Chevrolet R-V 1989 Manual

1989
WIRINGDIAGRAMS
R-V,P TRUCK
MODELS
Whenreferenceismadeinthismanualtoa brandname,number,orspecifictool,anequivalentproductmay
beusedinplaceoftherecommendeditem
Allinformation, illustrations,andspecificationscontainedinthismanualarebasedonthelatestproduct
informationavailableatthetimeofpublicationapproval.Therightisreservedtomakechangesatanytime
withoutnotice.
Nopartofthispublicationmaybereproduced,storedinanyretrievalsystemortransmitted,inanyformorby
anymeans,includingbutnotlimitedtoelectronic,mechanical,photocopying,recordingorotherwise,withoutthe
priorwrittenpermissionoftheGMCTruckDivisionofGeneralMotorsCorp.Thisincludesalltext,illustrations,
tablesandcharts.
X-8940
©1988GeneralMotorsCorporationAugust,1988
AHrightsreservedPrintedinU.S.A.

WIRINGDIAGRAMS
Alldiagramsinthismanualarebasedonthelatestproductinformationatthetimeofpublicationapproval.Therightis
reservedtomakechangesatanytimewithoutnotice.
SUBJECTPAGE
Description2
TracingCircuits2
BasteElectricCircuits2
CircuitDiagnosis8
AbbreviationList7
DiagnosticTools11
WireSizeConversionTable11
On-VehicleService11
CircuitMaintenanceandRepair11
WeatherPackConnectors12
Metri-PackConnectors12
WiringRepair14
SpecialTools15
VEHICLESECTION
R/VModelsA-1
P:ChassisB-1
WIRINGDIAGRAMS2
DESCRIPTION
Figure1—WireCoding
•Thediagramsaretobetracedfromthesourceof
electricity(thebatterypositivepost)toground.The
groundmaybea chassisgroundona certaincom-
ponent(suchasanalternatorora starter),ora wire
froma componenttoa chassisorframeground
(suchasusedontheelectroniccontrolmoduleand
instrumentpanei).Allgroundsareconnectedtothe
negativebatterypostthroughbodyand/orangina
groundwiresandstraps.
•Manytimesthesourceoftheelectricityisshownas
theignitionswitchorthefuseblock.Thisisdoneto
eliminatetheconfusionthatwouldoccuriftheentire
powerdistributionwasshownineachcircuit.Fora
detailedoutlineofthepowertotheignitionswitchor
thefuseblock,refertothepowerdistributioncircuit.
•Thegroundportionofthecircuit(usuallycircuit150
or151)maybeshownentirely,oritmayrefertothe
grounddistributioncircuitinordertoavoidconfu-
sionoflistingailthegroundsinonespliceona sin-
glepage.
•Foreaseofdiagnosis,alisplicesandgroundsare
identifiedbynumber,andallthewiresona common
spliceorgroundareidentifiedbycircuitnumber,
size(inmm)andcolor. Eachcomponentorcircuit
commontos splicedwireiscalledoutbythepage
numberofthatcircuit.Thiswillhelpidentifyanddi-
agnosemultipleelectricalproblemsthatcouldoccur
ina truck.
•Allconnectorsareshownwiththeirpartnumbersto
savetimewhenorderingtheseparts.
•Switchesareshownintheiratrestpositions,unless
otherwisemarked.
TRACINGCIRCUITS
Figures1 through3 areexamplesofhowthewiring
diagramsarelaidout.,andwillbereferredto,throughout
thisdescription.
Inordertotracea circuitonthesediagrams,startfrom
thesource,thebattery.Infigure2,thebatterypositive
circuitisa 19.0mmblackwire.Thiswirerunsfromthe
batterytothestartermotor,andsuppliespowertothe
startermotorpost.
Onceyouhavedeterminedthesourceofpowertoyour
component,fromthePowerDistributionCircuit(figure2),
thenrefertotheindividualcircuityouareworkingonfor
moredetailaboutthatcircuit.(Figure3 showsthestarting
circuit).
Infigure3,thestartermotorcircuitisshown.Thiscircuit
showsthebatteryfeedcomingfromthePower
Distributionpage.Thecablecomesfromthebatteryto
thestart©?positivepost.Atthestarterpost,othercircuits
suchasthegenerator,ignitionswitch,andelectronic
controlmodulearefed.
Whentheignitionswitchisinthestartposition,power
flowsfromcircuit#2throughtheswitch,tocircuit#6.
Circuit#6goesthroughtheclutchswitchwithan
automatictransmission.Attheclutchswitchthecircuitis
opened,unlessthedutchisdepressed.
Atthesolenoidthecurrentflowingfromcircuit#6
closesthesoiertoid,allowingcurrenttoflowfromthe
batteryatcircuit#1tothestartermotor.Thecurrent
flowingtothestartermotor,causesthestartermotorto
spin.
BASICELECTRICALCIRCUITS
Anelectricalcircuitstartsfroma supplyofelectricity
backtoa loadandthenconductstheelectricitybackto
thesupplyofelectricity.Thereshouldbea devicetoopen
andclosethecircuit,anda protectivedevicetoopenthe
circuitincasetoomuchcurrentisdrawnintothecircuitby
anoverloadcondition.Electricalcircuitscanbesetupas
seriescircuits,parallelcircuitsorseries/parallel'circuits.
Thecircuitsintrucksareusuallyparallelcircuits.

WIRINGDIAGRAMS5 WIRINGDIAGRAMS6
path.Forexampletheswitchcontrollingtheheadlightsis
atthepowerendofthecircuitwhilethedoorswitch
controllingthedomelightcompletesthegroundpath.
Relaysareremotelycontrolledswitches.Theyareused
inhighcurrentcircuitsandincircuitscontrolledby
sensors.
Relaysaredesignedsothata smallcurrentcircuitwi!3
heabletocontrola largecurrentcircuit.
CIRCUITBREAKERS(Figure7)
Circuitbreakersareanotherformofcircuitprotector.
Therearetwotypesofcircuitbreakers;automaticreset
andremotereset.
Theautomaticresetbreakeropenswhenexcess
currentheatsa bimetallicstrip,causingthestriptobend
andopena setofcontacts.Thenthestripcoolsand
closesthecontacts.Sothecircuitbreakeropensand
closes until the excess current condition is corrected or
the circuit is disconnected from the power supply.
Theremoteresetcircuitbreakerhasa heatingwire
woundaroundthebimetallicstrip.Whenanexcess
currenthappens,thestripheats,bends,andopensthe
contacts.Thena smallcurrentflowsthroughtheheating
wire,keepingthestriphotandthecontactsopen.This
typeofbreakerwillstayopenuntileitherthepowersupply
isdisconnectedfromthecircuitorthebreakerisremoved
fromthecircuit.Thenthebreakercancoolandreset.
CIRCUITLOADS(Figure7)
Circuitloadsarethecomponentsthatusemostofthe
energyincircuit.Theenergyconvertstomotion,light,or
heat,lights,motors,andengineheatersarethemost
commonloadsincircuits.
CIRCUITDIAGNOSIS
Aclearunderstandingofthecircuitanda wiring
diagramareneededforeffectivediagnosis.Usea logical
sequenceoftestingtofindthetrouble.Usethediagnostic
tools.Afterthetroubleisfixed,makesurethecircuit
workscorrectly.
CIRCUITMALFUNCTIONS
Therearethreeelectricalconditionsthatcancausea
nonworkingcircuit;an"OpenCircuit",a "ShortCircuit",
ora "GroundedCircuit"
OPENCIRCUIT(Figure8)
Anopencircuitoccurswheneverthereisa breakinthe
circuit.Thebreakcanbecorrosionatthe connector,a
wirebrokenoffina device,ora wirethatburnedopen
fromtoomuchcurrent.
SHORTCIRCUIT(Figure9}
Ashortcircuithappenswhenthecurrentbypassespart
ofthenormalcircuit.Thisbypassingisusuallycausedby
wirestouching,saltwaterinorona devicesuchasa
switchora connectororsoldermeltingandbridging
conductorsina device.
Figure7—CircuitControllers
FUSES(Figure8)
Themostcommonprotectorinthevehiclecircuitisa
fuse.A fuseconsistsofa finewireorstripofmetalinside
aglasstubeorplastichousing.Thestripmeltsand
interruptstheflowofcurrentinthecircuitwhenthereIsan
overloadcausedbyanunwantedshortorground.The
fuseisdesignedtomeltbeforethewiringorelectrical
componentsina circuitcanbedamaged.Naturally,the
causemustbelocatedandcorrectedbeforethefuseis
replacedorthenewfusewillalsoblow.
Sincedifferentcircuitshandledifferentamountsof
current,fusesofvariousratingsareused.Fusesarerated
inamperes.Besuretoreplacea blownfusewitha fuseof
theconnectingrating.
CIRCUITCONTROLLERS(Figure7)
Circuitcontrollersconsistofswitchesorrelays.
Switchesareusuallyoperatedbya mechanicalmeans
suchasa handorlever.Switchesareusuallyatthe
beginningofa circuitbutcanbeusedtocontrola ground
Figure5—Series/ParallelCircuits
FUSIBLELINK
Afusiblelinkisa sectionofwirethatisusuallyfour
gagesizessmallerthanthecircuititprotects.A special
insulationisusedthatswellswhenheatedbythewire.
Fusiblelinksareusuallyfoundintheenginecompartment
harnesses.Thefunctionofthefusiblelinkistomeltopen
whenanoverloadoccurs,thuspreventinganydamageto
thecircuit.
Figure6--CircuitComponents
Figure4—BasicCircuits
SERIESCIRCUITS(Figure4 and5)
Ina seriescircuit,theelectricaldevicesareconnected
togethertoformonecurrentpathtoandfromthepower
supply.Ina seriescircuitthesamecurrentflowsthrough
allofthedevices.
PARALLELCIRCUITS(Figure5)
Ina parallelcircuit,theelectricaldevicesareconnected
toformmorethanonecurrentpathtoandfromthepower
supply.Ina parallelcircuitthesupplyvoltageisthesame
ineachcurrentpath.
SERIES/PARALLELCIRCUIT(Figure5)
Aseries/parallelcircuitconsistsofa singlecurrentpath
circuitanda circuitwithmorethanonecurrentpathto
andfrom"thevoltagesupply.
CIRCUITCOMPONENTS(Figure6)
Theusualcircuitpathstartsatthepowersupplywhich
isthebattery/generatorsystem.Nextinthecircuitsisthe
circuitprotectioncomponentwhichcarshea fusiblelink,a
fuse,ora circuitbreaker.Thenthecircuitgoestothe
circuitcontrollerwhichcanbea switchora relay.From
thecircuitcontrollerthecircuitgoesintothecircuitload.
Thecircuitloadcanbeonelightormanylightsinparallel,
anelectricmotorora solenoid.Aftertheelectricityhas
passedthroughtheloaditmustreturntothepower
supplyviathegroundpath.Thegroundpathcanbea
wireintheharnessoritcouldbethroughtheload
housingintothebodyorframe,thusreturningthe
electricitytothepowersupply.Thebodyandframeare
connectedbyflexiblegroundstraps.

WIRINGDIAGRAMS7
GROUNDED CIRCUIT(Figure 10)
Agroundcircuitislikea shortcircuitbutthecurrent
flowsdirectlyintoa groundcircuitthatisnotpartofthe
originalcircuit.Thismaybecausedbya wirerubbing
againsttheframeorbody.Sometimesa wirewillbreak
andfallagainstmetalthatisconnectedelectricallytothe
groundsideofthepowersupply.A groundedcircuitmay
alsobecausedbydepositsofoil,dirtandmoisture
aroundconnectionsorterminals,whichprovidea good
pathtoground.
WIRINGDIAGRAMS8
EFE—EarlyFuelEvaporation
EGR—ExhaustGasRecirculation
ELEC—Electric
ELEC—Electronic
CNTRL—Control
MOD—Module
ENG-—Engine
EPR—ExhaustPressureRegulator
ESC—ElectronicSparkControl
EST—ElectronicSparkTiming
EVRV—ElectronicVacuumRegulatorValve
EXC---Except
F-PUMP—FuelPump
FLASH—Flasher
FRT—Front
4WD—FourWheelDrive
GEN—Generator
GRA—Gray
GRD—Ground
GRN—Green
HAND—Handling
HAZ—Hazard
HD—HeavyDuty
HDLP—Headlamp
HEI—HighEnergyIgnition
HI—High
HTR—Heater
IAC-IdleAirControl
IGN—Ignition
IL.LUM—Illumination
I/P—Instrument.Panel
INC—Increased
IND—Indicator
INJ—Injector
INSTPNLInstrumentPane!
INTER—Interior
LD—LightDuty
LH—LeftHand
LO—Low
LP—Lamp
LPS--Lamps
LT~~Light
LTR-~Ughter
M—Motor
MAN—Manual
MAP—ManifoldAbsolutePressure
MAX---Maximum
MED—Medium
MRKR—Marker
MULT—Multiple
NAT--Natural
NEUT—Neutral
NO—NormallyOpen
NC—NormaiiyClosed
ORN--Orange
PK—Park
PLR—Puller
PNKf-PInk
PNL—Panel
PPL—Purple
PRESS—Pressure
WR—Power
RCVR—Receiver
REF—Reference
RESIST---Resistance
RM—RightHand
RPO—RegularProductionOption
SEN---Sensor
SEND—Sender
SIG—Signal
SIL—Silver
SKT—-Socket
SOL—Solenoid
SPEEDO—Speedometer
STR—Stripe
SW—Switch
TACH-—-Tachometer
TBI—ThrottleBodyInjection
TCC-—TorqueConverterClutch
TEMP--Temperature
T/L-—TailLamp
TRANS--Transmission
TYP--Typical
V—Volt
VAC—Vacuum
VLV—Valve
VSS—VehicieSpeedSensor
W/—With
W/O—Wttmut
W/S—Windshield
WWASHER—WindowWasher
WOO—Window
WHT-White
WRG—-Wiring
YEL—Yellow
Figure10—GroundedCircuit
Figure9—ShortCircuit
ABBREVIATIONLIST
Thefollowingisa listofabbreviationsusedinthewiring
diagrams.Theabbreviationshavebeendevelopedin
sucha waythattheirmeaningshouldbeclear.
Usethispageasa referencetodeterminethemeaning
ofanabbreviationifnecessary.
A---Ampere
A/C---AirConditioner
ACC--Accessory
A.I.R.---AirInjectionReaction
AIR/COND—AirConditioner
ALDL—AssemblyLineDiagnosticlink
ALT—Alternator
AMP—Ampere
ANTI—Anticipate
ASM—Assembly
ASSY--Assembly
ALIO—Audio
AUTO—-Automatic
AUX—Auxiliary
BAT—Battery
BATT—Battery
BI--LEV—Bi-Level
BLK—Biack
BUT--Belt
BLU-Blue
BOT--Bottom
BRK—Brake
BRN--Brown
BU---Backup
BUZZ—Buzzer
CIR/BRK—CircuitBreaker
CIRC--Circuit
CLSTR--Cluster
CNTL---Control
COMP----Compartment
COMP—Compressor
CONN—Connector
PONV—Convenience
CTSY—Courtesy
CYL—-Cylinder
DK—Dark
DIAG—Diagnostic
DIM—Dimmer
DIR—Directional
DISC—Discrete
DIST—Distributor
DIV—Diverter
DM—Dome
DR—Door
ECM—ElectronicControlModule
Figure8--OpenCircuit

WIRINGDIAGRAMS9
DIAGNOSTICTOOLS
Figure15-MeterScales
OHMMETERSCALE:0 OhmsthroughInfinity
H= 5 Ohms
I= 36Ohms
J= 115Ohms
K= 350Ohms
AMMETERSCALE:0 Amperesthrough10Amperes
E= 1 Ampere
F= 1.8Amperes
G= 9 Amperes
VOLTMETERSCALE:0 Voltsthrough15Volts
A= 3 Volts
B= 7 Volts
C= 13Volts
50.PowerSource
51.CircuitBreaker
52.Switch(Closed)
53.Voltmeter
54.Load
40.PowerSource
41.CircuitBreaker
42.Switch(Open)
43.Ohmmeter
44.Load
30.PowerSource
31CircuitBreaker
32.Switch(Closed)
33Ammeter
34.Load
Figure12—Ammeter
UNPOWEREDTESTLIGHT(Figure12)
Thistoolconsistsofa 12voltlightwithleads.Theends
oftheleadsusuallyhavealligatorclamps,butvarious
kindsofprobes,terminalspades,andspecialconnectors
areusedalso.
Theunpoweredtestlightisusedonanopencircuit.
Oneleadofthetestlightisgroundedandtheotherleadis
movedaroundthecircuittofindtheopen.Dependingon
thephysicallayoutofthecircuit,sometimesitwillbe
easiertostartatthepowersupplyandothertimesitis
easiertostartattheCircuitloadorgroundcircuit.
POWEREDTESTLIGHT(Figure11)
Thislightisa pencilshapedunitwitha selfcontained
battery,a 1 5 voltlightbulb,a sharpprobeanda ground
leadfittedwithanalligatorclip.
Thistestlightisusedmainlyfortestingcomponents
thataredisconnectedfromthevehiclepowersupply.The
powertestlightisalsousefulfortestingsuspectedhigh
resistancepointsina circuitsuchasconnectorsand
groundcircuitsthatarecorrodedorloose.
JUMPER
Thejumperisusuallya longwirewithalligatorclamps.
Aversionofthejumperhasa fuseholderinitwitha 10
Ampfuse.Thiswillpreventdamagingthecircuitifthe
jumperisconnectedinthewrongway.
Thejumperisusedtolocalsopensina circuit.One
endofthejumperisattachedtoa powersourceandthen
theotherendisattachedtotheloadinthecircuit,i.e.;
light,motor.Iftheloadworks,try"jumping"tocircuit
pointsthatareprogressivelyclosertothepowersupply.
Whenthecircuitloadstopsworking,theopenhasbeen
located.
Thejumperisalsousedtotestcomponentsinthe
circuitsuchasconnectors,switches,andsuspectedhigh
resistancepoints.
Figure13--Ohmmeter
NOTICE: The followmg instruments: Ammeter,
Voltmeter, andOhmmeter, eachhave a
particular application for trouble shooting
electrical circuits.
When using a ammeter orvoltmeter,and the
value being testedisunknown always usethe
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 power circuit, or
asa substitute for a vohmeter orammeter as
damage to the instrument will result.
AMMETER(Figure12and15)
Disconnectthecircuitfromthepowersourcebefore
connectingtheammeter.Theammetermeasuresthe
amountofelectricalcurrent,amperes,movingthrougha
conductor.Theammetermustbeplacedinserieswiththe
circuitbeingtested.Besurethattheammeter'spositive
terminalisconnectedtothepositive(battery)sideofthe
circuitandisnegativeterminaltothenegative(ground)
sideofthecircuit.
OHMMETER(Figure13and15)
Theohmmeterisaninstrumentdesignedtoindicate
resistanceinohms,itisusedtotesttheconditionofa unit
disconnectedfromthecircuit.
OhmmeterCalibration
Whentheohmmeterprobesareconnectedtogether,a
circuitiscompletedcausingthemeterneedletodeflect
TheneedleshouldreadZEROohms,ifitdoesnot,rotate
theCALorADJknobtoZEROtheneedle.
Whentheprobesareheldapart,theneedlemovesto
themaximum(infinite)resistancesideofthescale.
Themeterisnowreadyforuse.Refertofigure14fora
typicalapplicationoftheohmmeter.
Figure14—Voltmeter
VOLTMETER(Figures14and15)
Thevoltmeter(properlyobserved)willgivethe
technicianmoreinformationthantheammeter,ohmmeter
andtestlightcombined,itsapplicationfortroubleshooting
hereistomeasuretheelectricalpressure(voltage)dropin
aresistancecircuit(figure14).
Iousea voltmeterfortroubleshootinganelectrical
problem,connectitinparallelwiththeexistingcircuit
(figure10).Ifthevoltmeterisconnectedinserieswiththe
circuitbeingtested,thenatureofthecircuitwouldbe
changedandthereadingwouldhavenoparticularvalue
oruse.Connectthemeterterminalsaccordingtopolarity
asshowninfigure14.
Thedashmountedvoltmeter(inthevehicle)should
alsobeobservedformonitoringproperoperationofthe
generatorbatterycrankingmotor,andcrankingcircuit.In
thisapplication,batteryvoltagedropcanbemonitored
whiletheengineiscranking;andaftertheengineis
running,generatoroutputvoltagecarsbemonitored.This
canbea valuablefirststeppriortodiagosingother
electricalproblems.
WIRINGHARNESSANDWIRES
Everywireisa specificsizewithcoloredorstriped
insulationthatisindicatedonthewiringdiagrams.
Insulationcolorshelptotracecircuitsandtomakeproper
connections.Abbreviationsandsymbolsusedfor
indicatingwireinsulationcolorsandpatternsareas
follows:
BIKBlackBLUBlue
BRNBrownPPLPurple
CHKCheckTRTracer
CRCrossYEL.Yellow
GRNGreen//Parallel
NATNatura!WHTWhite
SGLSingleSTRStripe
ORNOrangePNKPink
GRGrayDKDark
Somewiresaregroupedandtapedtogetheror
encasedina splitplasticcasing.Thisgroupingofwiresis
calleda harness.Forsomepurposes,itismorepractical
tousea singlewireprotectedbya braidedtubingcalleda
loom.
WIRINGDIAGRAMS10
B-06155
B-06087
B-06086

WIRINGDIAGRAMS11 WIRINGDIAGRAMS12
Withthelowcurrentandvoltagelevelsfoundinsome
circuits,itisimportantthatthebestpossiblebondatall
wiresplicesbemadebysolderingthesplices.
Usecarewhenprobingtheconnectionsorreplacing
terminalsinthem,itispossibletoshortbetweenopposite
terminals.Ifthishappenstothewrongterminalpart,itis
possiblethatdamagemaybedonetocertain
components.Alwaysusejumperwiresbetween
connectorsforcircuitchecking.Neverprobethroughthe
Weather-Packseals.
Whendiagnosingforpossibleopencircuits,itisoften
difficulttolocatethembysightbecauseoxidationor
terminalmisalignmentarehiddenbytheconnectors.
Merelywigglinga connectorona sensororinthewiring
harnessmaycorrecttheopencircuitcondition.This
shouldalwaysbeconsideredwhenanopencircuitis
indicatedwhiletroubleshooting.Intermittentproblems
mayalsobecausedbyoxidizedorlooseconnections.
METRl-PACKCONNECTORS
TheMetri-Packconnectorsusea pull-to-seattype
terminal,asshowninfigure19.Thespecialtoolrequired
toremovetheterminalisJ-35689-Aterminalremover.If
removalisattemptedwithanordinarypick,thereisa
goodchancethattheterminalwillbebentordeformed.
Refertofigure19.
[<>]RemoveorDisconnect(Figure19)
ToolRequired:
J-28742TerminalRemover
1.Primarylock(121)bylifting.
2.Connectorsections.
3.Secondarylock(125)byspreadingthesidesofthe
hasp,thusclearingthestaplesandrotatingthe
hasp(127).
4.Terminal(131)byusingJ-28742(128).
*Snipofftheoldterminalassembly.
5. 5 mm of the wire insulation (130).
[^] Clean
Terminalbarrel(124).
[><]InstallorConnect(Figure19)
1.Terminalinsulator(134)onthewire.Slidethe
insulatorbackonthewireabout8 cm(3inches).
2.Terminal(131)onthewire.
*Rollcrimp(132)andsoldertheterminal
3.Terminalinsulator(134)andtherollcrimp(133).
4.Terminalintotheconnector.
5.Secondarylock(125).
6.Connectorsectionsuntiltheprimarylock(121)
engages.
METRI-PACKCONNECTORREPLACEMENT
[<>]RemoveorDisconnect(Figure19)
ToolRequired
J-35689-ATerminalRemover
1.Primarylock(121)bylifting.
2.ConnectorBody(1ST).
3.Connectorseat(120)bypullingthesealbackonto
thewiresawayfromtheconnectorbody(137).Figure18—TwinLockConnectorTerminal
Figure17—ResettingtheLockTang
WEATHER-PACKCONNECTORS
SpecialconnectorsknownasWeather-Packconnectors
(figure19)requirea specialtoolJ-28742forservicing.
Thisspecialtoolisrequiredtoremovethepinandsleeve
terminals.Ifremovalisattemptedwithanordinarypick,
thereisa goodchancethattheterminalwillbebentor
deformed.Unlikestandardblade-typeterminals,these
terminalscannotbestraightenedoncetheyarebent.
Matesurethattheconnectorsarepropertyseatedand
allofthesealingringsinplacewhenconnectingthe
leads.Thehinge-typeflapprovidesa back-up,or
secondarylockingfeatureforterminals.Theyareusedto
improvetheconnectorreliabilitybyretainingtheterminals
ifthesmallterminallocktangsarenotpositioned
properly.
Molded-on-connectorsrequirecompletereplacementof
theconnection.Thismeanssplicinga newconnector
assemblyintotheharness.Environmentalconnections
cannotbereplacedwithstandardconnections.
InstructionsareprovidedwiththeWeather-Pack
connectorandterminalpackages.
Figure16—RemovingtheTerminalsfrom
theConnector
WIRINGCONNECTORTERMINAL
REPLACEMENT(TWINLOCKTYPE)
[<>]RemoveorDisconnect(Figure18)
ToolRequired:
J-22727TerminalRemover
1. Connector lock tangs.
2. Terminal lock tangs.
3. Terminal
[><] Install or Connect
1. Pry out the tangs
2. Terminal into the connector.
.
CIRCUITMAINTENANCE
ANDREPAIR
MAINTENANCEANDREPAIR
Allelectricalconnectionsmustbekeptcleanandtight.
Looseorcorrodedconnectionsmaycausea discharged
battery,difficultstarting,dimlights,andpossibledamage
tothegeneratorandregulator.Wiresmustboreplacedif
insulationbecomesburned,cracked,ordeteriorated.
Tosplicea wireorrepaironethatisfrayedorbroken
alwaysuserosinfluxsoldertobondthespliceand
insulatingtapetocoverallsplicesorbarewires.
Whenreplacingwire,itisimportantthatthecorrectsize
wirebeusedasshownonapplicablewiringdiagramsor
partsbook.Eachharnessorwiremustbeheldsecurelyin
placetopreventchafingordamagetotheinsulationdue
tovibration.
Neverreplacea wirewithoneofa.smallersizeor
replacea fusiblelinkwitha wereofa largersize.
WRINGCONNECTORTERMINAL
REPLACEMENT(BLADETYPE)
[<>]RemoveorDisconnect(Figure10)
1.Terminallocktang.
2.Terminal(61).
[><]InstallorConnect(Figure17)
I.Pryuponthetang(70).
2.Terminalintotheconnector.
ON-VEHICLESERVICE
Wiringharnessesarejoinedbyusinga multipleplug
andreceptacleconnectorblock,ora terminalpost
chassisjunctionblock.Intheinstrumentpanelarea
plasticinsulatedblade-typeconnectorsandscrew-type
terminalsareused.
Eachharnessorwiremustbeheldsecurelyinplaceby
clipsorotherholdingdevicestopreventchafingofthe
insulation.
WIRESIZE
Wiresizeina circuitisdeterminedbytheamountof
current,thelengthofthecircuitandthevoltagedrop
allowed.Wiresizeisspecifiedusingthemetricgage.The
metricgagedescribesthewiresizedirectlyincross
sectionareameasuredinsquaremillimeters.
WIRESIZE
CONVERSIONTABLE
METRICAWG
SIZESIZE
(mm)2
0.2224
0.3522
0.520
0.818
1.016
2.014
3.0 12
5.010
8.08
13.06
19.04
32.02
40.0 1
50.0 0
62.0 00

Figure19—Weather-PackandMetri-PackConnectors
Figure20TwistedWireRepair
4.Terminal(138)byinsertingJ-35689(139)intothe
connectorbody(137)todepressthelockingtang
(138),thenpushthewireandterminalthroughthe
connectorbody(figure20).
•Snipofftheoldterminalunlesstheterminalistobe
reused,reshapethelockingtang.
5.5mm(0.2-inch)ofthewireinsulation(130).
*Terminalcavityoftheconnectorbody.
[><]InstallorConnect(Figure19)
1.Terminal(136)onthewire.
•Crimpandsoldertheterminal.
2.Terminal(136)intotheconnectorcavitybypulling
thewireonthesealsideoftheconnectoruntilthe
lockingtang(138)isfullyseated.
3.Seal(120)bypressingthesealintotheconnector
body(137)untilitisfullyseated.
4.Connectoruntiltheprimarylock(121)engages.
WIRINGREPAIR
Thewirerepairisveryimportantforthecontinued
reliableoperationofthevehicle.Thisrepairmustbedone
asdescribedinthefollowingprocedures.
TwistedWires(Figure20)
[<>]RemoveorDisconnect
1.Jacket(30).
2.Twistedwires(91).
Figure21—Twisted/ShieldedWireRepair
3.Insulationfromthewire.
[><]InstallorConnect
1.Spliceclip(93).
•Crimp.
•Solder.
2.Electricaltapewrap(94)onwires.
3.Outerelectricaltapewrap(95).
TwistedWires/ShieldedCable(Figure21)
[<>]RemoveorDisconnect
1.Jacket(100).
2.Unwrapaluminum/mylartape(101).
3.Drainwire(102).
A.Leads.
5,Insulationontheleads.
[><]InstallorConnect
1.Spliceclips(103).
2.Crimpandsolderthespliceclips(104).
3.Electricaltape(105)onthesplices.
WIRINGDIAGRAMS13 WIRINGDIAGRAMS14
120.ConnectorSeal
121.PrimaryLock
122.SecondaryLockStaple
123.SecondaryLock
124.terminalBarrel
125.SecondaryLock
128.LockOpened
127.LockOpened
128.J-28742TerrninalRemover
129.Wire
130.5 mm(0.2inch)
131.Terminal
132.RollCrimp
133.RollCrimp
134.TerminalInsulator
136.Metri-PackSeries150FemaleTerminal
137.ConnectorBody
138.LockingTang
139.J-35689TerminalRemover
VIEWB
F-02349
100.Jacket
101.Aluminum/MylarTape
102.DrainWire
103.SpliceClip
104.CrimpandSolder
105.ElectricalTapeWrap
106.DrainWireSpliceClip,CrimpedAndSol-
dered.
107.OuterElectricalTapeWrap.
B-06231
90.Jacket
91.TwistedWires
92.SpliceClip
93.CrimpandSolder
94.ElectricalTapeWrap
95,.OuterElectricalTapeWrap.
B-06230

WIRINGDIAGRAMS15
4.Aluminum/mylartapebywrappingandtaping.
5.Drainwirewitha spliceclip(106).Crimpandsolder
thespliceclip.
6.Outerjacketelectricaltapewrap(107).
SPECIALTOOLS
1Weather-PackIITerminalRemover
2.ElectricalTerminalRemover
3.WindshieldAntennaTester

1989R/VTRUCK
PAGEDESCRIPTION
2FUSEBLOCKDETAIL
3-4POWERDISTRIBUTION(GASOLINE)
5POWERDISTRIBUTION(DIESEL)
6AUXILIARYBATTERY(TP2)
7-8HEADLAMPS& PARKINGLAMPS
9-10MARKERLAMPS
11ROOFMARKERLAMPS
12-14HAZARDLAMPS
15HORN
16-17DIRECTIONALLAMPS
18START(8CYL.)I..25,(8CYL,)LE8,LT9
19START(8CYL.)LO5,L19
20START(DIESEL)LL4,LH5
21IGNITION(6CYL.)L25
22-23IGNITION(8CYL.)LE8,LT9
24IGNITION(8CYL.)LO5,LT9
25THROTTLEBODYINJECTION
26HOTFUELHANDLING
27-28GLOWPLUGS(DIESEL)
29-30ENGINECONTROLS(DIESEL)
31FUELCONTROL& IDLEAIRCONTROL(8CYL„)LO5,L19
32AUXILIARYCOOLANTFAN
33-34AUXILIARYFUELTANK(NL2)/FUELTANKSELECTORSWITCH
35-37EMISSIONCONTROLS
38-39ELECTRONICCONTROLMODULE(ECM)-INPUTS(8CYL.)LO5,L19
40-41ELECTRONICCONTROLMODULE(ECM)-OUTPUTS(8CYL.)LO5,L19
42ECMCHART(8CYL.)
PAGE DESCRIPTION
43ECMCHART(DIESEL)
44-45ELECTRONICCONTROLMODULE(ECM)-OUTPUTS(DIESEL)
46ELECTRONICCONTROLMODULE(ECM)-INPUTS(DIESEL)
47TRANSMISSIONCONVERTERCLUTCHDETENTSOLENOID
48AUTOMATICTRANSMISSIONKICKDOWNSOLENOID(M40)
49AIRCONDITIONING(C60)
50REARAIRCONDITIONING(C69)
51HEATER
52AUXILIARYHEATER(C36)
53INSTRUMENTPANELLAMPS
54-55INSTRUMENTPANELGAGES
56-57INDICATORLAMPS
58SEATBELTWARNINGBUZZER
59BRAKEWARNINGSYSTEM
60FOUR-WHEELDRIVEINDICATORLAMP
61CRUISECONTROL(K34)
62DOMELAMPS
63CARGOLAMP(UF2)
64RADIOEQUIPMENT(UM6.UP8)
65RADIOEQUIPMENT(U63)
66-67POWERWINDOWS(A31)
68POWERREARWINDOW(A33)
69REARDEFOGGER(C49)
70-71POWERDOORLOCKS
72WIPER/WASHER
73PULSEWIPER/WASHER(CD4)
74-76BACKUPLAMPS
77-80TAILLAMPS
81-84LICENSELAMPS
85CAMPER& TRAILERWIRING
SECTIONA - PAGE1

0
6294015
R.H.
SIDE MARKER
LAMP
HEADLAMP
SWITCH
TO l/P
► CLUSTER
CONN.
R.H. PARK
LAMP
E
J24 19 D
1
18 9
6294015
0L.H.
SIDE MARKER
LAMP
FRONT REAR
FUSE BLOCK
9 .8 BRN
R.H.
SIDE MARKER
LAMP
SPLICE 9
SHEET
METAL
GROUND
R.H. TAIL. STOP &
DIRECTIONAL
LAMP
BACKUP
LAMP
SPLICE 150
^ LICENSE
LAMP
SPLICE 150
9 .8 BLK-
SHEET
METAL
GROUND
150 .8 BLK
SPLICE 9
R.H.
SIDE MARKER
LAMP
BACKUP
LAMP
L.H. TAIL. STOP &
DIRECTIONAL
LAMP
MARKER LAMPS (UTILITY VEHICLE)
SECTION A - PAGE 9

0
6294015
R.H.
SIDE MARKER
LAMP
HEADLAMP
SWITCH
R.H. PARK LAMP
$
O
O
U 9 1 2
i b 9 419 50 :
J L 0
o l
0 >
1
1 0
5 z
19 97 :
J>| 91 92
T7 C
1202184
T/L CTSY
20 AMP
6294015
MARKER LAMPS
FLEETSIDE (E6 )
WIDESIDE (R05)
SECTION A - PAGE 10
0L.H.
SIDE MARKER
LAMP
E3 S) GS a B e OD
S3 S) ff S O IB (D
83 ff 9 a IB O QD
Lr—u i-r-xj
[g ][g ]
FRONT FUSE BLOCK REAR
WIDESIDE PICK-UP
(R05) ONLY
0
R.H. FRONT /^ "T \ R.H
CLEARANCE U M i* CLE /
LAMP U— U i i
. REAR
CLEARANCE
LAMP
6294015 6294015
L
L
R.H.
SIDE MARKER
LAMP
'lh © S § - 150 .8 BLK ■
1
SHEET n
METAL L.
GROUND SPLICE 1!
R.H. TAIL. STOP &
DIRECTIONAL
LAMP
BACKUP
LAMP
1201 LICENSE
LAMP(S)
6294015
0
i i h g > a -
SHEET
METAL
GROUND
L.H. FRONT
CLEARANCE
LAMP
L.H. REAR
CLEARANCE
LAMP
L.H. TAIL. STOP &
DIRECTIONAL
LAMP
WIDESIDE PICK UP
(R05 ONLY)
6294015
0L.H.
SIDE MARKER
LAMP