eg..
eM "'e
L-~~------------~~----------------~----------------~----------~--+-+-t--39----~==~&.~ M
..~te~
--~----~
.=
==
-------
~
~
C218
12040746
~----
68----.....
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_-+----~- 39
---------------t----------------""""I~-------------+----_I~_+--1_-150 - I
--- 8
C1i
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' - - - - - 3 5 -~"-=HI"~ ~.
r - - 31
_~~---150
1""'"1234
t:i :!e
TEMP
~. ~ ...~
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OIL
:::==
593----~~-----+~
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!==
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-----+-----..
A~ ~~f.p;;;~1-P-15----_+----""
--------------""""I~--------------~------_I--_+--~--+_11~29--~t:~~~~~~~~~::J1~14----~~
----"
........... I
'"
l\.T}JI.
INSTRUMENT PANEL
C-55
RPO
RPO CODES
CODES
C7P
C7P -- 16,000
16,000 lBS
LBS GWI
GVW RATING
RATING
ALT
20 AMP
GAUGES
20 AMP
'-- -
550-.8 BLK/ORN _
-"..,,,"'"'-
-- - -------- ---- ---~

."
15
.-r _ _ .-r
,..,.
Z
::::j
..-r
-< 02l
Cl
2l
c:
;:
UI
."
::::j
Z
0
0
z
;:
LOW COOLANT
WARNING MODULE
::E
(')
:r
150
550
LOW COOLANT
WARNING
SENSOR
(DIESEL ONLy)
69 68
AUTO APPLY
PARK BRAKE
SWITCH
C223
12004706
(DIESEL ONLy)
ONLY)
(DIESEL
C126
. - 550-.8 BlK/ORN _
...... . - r _
---
,
~
"A
o
~ ..-r _
9 508133l
E 35 8 397
F
300 30 50
G 391 12341311591501 1
1
2
3
4
5
10
--
439 17
4:!11 440
593
68 250
10 505
901 93
824'14
9
8
7
~ 508-.8YELJBlK"'..-r _ _
IS APPLIED)
33
450
2
592
11
419
75
4
6
I/P
...,.. _
33-.8 TAN/WHT _
J
K
l
MI
N
P
(CLOSED
(CLOSED WHEN
WHEN
PARKING
PARKING BRAKE
BRAKE
IS
IS APPLIED)
APPLIED)
C220
12010651
IGNITION
SWITCH
(SEE PAGE 4)
_33-.5TAN/WHT..,. . . . .
481 W/GASOlINE
. . . . . -1..-450-.8BlKIWHT . . -
10 W/DIESEl
...J
III
12015964
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2 "50 240 111
68-.8YELJBLK . . . . . - r
cru
C189
_111
16 350
B 3
C 140 120
,
~ _
.-r _ _ _
(GASOLINE W/C7P)
CLOSED WHEN
AUTO PARK BRAKE
PARK
BRAKE
SWITCH
(!)
.....,
S209
(SEE PAGE 42)
<Xl
a;
co
\ ,-"'''''"'
rr4~--~~--~~
~ lIP
l/P CLUSTER
~CONNECTOR
CONNECTOR
(SEE
(SEE PAGE
PAGE 55)
55)
,
~ 508-.8 YELJBLK ..,.
.-r
68-.8 YELJBll< IF . . - r _ _ ,
...
_505-1.0YEL _
PCM
..
(SEE PAGE 35)
_-,
C-56
INDICATOR LAMPS
419-.B BRN/WHT_
(GASOLINE ONLy)
..-r
--
RH TURN SIGNAL
(SEE PAGE 24)
,._ _ _ _ _ _ __
, - 68-.8 YELJBLK -
LH TURN SIGNAL , , - - - - - - - (SEE PAGE 24)
~
~
,,
J
BRAKE
PRESSURE
WARNING
SWITCH
39-.8 PNK/BLK
_111-.BBLK
.. -
- - - - -...-@I1(j~-jItI-
-::::::tt::~~ L=...._
150-.B BlK
15-.5 DK BLU I
-1
150-.8 BLK - - .
..
-1~.5DKGRN_~~~~~~~~~~~~"r-""
III.
Slll
(SEE PAGE 11)
PCMITCM
(SEE PAGE 41)
C218
12040744
150-.8 BLK
150-.8 BLK
C154
12004635 ~
(DIESEL
(DIESEL ONLY)
ONLy)
C127
12015793
(DIESEL ONLy)
111-.8BLK
12085003 (UPPER)
12085002 (LOWER)
WATER
IN FUEL
SENSOR
SENSOR
GlOWPLUGS ~
(SEE PAGE 44)
(CLOSES WHEN
UNEQUAL PRESSURE
EXISTS BETWEEN
FRONT AND REAR
. ._ _ _ _ 111-.8 BlK _ _ _ _ _ _ _ _. . BRAKES)
~l
---
--
G200
lIP
GROUND
~-
450 2.0
2.0 BLK/WHT
BLKlWHT '
450
G100
G
100
SHEET
SHEET
METAL
GROUND
SWITCH
1H.OLTGRN ~ DIMMER
DIMMERSWITCH
(SEE PAGE
PAGE 14)
14)
(SEE
I 11-1.0 LT GRN I
I 39-.8 PNK/BLK
ALT
20 AMP
ENGINE
TEMPERATURE
SWITCH
COOLANT
TEMPERATURE
SENDER
OIL PRESSURE
SWITCH
(DIESEL)
FUEL PUMP
OIL PRESSURE
SENSOR AND SWITCH
DRAC
(SEE PAGE 42)
(CLOSES AT
APPROXIMATELY
107C (225F)
31-.5 TAN
cc
<3
IS
GT100
12085003 (UPPER)
12085002 (LOWER)
GASOUNE ONLY
DIESEL ONLY
c io o
FRAME
GROUND
G400
(O )
=
l/P
GROUND
G200
GAGES
C-57
C203
12020030
PANEL
DIMMER
SWITCH
-1 5 6
I 44-1.0 DK GRN
INSTR-LPS
5 AMP
LIGHT
SWITCH
(SEE PAGE 14)
19*1.0 BRN I
PROVISIONS
FOR DOME LAMPS
(SEE PAGE 59)
I 156-. 8 WHT I
HEAD
18-.5 GRA I
S208
I 150-3.0 BLK I
A
B
C
D
E
F
G
2
3
[ 17 | 2
14201440! 592
11
L_ 68 593
250 419
10 505
l | 5 0 I 240 11111
I 439
I Me 13501 |
120 J / - \
140
33
9
35 8 397 ^
^
1300 30 ! 50
39 11234 31 I 59 | SO | |
5
l 0 1 l 93
1
10
18241 14
9
8
75
4
H l/P
J
K
L .481 W/GASOLINE
M
N* 10 W/DIESEL
P
12015964
12015113
DIESEL ONLY
GASOLINE ONLY I
GASOLINE ONLY
10
31 ly59 | 50 |
. 30 P 50
397?
6 |350j*
50 I 24011111/
SOLINE ONLY
7
6
4 p
14
93 75 N
505
-is
2t>0 419
593 11 K
14201440)592 J
I 439 j 17 I 2 H
8
I \|8 2 4 |
I
19011
I
1 10
T l
ENGINE
481 W/GASOUNE
'1 0 W/DIESEL
DIESEL ONLY
19
18
I
M
16
27
15
he
14
28
G
f
I
[
I S-.5 GRA I
F
E
D
12004147
PRNDLLAMP
12004148
C211
- 8-.5 GRA -
TURN
SIGNAL SWITCH
C-58
l/P
GROUND
G200
HORN/OM
~_ _ _ _ _ _ _ _ _ _ _ 240-1.00RN _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. .
15 AMP '1
A 2 150 240 111

16 350
B 3
C 140 15 120
0950833
E358397
F
300 30 50
G 39 1234 31 59 50
1
2
3
4
5
439 17
2
420 440 592
593 11
68 250419
10 505
901 93 75
o
10
824 14
8
7
H
J
liP
K
L
481 W/GASOLINE
10 W/OIESEL
12015964
M(
44
C100
PANEL DIMMER
SWITCH
C202
12020029
156
150
DOME
2
C203
12020030
CIRCUIT
BREAKER
25 AMP
"PARK
HEAD
LIGHT
SWITCH
40
15B-.8WHT
.............................
(SEE PAGE 18)
'PARK
LIGHT SWITCH
.-_150-3.0 BLK _ _ _"
S214
HEAD
S206
10
OFF
1"__
24O-1.00RN _ _ _~
. . . .- - - - - - - -. .- - -. .- - - - - - - - - - - -. .- - - - - - - - - - - - - - - - - -. .
PROVISIONS
FOR
DOME LAMPS
2~5981
HORN RELAY
(SEE PAGE 26)
liP
l/P
GROUND
G200
~
-
PROVISIONS FOR DOME LAMPS
C-59
CIRCUIT OPERATION

TEST
BACKUP LAMPS
PARK, TAIL, MARKER, AND LICENSE LAMPS

the gear selector lever is shifted to REVERSE, the
the lamps turn on.

License Lamps.
1.
2.
Place transmission in reverse.

(24) wire at rear lamp harness
RESULT
Test lamp lights.

installed wiring.
GO to step 2 .

Test lamp lights.
GO to step 3.

connector C214 to fuse block and
DK BLU (38) wire.

Test lamp lights.

switch connector C214 to rear
lamp harness connector C400.

switch.
DIAGNOSIS - REAR EXTERIOR LAMPS

PRELIMINARY CHECKS:
The rear lamp systems (taillamps, backup lamps, and
license plate lamps) all receive voltage from the same
wire circuit (BRN 9) and are grounded at the bulb
socket(s). If only one system is not working, LOCATE

and REPAIR an open in the wiring and/or bulbs that
pertain to that system.
NONE OF THE REAR LAMP SYSTEMS OPERATE

TEST
1.
2.
3.
RESULT
ACTION

(40) wire at light switch connector
C202 to ground.
Test lamp lights.
GO to step 2.

REPAIR open in RED (2) wire from
light switch connector C202 to
battery junction block and/or ORN
connector C202 to fuse block.
Place light switch to PARK

BRN (9) wire at light switch
Test lamp lights.
GO to step 3.
Test lamp lights.

(150) wire.

connector C400 to light switch
connector C202.

wire at rear lamp harness
C-60
REAR LAMPS
3.
ACTION
24-.8 LT GRN
RH
BACKUP
LAMP
PROVISIONS FOR
RH SIDE MARKER
[CUD]
(CHDh-8BLK
C406
2977107
RH TAIL STOP AND

TURN LAMP
07
RH LICENSE
LAMP
NOTE: THIS HARNESS IS

VEHICLE AND INSTALLED
LH LICENSE
LAMP
LH
BACKUP
LAMP
LH TAIL, STOP AND
TURN LAMP
^ 2 4 ^ - 6BLK^
C405
2977107
PROVISIONS FOR
LH SIDE
MARKER
24-,8 LT GRN
REAR LAMPS HARNESS
C-61
C247
12020030
PANEL DIMMER
SWITCH
156
C202
12020029
9
HEAD
LIGHT
SWITCH
I 9-1.0 BRN
_J
LZ
o
^
^
r~
I 59! I I
-------------- -----DIESEL ONLY
CM
39
1
-
[ 439 17 |
14201440
593
250
10
|
19011 93
14
10 9
8
7
r\
|
|
2
592
11
419
75
4
6
9-.8 BRN
1
9
35
i
1150 | 2 4 0 11111
I 16 1350J
|
15 120
33
^
8 397
!300 30 I 50 I
I
31
2
3
4
5
CO
p
A
B
C
D
E
F
G
H l/P
J
K
L .481 W/GASOLINE
M
N* 10 W/DIESEL
P
12015964
C100
GT100
C-62
TAILLAMPS
S115
(SEE PAGE 15)
12085003
(UPPER)
12085002
(LOWER)
C400
12065150
I ID
0]
TRANSMISSION
BACKUP LAMP
SWITCH
I 1 !I J] [][][
I
VAM M M /W VW V*
< HOT IN START OR RUN ?
m w /w w v w ^
II
11 I
H I B/f I II I H
IkS Ekfi 4-0 (pi

0yfl Ik Skf I [ kS
A S [k1 I [ k S
fri I
o)
REAR LAMP
HARNESS
I 24-1.0 LTGRN1
A
B
C
D
E
F
G
2 150 | 240 J1111

|
3 I 16 13501
|
i
140 15 120
I
^ -\
9 508 33

35 8 397 ^
^
|300 30 i 50 |
I
39 11234 311 59 | 50 | |
1
2
3
4
5
10
-j
v -r
I 4391 17 1 , 2
I420l44tf L592
59: I 11
I
68 250 B19
^
10 5 0 5 1 ,3
n
1901] 93 75
J824I 14 4
9
8
7
6
-r
H l/P
J
K
L -481 W/GASOLINE
M
[-10 W/DIESEL
P
12020926
7S-.BOKBLU
C100
BACKUP LAMPS
C-63
CIRCUIT OPERATION
VACUUM SYSTEMS
pressure of a partial vacuum to operate the component.
The vacuum created within the inlet manifold when the
engine is running is stored in a vacuum tank in the
engine compartment. A check valve in the line feeding
vacuum to the tank keeps the stored vacuum from
weakening when inlet manifold vacuum drops during
high speed or high power operation.
Vacuum is routed through hoses (and in some cases,
tubing) to a mechanical or electric valve that provides a
means of controlling the vacuum-operated component.
When the valve is open, it allows vacuum to go to an
actuator that actually operates the component. When
the component is to be returned to its original position,
the valve cuts off the vacuum to the actuator hose and
vents the hose to normal air pressure.
A typical actuator is a metal shell with a movable shaft
that retracts and extends to mechanically operate the
component. A flexible diaphragm separates the interior
of the shell into two chambers - a sealed chamber to
which vacuum can be admitted, and an open chamber
exposed to normal air pressure. The movable shaft is
attached to the center of the diaphragm and extends
from the open chamber.
When the vacuum is directed to the sealed chamber,
shaft.
positions. This extends the shaft.
EXHAUST GAS RECIRCULATION

VACUUM SYSTEM
All 1991 P-Motorhome gasoline engines are equipped
with an exhaust gas recirculation (EGR) system. The
EGR system allows a small amount of exhaust gas to
flow from the exhaust manifold into the inlet manifold
when the throttle is opened beyond idle and inlet
manifold vacuum is normal. This reduces combustion
temperatures in the engine to control oxides of nitrogen
emissions.
C-64
VACUUM SYSTEM

the pintle to open, allowing a measured flow of exhaust
The EGR system remains closed during periods of
engine idle and deceleration to prevent rough idle from
excessive dilution of the fuel-air mixture. It also remains
closed at wide-open throttle to prevent power loss. At
other times, it rapidly cycles open and closed to
modulate the flow of exhaust gas as required. Under
certain circumstances, it may remain fully open to
provide the maximum EGR.
A manifold absolute pressure (MAP) sensor measures
the strength of the vacuum in the EGR vacuum circuit
and sends a signal back to the electronic control module
(ECM).
If actual vacuum differs from the preferred
of exhaust gas into the cylinders. This provides the
required control of oxides of nitrogen emissions while
retaining engine performance under all operating
conditions. The ECM also uses the signal from the MAP
sensor to control fuel delivery and ignition timing.
Vacuum for the EGR system is taken from the throttle
body and routed through a hose to the electronic
vacuum regulator valve (EVRV) solenoid. The solenoid
is controlled by the 435 circuit from the ECM. When the
solenoid opens the electronic vacuum regulator valve
vacuum reaches the EGR actuator through another
vacuum hose and opens the EGR pintle valve to allow
exhaust gas to flow into the inlet manifold. When the
EVRV solenoid is released, the valve vents the EGR
actuator to outside air to close the EGR pintle valve.

exhaust gas recirculation and adversely affected engine
cruise can result in the engine stalling after closed
throttle deceleration, surging during steady throttle
cruising, or a rough idle. Too little exhaust gas flow
allows combustion temperatures to become too high and
bring about detonation ("spark knock") or an overheated
engine. In addition, nitrous oxide emissions may be high
enough to cause the vehicle to fail an emissions test.
Because the source of a EGR system symptom might
be traced to a mechanical or electrical condition as well
as a faulty vacuum system, an effective systematic
diagnosis procedure should examine all three categories
of components - not just the vacuum system alone.
Therefore, no exclusive vacuum system diagnosis
the EGR system, refer to the 1991 Fuel and Emissions
Service Manual."
DIAGNOSIS
Conditions most likely to cause vacuum system
binding components.
A vacuum pump can be used as a vacuum source to
operate components and test the system. The built-in
On vacuum systems that are controlled by electrical
or electronic switches, check for a blown fuse, wiring that
is cracked, frayed or burned, and high resistance in
connectors of the control circuits) before checking for a
S111
(SEE PAGE 11)
I 450-.6 BLK/WHT W T JL I
ENGINE
GROUND
G100
EXHAUST GAS RECIRCULATION (EGR) VACUUM SYSTEMS

V8 GASOLINE ENGINE
C-65
S113
S116
C108
C196
C197
C105
C199
4
1.
2.
3.
4.
5.
6.
Cold Advance Control

Fast Idle Solenoid
Fuel Shut-Off Valve
Generator
Glow Plug (RH)
Cold Advance and Fast Idle
Temperature Switch
Figure 1 Engine W iring Harenss -- RH Side (6.2L V 8 HD Diesel Engine)
C-66
1.
2.
Glow Plug (LH)

Figure 2 - Engine Wiring Harness -- LH Side (6.2L V8 HD Diesel Engine)
1.
2.
3.
Figure 3 - Batteries and Cables (6.2L V8 HD Diesel Engine)
C113
Low Coolant Warning Switch

Map Sensor
Figure 5 - Engine Wiring Harness to Cowl/Radiator (6.2L V8 HD Diesel Engine)
C121
8
C128
1.
2.
3.
4.
5.
6.
7.
8.

Fuel Heater
Output Speed Sensor
Transmission
Input Speed Sensor
Oil Pressure Sender
Engine Speed Sensor
C120
C104
C190
1.
2.
C191
3.
4.
5.
6.
7.
FRONT
OF
VEHICLE
VIEW
C172
Figure 4 - Engine Wiring Harness -- Rear (6.2L V8 HD Diesel Engine)
Coil
7
Distributor
Electronic Spark
Module
Input Speed Sensor
Output Speed Sensor
Transmission
Engine Temperature
Sensor
C172
C174
12H31
Figure 6 - Engine Wiring Harness - LH Side (7.4L V8 Gasoline Engine)
C-67
S106
C115
?I [ I]
C110
C111
C112
S108
12H11
S109
C175-
C1061.
2.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10 .
Idle Air Controller

TP Sensor
Injectors
EVRV
Cooling Fan Switch
Starter Motor
Knock Sensor
Map Sensor
Generator
Coolant Temperature
Sensor
Fuel Pump Relay

Figure 8 - Engine W iring Harness to Cowl (7.4L V8 Gasoline Engine)
C117
S103
12H32
C116
C109
GJ03
C105
10
FRONT
OF
VEHICLE
FRONT
OF
VEHICLE
VIEW A
VIEW B
C-68
Figure 9 - Steering Column Switches
1.
2.
3.
4.
5.
Horn Relay
Cooling Fan Relay
DRL Relay
Hazard Flasher
DRAC Module
6.
7.
8.
9.
PCM
S126
Dimmer Switch
Ignition Switch
Backup Lamp Switch
C100
C208
IT]
C210
1.
Fuel Sender Assembly
[I]
C206
C207
C251
C205
C250
GT100
S214
VIEW
VIEW
12H10
Figure 10 - Engine Wiring Harness to Cowl (7.4L
12H47
va Gasoline Engine)
12H42
Figure 12 - Fuel Sender and Rear Lamp Wiring
C209~
S1
,.....,........-----7'~"'-~
C208
~~=---I~J
o
C200
1.
2.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Horn Relay
DRL Relay
DRAC Module
Hazard Flasher
rCM
ALDL
G109
Ignition Switch
Dimmer Switch
Backup Lamp Switch
Battery
Starter Motor
S200
FRONT~
OF VEHICLE
C214
Figure 11 - Engine Wiring Harness to Cowl (6.2L va HD Diesel Engine)
12H42
VIEW0
Figure 13 - Battery and Leads (7.4L
va Gasoline Engine)
C-69
C O M P O N E N T L O C A T IO N
Auxiliary Cooling Fan Relay ................
Auxiliary Cooling Fan Switch ..............
Backup Lamp S w itc h ............................
Top LH side of shipping p a n e l.....................

RH side of e n g in e ..........................................
On steering c o lu m n ........................................
Page -- Figur
.............. 69
10
.............. 68
7
.............. 69
10
69
11
.............. 67
3
.............. 67
3
69
13
.............. 67
5
.............. 68
8
.............. 66
1
Battery, F ro n t..........................................
Battery, Rear ..........................................
RH frame rail behind engine .......................

RH frame rail behind engine ........................
Battery Junction B lo c k ..........................

Brake Pressure Warning Switch .........
Cold Advance Control ..........................
Cold Advance Fast Idle Temperature
Switch .................................................
(D ie s e l).................................................
(G asoline).............................................
Cruise Control S w itc h ............................
Distributor ...............................................
DRAC Module ........................................
LH side of shipping panel ............................

Near master c y lin d e r......................................
Top front of e n g in e ........................................
Top RH front of engine .................................

LH side of steering column ..........................
Top rear of e n g in e ..........................................
Inside LH side of shipping p a n e l................
DRL R e la y ...............................................
Top LH side of shipping p a n e l..................... ..............
Engine Speed Sensor ..........................

Engine Temperature S e n s o r................
ESC Module ..........................................
E V R V ........................................................
Fast Idle Solenoid .................................
Fuel Heater .............................................
Fuel Pump Relay ...................................
Fuel S e n d e r.............................................
Fuel Shutoff Valve .................................
Generator (Diesel) .................................
Generator (Gasoline) ............................
Glow Plug #1 ........................................
Glow Plug # 2 ........................................
Glow Plug # 3 ........................................
Glow Plug # 4 ........................................
Glow Plug # 5 ........................................
Glow Plug #6 ........................................
Glow Plug # 7 ........................................
Glow Plug #8 ........................................
Glow Plug Controller ............................
Hazard Flasher ......................................
Rear of engine ............................................... ..............

LH side of engine .......................................... ..............
Top of engine near d is trib u to r..................... ..............
RH front of e n g in e .......................................... ..............
Top front of e n g in e ........................................ ..............
Top rear of e n g in e ......... ? .............................. ..............
LH frame rail behind shipping panel ......... ..............
Inside fuel tank ............................................... ..............
Top front of e n g in e ........................................ ..............
Front of e n g in e ................................................. ..............
Front of e n g in e ................................................. ..............
LH side of engine .......................................... ..............
RH side of e n g in e .......................................... ..............
LH side of engine .......................................... ..............
RH side of e n g in e .......................................... ..............
LH side of engine .......................................... ..............
RH side of e n g in e .......................................... ..............
LH side of engine .......................................... ..............
RH side of e n g in e .......................................... ..............
Top LH rear of e n g in e ................................... ..............
RH rear of engine .......................................... ..............

LH front of e n g in e .......................................... ..............
..............
..............
..............
..............
66
66
Input Speed S e n s o r........................
LH side of transm ission.......................................... . . . 67

67
RH side of e n g in e ................................................... . . . 68
RH side of radiator ................................................. . . . 67
LH side of shipping panel ..................................... . . . 67
RH rear of e n g in e ................................................... . . . 68
LH rear of engine ................................................... . . . 67
LH side of transm ission.......................................... . . . 67
67
LH side behind shipping panel ............................ . . . 69
RH side of e n g in e ................................................... . .. 67
Knock Sensor .................................

Low Coolant Warning Switch . . . . . . .
MAP Sensor (Diesel) .....................
MAP Sensor (Gasoline) ................
Oil Pressure S e n d e r.......................
Output Speed Sensor ...................
PCM .................................................
Starter M o t o r ...................................
68
7
9
67
69
69
69
69
67
67
67
6
10
11
10
11
Turn Signal S w itc h ..........................

Water in Fuel S e n s o r .....................
Connectors:
C100 ............................................. . . .
68
66
67
68
8
12
1
1
69
66
66
68
66
66
66
66
66
66
66
66
6
6
1
2
1
2
1
2
1
2
1
67
69
69
69
69
69
10
11
11
10
11
LH side of steering column .......................... ..............

Idle Air Control A c tu a to r.......................

Ignition C o i l .............................................
Ignition S w itc h ........................................
Top LH side of e n g in e ................................... ..............

Top rear of e n g in e .......................................... ..............
On steering c o lu m n ........................................ ..............
68
67
69
69
6
10
11
Injector # 1 ...............................................
Top of e n g in e ................................................. ..............
68
COMPONENT LOCATOR INDEX
Top of e n g in e .................................................................
TCM
68
68
Page - Figure
68
7
Injector # 2 ...............................................
Headlamp Dimmer Switch ...................

Horn R e la y ...............................................
C-70
COMPONENT LOCATION
.................................................
C101
................................. . . .
C102
C103
C104
C105
.............................................
............................................. . . .
.............................................
.............................................
C106
C108
C109
C 110
.............................................
.............................................
.............................................
.............................................
cm
...
....... . . .
.............................................
.............................................
............................................. . . .
............................................. . . .
. ...........................................
C112
C113
C114
C115
C116
C117 .............................................
C119 .............................................
C120 ............................................. . . .
C121
................................. . . .
C123 .............................................
C125 .............................................
C126 .............................................
C127 .............................................
C128 .............................................
C129 .............................................
C130 .............................................
C131 .............................................
LH side behind shipping panel ............................

Top of e n g in e ..........................................................
LH side of steering column ...................................
RH rear of e n g in e ...................................................
.
.
.
.
.
.
.
.
.
.
.
.
69
69
68
68
6
7
5
5
7
4
4
6
10
3
7
13
11
67
7
9
4
Top of LH cowl ........................................................ . . . 69

69
Front of LH cowl ..................................................... . . . 69
69
LH frame rail near f r o n t .......................................... . . . 68
At fuel pump re la y ................................................... . . . 68
At engine temperature s e n s o r.............................. . . . 67
At generator ............................................................ . . . 66
10
11
10
11
8
8
6
1
68
7
7
cooling fan s w itc h ...............................................

coolant temperature s w itc h ..............................
coolant temperature s e n d e r..............................
TP s e n s o r............................................................
RH in je c to r ..........................................................
LH injector ..........................................................
glow plug controller............................................
cold advance/fast idle temperature switch . . .
idle air c o n tro lle r.................................................
MAP sensor ........................................................
. ..
...
...
. ..
...
...
...
...
...
...
At knock sensor .....................................................

At oil pressure s e n d e r............................................
At electronic spark c o n tro l.....................................
At ignition c o i l ..........................................................
At engine speed sensor ........................................
Left of d is trib u to r.....................................................
At low coolant warning switch ..............................
At water in fuel s e n s o r............................................
At fuel heater ..........................................................
At fast idle s o le n o id .................................................
At cold advance co n tro l..........................................
At fuel shutoff v a lv e .................................................
...
...
...
...
...
...
...
...
...
...
...
...
At
At
At
At
At
At
At
At
At
At
68
66
68
68
68
68
67
66
68
67
68
68
2
7
7
7
7
4
1
7
5
7
7
4
67
67
67
67
67
67
67
67
5
4
4
66
66
66
1
1
1
6
fi
4
COMPONENT LOCATION
C150
................... .......................
Page - Figure
LH side of front cro s s m e m b e r..................... ..............
69
69
..............
..............
..............
..............
..............
68
68
68
68
C151
C153
C154
C155
C172
....
..........................
..........................
..........................
..........................
.......................
.......................
.......................
.......................
.......................
LH side of front cro s s m e m b e r.....................

RH side of front cro ssm e m b er.....................
At brake pressure warning switch ..............
Center of front cro ssm e m b er........................
At transmission electronic control ..............
C173
..................................................
.......................
At output speed s e n s o r................................. ..............
C174
.......................... .......................
At input speed s e n s o r................................... ..............
C175
C190
C191
C192
C193
C194
C195
C196
C197
C198
C199
C200
C201
C204
C205
..........................
..........................
At EVRV .................................................................................................................. ...........................

At glow plug co ntro lle r .................................................................... ...........................
At glow plug co n tro lle r................................... ..............
C206
.......................... .......................
.............................................
.............................................
.......................
. .
..........................
..........................
..........................
.......................... .......................
..................................................
.............................................
...........................
..............
..............
At #8 glow plug
At # 7 glow plug
.............................................
............................
......................................................................................
...........................
...........................
..................................................
..................................................
............................................
..................................................
.............................................
.......................... .......................
.................. .......................
..................................................
............................................
..................................................
............................................
At
At
At
At
At
At
# 3 glow plug ......................................................................................

#1 glow plug .............................................
ignition s w itc h ......................................................................................
ignition s w itc h ......................................................................................
ALDL .................................................................................................................
DRAC m o d u le ......................................................................................
Base of steering column
C207
..................................................
............................................
LH frame rail behind cowl
C208
..................................................
............................................
At DRL relay
C209
C210
C211
C212
C213
C214
C215
C220
C222
C244
C250
C251
..................................................
.......................
..................................................
............................................
..................
.......................
..................................................
............................................
..................................................
............................................
...........................................................
At horn re la y ....................................................................................................
At cooling fan r e la y .............................................................................
Lower left of steering c o lu m n ..............................................
At hazard fla s h e r ......................................................................................
At headlamp dimmer s w itc h ..................................................
..................................................
............................................
..................................................
............................................
..................................................
............................................
...........................
...........................
...........................
............................................
............................................
............................
............................
....................................................................................................
..................................................
.......................
...........................
............................
Lower left of steering c o lu m n ..............................................

At backup lamp switch ................................................................
.......................
...........................
.......................................................
.......................
..................................................
...........................
LH frame rail near cowl ................................................................

LH cowl top center .............................................................................
Base of steering column ...........................................................
LH front frame r a i l ..........................................
LH front frame r a i l ..................................................................................
...........................
...........................
...........................
...........................
...........................
...........................
............................
...........................
...........................
...........................
...........................
...........................
67
67
67
67
67
67
68
67
67
66
66
66
66
66
66
66
66
10
11
8
8
8
8
6
4
6
4
6
7
4
4
69
69
69
69
69
68
69
69
69
69
69
69
69
69
69
69
69
69
69
69
69
69
69
10
10
11
10
11
10
11
10
10
11
10
11
10
10
11
10
11
8
8
8
10
10
69
69
Page -- Figure
C252 ........................................
C253 ........................................
C401 ........................................
C402 ........................................
Grommets:
GT100 ......................................
LH front frame r a i l ...........................................................

LH front frame r a i l ...........................................................
At fuel level s e n d e r .........................................................
LH side of rear crossm em ber........................................
69
69
69
69
11
11
12
12
LH side of c o w l................................................................
69
69
GT101 ......................................
Grounds:
G100 ........................................
G101 ........................................
G103 ........................................
G109 ........................................
G110 ........................................
Injector b o d y ....................................................................
68
10
11
7
1
1
1
1
2
2
2
2
11
11
11
10
11
68
68
68
COMPONENT LOCATION
G4Q0 ........................................
Splices:
510 0
510 1
510 2
510 3
510 4
S 1 0 6 ..........................................
510 8
510 9
511 0
511
511
511
511
1
2
3
4
Lower LH side of c o w l....................................................

Top front of e n g in e .........................................................
At alternator bracket ......................................................
Lower LH side of c o w l....................................................
RH frame rail below rear battery .................................
LH crossmember in front of fuel t a n k ..........................
Battery junction block ....................................................
RH lower side of engine ...............................................
LH frame rail behind cowl .............................................
LH frame rail behind cowl .............................................
Front center of e n g in e ....................................................
LH side of transmission (d ie s e l)...................................
LH side of cowl (g a s o lin e ).............................................
Front RH side of engine ...............................................
Rear center top of engine .............................................
LH top of e n g in e .............................................................
LH side of c o w l...............................................................
69
69
67
69
69
10
1
7
11
3
13
12
67
67
67
5
5
5
66
68
68
67
68
68
68
8
8
67
6
8
68
68
67
68
66
68
69
7
4
7
2
8
10
RH side of c o w l...............................................................
68
69
511 6
S 1 2 6 ........................................
515 0
515 1
515 2
515 3
515 4
515 6
515 7
S200 ........................................
LH top rear of engine ....................................................

LH side of c o w l...............................................................
RH lower side of engine ...............................................
Rear center of engine ....................................................
Rear center of engine ....................................................
LH side of tra n sm issio n .................................................
LH top rear of engine ....................................................
RH top side of c o w l........................................................
LH top side of c o w l........................................................
Cowl near steering column ..........................................
66
11
2
10
1
5204
5205
521 3
521 4
Lower
Lower
Lower
Lower
521
Lower RH corner
511
RH
RH
RH
RH
corner
corner
corner
corner
69
66
67
67
67
67
69
69
69
69
behind cowl ...................................... 69
behind cowl ...................................... 69
behind cowl ...................................... 69
behind cowl ...................................... 69
69
behind cowl ...................................... 69
4
4
4
4
11
11
10
11
10
10
10
10
11
10
C-71
COMPONENT LOCATION
8216
.
521 .......................
6
521 .......................
7
8217
.
.
8250
S250 .......................
..........................................
C-72
Page -- Figure
LH top of cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69
Top LH corner
comer of cowl.
cowl . . . . . . . . . . . . . . . . . . . . .. 69
Top LH corner
corner of cowl.
cowl . . . . . . . . . . . . . . . . . . . . .. 69
11
10
11
Abbreviation List ................................................... 10

Air Conditioning, Front Manual, R/V ................ A-94
Air Conditioning, Provisions For,
P Motorhome ................................................... C-50
Air Conditioning, Rear, R /V ................................ A-95
Alarm, Audio, R /V .................................................A-111
AM Radio, R / V ......................................................A-144
Antilock Brakes, Rear Wheel, R / V .....................A-116
Audio Alarm, R / V .................................................A-111
Auxiliary Battery, R/V ..........................................A-22
Auxiliary Cooling Fan, R/V ................................ A-89
Auxiliary Cooling Fan, P M o torho m e ................ C-49
Auxiliary Fuel Tank and Fuel Tank
Selector Switch, Diesel, R/V ......................... A-81
Auxiliary Fuel Tank and Fuel Tank
Selector Switch, Gasoline, R/V .....................A-80
Auxiliary Heater, R/V ..........................................A-99
Backup Lamps (Fleetside and Wideside),
R /V ...................................................................... A-154
Backup Lamps (Stepside), R /V ......................... A-155
Backup Lamps (Suburban and Utility),
R /V ...................................................................... A-155
Backup Lamps, P Commercial ......................... B-77
Backup Lamps, P M otorhom e............................ C-63
Basic Electricity ..................................................... 4
Battery, Auxiliary, R /V ..........................................A-22
Block, Fuse, R/V .................................................A-14
Block, Fuse, Gasoline W/Man Trans,
P C o m m e rcial................................................... B-10
Block, Fuse, Gasoline W/Auto Trans,
P C o m m e rcial................................................... B-11
Block, Fuse, Gasoline, P Motorhome .............. C -8
Block, Fuse, Diesel W/Man Trans,
P C o m m e rcial................................................... B-12
Block, Fuse, Diesel W/Auto Trans,
P C o m m e rcial................................................... B-13
Block, Fuse, Diesel, P Motorhome ................... C-9
Brake Booster Vacuum System, Power, R/V . . A-164
Brake Warning System, School Bus,
P C o m m e rcial................................................... B-74
Brake Warning System, R / V .............................. A-114
Brake Warning System Without Rear
Wheel Antilock Brakes, R /V ............................A-115
Bulb Data, R / V ..................................................... A-15
Bulb Data, P C o m m e rcia l................................... B-14
Bulb Data, P Motorhome i ................................ C-10
Camper and Trailer Wiring, R/V ....................... A-160
Cargo Lamp, R / V .................................................A-120
Center, Convenience, R/V ................................ A-21
Charge, Start and, Diesel, R/V ......................... A-56
Charge, Start and, Diesel, P Commercial . . . . B-41
Charge, Start and, Diesel, P M otorhom e......... C-31
Charge, Start and, Gasoline, R/V .....................A-55
Charge, Start and, Gasoline, P Commercial . . B-40
Charge/Start and, Gasoline, P Motorhome . . . C-30

Circuit Diagrams .................................................... 3
Circuit M a lfu n c tio n s ............................................... 4
Circuit Operation .................................................... 3
Circuit Wiring Repair Procedures ....................... 6
Cluster, Instrument Panel, R/V ..........................A-103
Cluster, Instrument Panel, P Commercial . . . . B-69
Cluster, Instrument Panel, P M o torho m e ......... C-55
Component Locations .......................................... 3
Component Locater Index, R /V ..........................A-194
Component Locater Index, P Commercial . . . . B-87
Component Locater Index, P Motorhome . . . . C-70
Component Locator Views, R/V ....................... A-166
Component Locator Views, P Commercial . . . B-81
Component Locator Views, P Motorhome . . . . C -66
Conditioning, Air, R /V .......................................... A-94
Conditioning, Air, Provisions For,
P M o to rh o m e ....................................................C-50
Connectors, Metri-Pack ........................................ 8
Connectors, W eather-P ack................................... 8
Contents, Table o f ................................................. 1
Control, Cruise, R / V .............................................A-124
Control, Cruise, P Motorhome ..........................C-52
Control Module, Electronic, Pinouts,
Diesel, R / V ........................................................ A-62
Gasoline, R / V ....................................................A-57
Gasoline, P Commercial ................................. B-43
Control Module, Powertrain, Pinouts,
Gasoline, R / V ....................................................A -66
Gasoline, P Commercial ................................. B-49
Control Module, Transmission, Pinouts,
Gasoline, P M otorhom e................................... C-33
Diesel, R / V ........................................................ A-67
Diesel, P Commercial ..................................... B-55
Diesel, P M otorhom e........................................C-39
Control Module, Inputs, Diesel,
Electronic, R / V ................................................. A-63
Control Module, Inputs, Gasoline,
Electronic, R/V ................................................. A-58
Electronic, P Commercial .............................. B-44
Powertrain, R /V ................................................. A -68
Powertrain, P C o m m e rcial.............................. B-50
Powertrain, P Motorhome ...............................C-34
Control Module, Outputs, Diesel,

Electronic, R / V ................................................. A-64
Control Module, Outputs, Gasoline,
Electronic, R/V ................................................. A-60
Electronic, P Commercial ...............................A-46
Powertrain, R /V ................................................. A-70
Powertrain, P C o m m e rcial............................... B-52
Powertrain, P Motorhome ...............................C-36
Control Module, Outputs, Diesel
Transmission, R /V .............................................A-72
Control Module, Outputs, Diesel Transmission,
P C o m m e rcial.................................................... B-56
Control Module, Outputs, Diesel Transmission,
P M o to rh o m e ....................................................C-40
Controller (DRAC) Module, Digital
Ratio Adapter, R/V .......................................... A-75
Controller (DRAC) Module, Digital Ratio
Adapter, W/Man or Auto Trans and Trans
and Diesel W/Auto Trans, P Commercial . . . B-64
Adapter, Diesel W/Man Trans,
P C o m m e rcial.................................................... B-65
Adapter, P Motorhome ................................... C-42
Convenience Center, R / V ................................... A-21
Cooling Fan, Auxiliary, R / V ................................. A-89
Cooling Fan, Auxiliary, P Motorhome .............. C-49
Cruise Control, R/V .............................................A-124
Cruise Control, P M o to rh o m e ............................ C-52
Data, Bulb, R/V ....................................................A-15
Data, Bulb, P C om m ercial................................... B-14
Data, Bulb, P M o to rh o m e ................................... C-10
Daytime Running Lamps (Canada Only),
R /V .......................................................................A-22
P C o m m e rcial.................................................... B-28
P Motorhome ....................................................C-18
Defogger, Rear, R / V .............................................A-146
Diagnosis C h a r ts .................................................... 4
Diagrams, C ir c u it.................................................... 3
Diesel, Electronic Control Module, R / V ............A-63
Diesel Engine Fuel Controls, P Commercial . . B-63
Diesel Engine Fuel Controls, P Motorhome . . . C-47
Diesel Engine Fuel Controls, 6.2L, R / V ............A-87
Diesel Engine Fuel Controls, 6.2L HD,
R /V .......................................................................A -88
Diesel, Transmission Control Module, R/V . . . . A-72
Diesel, Transmission Control Module,
P C o m m e rcial.................................................... B-56

P M o to rh o m e ....................................................C-40
Pinouts, R / V ...................................................... A-67
Pinouts, P Commercial ................................... B-55
Pinouts, P M otorhom e......................................C-39
Digital Ratio Adapter Controller (DRAC)
Module, R / V ...................................................... A-75
Digital Ratio Adapter Controller (DRAC) Module,
Gasoline W/Man Trans or Auto Trans and Diesel
W/Auto Trans, P Commercial ........................ B-64
Digital Ratio Adapter Controller (DRAC) Module,
Diesel W/Man Trans, P Com m ercial.............. B-65
Digital Ratio Adapter Controller (DRAC)
Module, P M otorhom e......................................C-42
Distribution, Power, Diesel, R /V ..........................A-12
Distribution, Power, Diesel W/Man Trans,
P C o m m e rcial.................................................... B-6
Distribution, Power, Diesel W/Auto Trans,
P M o to rh o m e ...................................................... B-7
Distribution, Power, Diesel W/Auto Trans,
P Motorhome .................................................... C-5
Distribution, Power, Diesel Driveaway
P C om m ercial.................................................... B-8
Distribution, Power, Diesel Driveaway,
P M o to rh o m e .................................................... C-7
Distribution, Power, Gasoline, R /V ..................... A-10
Distribution, Power, Gasoline W/Man Trans,
P C o m m e rcial.................................................... B-4
Distribution, Power, Gasoline W/Auto
Trans, P Commercial ........................................ B-5
Distribution, Power, Gasoline W/Auto
Trans, P M o to rh o m e ........................................ C-4
Distribution, Power, Gasoline Driveaway
P C om m ercial.................................................... B-9
Distribution, Power, Diesel Driveaway,
P M o to rh o m e .................................................... C-6
Dome Lamps, Instrument Panel Compartment
Lamp and Lighted Vanity Mirror, R /V ............A-119
Dome Lamps, Provisions For, P Motorhome . . C-59
Door Locks, 2-Door, (With Power Outside
Rearview Mirrors), Power, R / V ....................... A-131
Door Locks, 2-Door, (Without Power Outside
Door Locks, 4-Door, (With Power Outside
Door Locks, 4-Door, (Without Power Outside
Drive, Four-Wheel, R / V ........................................ A-126
Electrical Test E qu ip m e n t...................................... 4
Electricity, B a s ic ...................................................... 4
GENERAL INDEX
Electronic Control Module Pinouts, Diesel,

R /V .......................................................................A-62
Electronic Control Module Pinouts, Gasoline,
R / V .......................................................................A-57
Electronic Control Module Pinouts, Gasoline,
P C o m m e rcial.................................................... B-43
Electronic Control Module - Inputs, Diesel,
R / V .......................................................................A-63
Electronic Control Module - Inputs, Gasoline,
R / V .......................................................................A-58
Electronic Control Module - Inputs, Gasoline,
P C o m m e rcial.................................................... B-44
Electronic Control Module - Outputs, Diesel,
R / V .......................................................................A-64
Electronic Control Module - Outputs, Gasoline,
R /V .......................................................................A-60
Electronic Control Module - Outputs, Gasoline,
P C o m m e rcial.................................................... B-46
Four-Wheel Drive, R/V ........................................ A-126
Forward Lamp Harness, P C om m ercial............B-24
Forward Lamp Harness, P M o to rh o m e ............C-14
Forward Lamp Harness, W/DRL,
P C o m m e rcial.................................................... C-27
Forward Lamp Harness, W/DRL,
P Motorhome .................................................... C-20
Front Manual Air Conditioning, R /V ...................A-94
Front Park, Marker, Roof and Hazard
Lamps, R /V ........................................................ A-33
Fuel Control and Idle Air Control,
Gasoline, R / V ....................................................A-78
Fuel Control and Idle Air Control, Gasoline,
P C om m ercial.................................................... B-54
Fuel Controls, Diesel Engine, P Commercial . . B-63
Fuel Controls, Diesel Engine, P Motorhome . . C-47
Fuel Controls, (6.2L), Diesel Engine,
R /V .......................................................................A-87
Fuel Controls, (6.2L HD), Diesel Engine,
R /V .......................................................................A -88
Fuel Handling, Gasoline, Hot, R /V ..................... A-79
Fuel Tank Selector Switch, Diesel,
Auxiliary Fuel Tank and, R / V ..........................A-81
Fuel Tank Selector Switch, Gasoline,
Auxiliary Fuel Tank and, R / V ..........................A-80
Fuse Block, R / V ....................................................A-14
Fuse Block, Diesel W/Man Trans,
P C o m m e rcial.................................................... B-12
Fuse Block, Diesel W/Auto Trans,
P C o m m e rcial.................................................... B-13
Fuse Block, Diesel W/Auto Trans,
P M o to rh o m e .................................................... C-9
Fuse Block, Gasoline W/Man Trans,
P C o m m e rcial.................................................... B-10
Fuse Block, Gasoline W/Auto Trans,
P C o m m e rcial.................................................... B-11
GENERAL INDEX
Fuse Block, Gasoline W/Auto Trans,

P M o to rh o m e ....................................................
C -8
Fuse Block ID and Bulb Data, R/V ...................A-15
Gages (Fleetside), Instrument Panel, R/V . . . . A-109
Gages (Suburban and Utility), Instrument
Panel, R/V .........................................................A-108
Gages, Instrument Panel, P C o m m e rcial......... B-72
Gages, Instrument Panel, P M o to rh o m e ......... B-57
Glow Plugs, R /V ....................................................A-84
Glow Plugs, P C o m m e rcia l................................. B-60
Glow Plugs, P Motorhome ................................. C-44
Ground Distribution, Diesel, R / V ........................A-18
Ground Distribution, Diesel W/Man Trans,
P C o m m e rcial.................................................... B-19
Ground Distribution, Gasoline W/Auto Trans,
P C o m m e rcial.................................................... B-20
Ground Distribution, Diesel, P Motorhome . . . C-12
Ground Distribution, Forward Lamps,
P C o m m e rcial.................................................... B-15
Ground Distribution, Gasoline, R / V ...................A-16
Ground Distribution, Gasoline W/Man Trans,
P C om m e rcial.................................................... B-16
Ground Distribution, Gasoline W/Auto Trans,
P C om m e rcial.................................................... B-17
Ground Distribution, Gasoline, P Motorhome . C-11
Ground Distribution, Rear, P Commercial . . . .
B-21
Harness, Forward Lamps, P Commercial . . . . B-24
Harness, Forward Lamps, P M o to rh o m e ......... C-14
Harness, Forward Lamps W/DRL,
P C om m e rcial.................................................... B-27
Harness, Forward Lamps W/DRL,
P Motorhome ....................................................C-20
Harness, Rear Lamps, P C o m m e rc ia l.............. B-76
Harness, Rear Lamps, P Motorhome .............. C-61
Harnesses, Vacuum, R/V ................................... A-164
Hazard Lamps, (All Models), Rear, R / V ............A-35
Hazard Signal Lamps, P Commercial .............. B-32
Hazard Signal Lamps, P M otorhom e ................ C-22
Hazard Lamps with Quad Halogen
Headlamps, R / V ............................................... A-36
Hazard Lamps, Front Park, Marker, Roof
and, R /V ............................................................. A-33
Headlamps - Base, R/V ......................................A-25
Headlamps - Base, P Commercial ................... B-23
Headlamps - Base, P M o to rh o m e ..................... C-15
Headlamps With Daytime Running Lamps,
R /V ...................................................................... A-26
Headlamps with Daytime Running Lamps,
P C om m ercial.................................................... B-28
Headlamps with Daytime Running Lamps,
P Motorhome ....................................................C-18
Headlamps, Quad Halogen, R /V ........................A-32
Heater, Auxiliary, R / V .......................................... A-99
Heater, R/V ...........................................................A-96
Horns, R /V ............................................................. A-49

Horns, P C o m m e rcia l.......................................... B-36
Horns, P Motorhome .......................................... C-26
Hot Fuel Handling, R /V ........................................ A-79
How To Use This M a n u a l..................................... 3
Idle Air Control, Fuel Control and, R/V ............A-78
Idle Air Control, Fuel Control and,
P C o m m e rcial.................................................... B-54
Ignition, Gasoline, R/V ........................................ A-76
Ignition, Gasoline, P Commercial ..................... B-42
Ignition, Gasoline, P M o torho m e ....................... C-32
Index, Component Locater, R/V ....................... A-94
Index, Component Locater, P Commercial . . . B-87
Index, Component Locater, P Motorhome . . . . C-70
Index, Symptoms, R/V .......................................... A -8
Index, Symptoms, P Commercial ....................... B-3
Index, Symptoms, P M o torho m e....................... C-3
Indicator Lamps (Fleetside), R /V ....................... A-106
Indicator Lamps (Suburban and Utility),
R /V ...................................................................... A-104
Indicator Lamps, P Commercial ....................... B-70
Indicator Lamps, P M o torho m e ..........................C-56
Injection, Throttle Body, R / V .............................. A-77
Injection, Throttle Body, P C o m m e rc ia l............ B-48
Injection, Throttle Body, P Motorhome ............C-38
Instrument Panel Cluster, R /V ............................ A-103
Instrument Panel Cluster, P C o m m e rcial......... B-69
Instrument Panel Cluster, P Motorhome ......... C-55
Instrument Panel Indicators, R /V ....................... A-104
Instrument Panel Indicators, P Commercial . . . B-70
Instrument Panel Indicators, P Motorhome . . . C-56
Instrument Panel Gages (Fleetside,
Wideside, Crew Cab), R /V .............................. A-106
Instrument Panel Gages (Suburban and
Utility), R / V ........................................................ A-108
Instrument Panel Gages, P Commercial ......... B-71
Instrument Panel Gages, P M otorhom e............C-57
Instrument Panel Lamps (Fleetside),
R /V ...................................................................... A-109
Instrument Panel Lamps (Suburban and
Utility), R / V ........................................................ A-110
Instrument Panel Lamps, P C o m m e rc ia l......... B-72
Instrument Panel Lamps, P Motorhome ......... C-58
In tro d u c tio n ............................................................. 3
Key-ln and Lights-On Warning Buzzer,
R /V ...................................................................... A-113
Lamp, Cargo, R/V ...............................................A-121
Lamp (Fleetside and Wideside), License,
R /V ...................................................................... A-159
Lamp (Suburban and Utility), License,
R /V ...................................................................... A-159
Lamps, Turn Signal, R /V ..................................... A-44
Lamps, Turn Signal, P C om m ercial................... B-34
Lamps, Turn Signal, P M o to rh o m e ...................C-24
Lamps (Fleetside and Wideside), Backup,

R /V ...................................................................... A-154
Lamps, Backup, P C om m ercial.......................... B-77
Lamps, Backup, P M o to rh o m e ..........................C-63
Lamps (Fleetside and Wideside), Park and
Marker, R/V ...................................................... A-35
Lamps, Front Park, Marker, Roof and
Hazard, R/V ...................................................... A-34
Lamps, Park and Marker Signal,
P C om m ercial.................................................... B-31
Lamps, Park and Marker Signal,
P M o to rh o m e ....................................................C-22
Lamps, Rear Exterior, R/V ................................. A-149
Lamps, Roof Marker, R / V ................................... A-34
Lamps (Stepside), Backup, R/V ....................... A-154
Lamps (Suburban and Utility), Backup,
R N ...................................................................... A-157
Lamps (Suburban and Utility), Indicator,
R /V ...................................................................... A-104
Lamps (Suburban and Utility), Park and
Marker, R/V ...................................................... A-159
Lamps (With Quad Halogen), Hazard, R/V . . . A-38
License Lamp (Fleetside and Wideside),
R /V ...................................................................... A-159
License Lamp (Suburban and Utility),
R /V ...................................................................... A-158
Locations, C o m p o n e n t.......................................... 3
Malfunctions, C irc u it............................................... 4
Manual, How To Use This ................................... 3
Marker Lamps (Fleetside and Wideside),
Park and, R /V ....................................................A-35
Marker Lamps (Suburban and Utility),
Park and, R /V ....................................................A-34
Marker Signal Lamps, Park and,
P C om m ercial.................................................... B-31
Marker Signal Lamps, Park and,
P M o to rh o m e ....................................................C-22
Marker, Roof and Hazard Lamps, Front
Park, R/V ...........................................................A-34
Metri-Pack C o n ne ctors .......................................... 8
Operation, C irc u it.................................................... 3
Panel Doors, Rear Defogger, R / V ..................... A-147
Park and Marker Lamps (Fleetside and
Wideside), R / V ................................................. A-157
Park and Marker Lamps (Suburban and
Utility), R / V ........................................................ A-156
Park and Marker Signal Lamps,
P C om m ercial.................................................... B-31
Park and Marker Signal Lamps,
P M o to rh o m e ....................................................C-22
Phantom View, R/V ............................................... A-2
Phantom View, P C om m ercial...............................B-2
Phantom View, P M o to rh o m e ............................ C-2
Plugs, Glow, R/V ................................................. A-84
Plugs, Glow, P Commercial .............................. B-60

Plugs, Glow, P M o to rh o m e ................................ C-44
Power Brake Booster Vacuum System, R/V . . . A-164
Power Distribution - Diesel, R/V ....................... A-12
Power Distribution, Diesel W/Man Trans,
P C o m m e rcial......................................................B-6
Power Distribution, Diesel W/Auto Trans,
P C o m m e rcial......................................................B-7
Power Distribution, Diesel W/Auto Trans,
P M o to rh o m e ................................................... C-5
Power Distribution, Diesel Driveaway,
P C o m m e rcial..................................................... B-8
Power Distribution, Diesel Driveaway,
P M o to rh o m e ................................................... C-7
Power Distribution - Gasoline, R/V .................. A-10
Power Distribution, Gasoline W/Man Trans,
P C o m m e rcial..................................................... B-4
Power Distribution, Gasoline W/Auto Trans,
P C o m m e rcial..................................................... B-5
Power Distribution, Gasoline W/Auto Trans,
P M o to rh o m e ................................................... C-4
Power Distribution, Gasoline Driveaway,
P C o m m e rcial..................................................... B-9
Power Distribution, Gasoline Driveaway,
P M o to rh o m e ................................................... C -6
Power Door Locks, 2-Door (With Power
Outside Rearview Mirrors), R / V .....................A-131
Power Door Locks, 2-Door (Without Power
Power Door Locks, 4-Door (With Power
Power Door Locks, 4-Door (Without Power
Power Door Locks and Power Mirrors,
R /V ...................................................................... A-131
Power Mirrors and Power Door Locks,
R /V ...................................................................... A-131
Power Outside Rearview Mirrors, R / V ..............A-129
Power Rear Window, R / V ...................................A-142
Power Windows, 2-Door, R / V ............................A-139
Power Windows, 4-Door, R / V ............................A-140
Power Windows, R/V ..........................................A-136
Powertrain Control Module Inputs Gasoline, R / V ................................................... A -68
Powertrain Control Module Inputs Gasoline, P C o m m e rc ia l................................ B-50
Powertrain Control Module Inputs Gasoline, P M otorhom e...................................C-34
Powertrain Control Module Outputs Gasoline, R / V ...................................................A-70
Powertrain Control Module Outputs Gasoline, P C o m m e rc ia l................................ B-52
Powertrain Control Module Outputs Gasoline, P M otorhom e...................................C-36
Powertrain Control Module Pinouts, R / V ......... A -66

Powertrain Control Module Pinouts,
P C om m e rcial....................................................A-49
Powertrain Control Module Pinouts,
P M o to rh o m e ................................................... A-33
Pulse Wiper/Washer, R / V ................................... A-50
Radio, AM ETR, R /V ............................................ A-144
Radio, Stereo, R / V ...............................................A-145
Radio, R / V ............................................................. A-143
Rear Air Conditioning, R / V .................................A-95
Rear Defogger - Panel Doors, R/V ...................A-147
Rear Defogger, R/V .............................................A-146
Rear Defogger - Tailgate, R /V ............................ A-148
Rear Exterior Lamps, R / V ................................... A-149
Rear Hazard Lamps, R/V ................................... A-35
Rear Wheel Antilock Brakes, R/V ..................... A-116
Rear Window, Power, R /V ................................... A-142
Rearview Mirrors, Power Outside, R /V .............. A-129
Regular Production Option (RPO) L is t................ 10
Repair Procedures, Circuit W irin g ....................... 6
Roof and Hazard Lamps, Front Park,
Marker, R/V ......................................................A-34
Roof Marker Lamps, R/V ................................... A-40
Safety Belt Warning Buzzer, R /V ....................... A-112
Special T o o ls ........................................................... 9
Start and Charge, Diesel, R /V ............................ A-56
Start and Charge, Diesel, P C o m m e rcial......... B-41
Start and Charge, Diesel, P Motorhome ......... C-31
Start and Charge, Gasoline, R /V ....................... A-55
Start and Charge, Gasoline, P Commercial . . . B-40
Start and Charge, Gasoline, P Motorhome . . . C-30
Symptoms Index, R /V ............................................ A -8
Symptoms Index, P Commercial . ..................... B-3
Symptoms Index, P Motorhome ....................... C-3
Table of Contents ................................................. 1
Tailgate, Rear Defogger, R/V ............................ A-148
Tailiamps (Fleetside and Wideside),
R /V ...................................................................... A-151
Tailiamps (Stepside), R / V ................................... A-152
Tailiamps (Suburban and Utility),
R /V ...................................................................... A-150
Tail, Rear Marker and License Lamps,
P C om m ercial.................................................... B-78
T a ilia m p s............................................................... C-62
Test Equipment, Electrical ................................... 4
Throttle Body Injection, R/V ...............................A-77
Throttle Body -Injection, P Commercial ............ B-48
Throttle Body Injection, P M o to rh o m e .............. C-38
Tools, Special ........................................................ 9
Trailer Wiring, Camper and, R / V ....................... A-160
Transmission Control Module Pinouts,
R /V ...................................................................... A-67
P C om m ercial.................................................... B-55

P Motorhome . ............................................... C-39
Transmission Control Module, Diesel,
R /V .......................................................................A-72
P C om m ercial.................................................... B-56
P M o to rh o m e ......... ..........................................C-40
Transmission Converter Clutch
Detent Solenoid (5.7L), R /V ............................ A-74
Turn Signal Lamps, R / V ......................................A-44
Turn Signal Lamps, P .C o m m e rcia l................... B-34
Turn Signal Lamps, P M otorhom e..................... C-24
Underhood Lamp, R / V ........................................A-121
Vacuum Systems, R/V ........................................ A-164
Vacuum Systems, P Commercial ..................... B-79
Vacuum Systems, P M o torho m e ........................C-64
View, Phantom, R / V ............................................... A-2
View, Phantom, P Commercial ............................ B-2
View, Phantom, P M otorhom e............................ C-2
Views, Component Locator, R / V ....................... A-166
Views, Component Locator, P Commercial . . . B-81
Views, Component Locator, P Motorhome . . . C -66
Warning Buzzer, Key-ln and Lights-On,
R /V .......................................................................A-113
Warning Buzzer, Safety Belt, R/V ..................... A-112
Warning System Without Rear Wheel
Antilock Brakes, Brake, R /V ............................ A-115
Weather-Pack Connectors ................................... 8
Windows, Power, R/V . ........................................ A-136
Windows, 2-Door, Power, R /V ............................ A-139
Windows, 4-Door, Power, R /V ............................ A-140
Windshield Wiper/Washer, P Commercial . . . . B-38
Windshield Wiper/Washer, P Motorhome . . . . C-28
Wiper/Washer, Pulse, R /V ................................... A-50
Wiring, Camper and Trailer, R / V ........................A-160
GENERAL INDEX

X 9130 1991 GMC RV P Wiring Manual

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1991

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

1991 R/V, P TRUCK MODELS

R/V TRUCK MODELS - SECTION A

Air Conditioning.............................................................................................. A-91

P TRUCK MODELS - SECTION B

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

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

Circuit diagrams provide a schematic picture of how a

HOW TO USE THIS MANUAL

The purpose of this manual is to provide:

Each electrical system or circuit will provide the follow

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

The following is a list of Zones for the vehicle:

HANDLING ELECTROSTATIC DISCHARGE

For ease of diagnosis, all connectors (C), splices (S),

Figure 1 Electronic Discharge Warning

All connectors are shown with their part numbers and

Each wiring circuit is identified by circuit number, size

-s .o n E D B i^ Solid Color Circuit Line

mm Circuit Line With Tracer

Headlamp Dimmer Switch...........................................

Figure 3 Component Location Chart

Check for the cause of the problem

Verify the problem

The Diagnosis Charts (Figure 4) are a step-by-step

Operate the system and list symptoms in order to:

Check the circuit diagram

Read circuit operation

The charts are divided into three columns; Test, Result

Grounded Circuit (Figure 7)

I = 12 volts (E)/2 ohms (R), or I = 6 amps.

Repair the problem circuit as directed in the diagnosis

Verify that the repair is complete

Check condition of PARK LP fuse.

Open Circuit (Figure 5)

LOCATE and REPAIR source of

With the light switch ON,

Test lamp lights.

Test lamp does not light.

LOCATE and REPAIR open in ORN

Connect a test lamp from YEL (10)

Test lamp lights.

Test lamp does not light.

REPLACE light switch.

Test lamp lights.

REPAIR open in LT GRN (11) wire

Test lamp does not light.

REPLACE dimmer switch.

Figure 4 Typical Diagnosis Chart

Figure 7 Grounded Circuit

Fuse is not blown.

Connect a test lamp from LT GRN

A grounded circuit is like a short circuit but the current

Make the repair

HEADLAMPS DO NOT ILLUMINATE HIGH OR LOW BEAMS BOTH SIDES

Figure 6 Short Circuit

I = E/R. Filling in the numbers for the equation:

Figure 5 Open Circuit

Short Circuit (Figure 6)

ELECTRICAL TEST EQUIPMENT

Self-powered test lamps

All of these testers come in a variety of models and any

Unpowered Test Lamp