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GMC SYCLONE 1992 Service Manual Supplement

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1992

SERVICE MANUAL

SUPPLEMENT

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Summary of Contents for GMC SYCLONE 1992

Page 1 1992 SERVICE MANUAL SUPPLEMENT...
Page 3 CAUTION property damage, the To reduce the chance of personal injury and/or following instructions must be carefully observed: Proper service and repair am important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
Page 4 Special service tools that are shown in this service manual that have tool product numbers beginning with “J” or “ST” are available for worldwide distribution from: Kent-Moore SPX Corporation 29784 Little Mack Roseville, MI 48066-2298 1-800-345-2233 Mon.-Fri. 8:00 p.m. EST Telex: 244040 KMTR VR FAX: 313-578-7375 General Motors dealers can purchase TECH 1 scan tools and accessories through Kent-Moore at the above...
Page 5 No part of this publication may be reproduced, stored in any retrieval system, or transmitted, in any form or 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 Corp. This includes all text, illustrations, tables, and charts.
Page 6 TABLE OF CONTENTS The table of contents on this page indicates the sections covered in this manual. At the beginning of each individual section is a table of contents which gives the page number on which each major subject begins. SECTlON SUBJECT CONTENTS...
Page 7 Pontiacs, Oldsmobiles, Buicks, Cadillacs, That’s why Mr. Goodwrench wants to have a GMC and Chevy Trucks. good stock of genuine GM Parts available. Everything from exclusive GM Goodwrench replacement engines and transmissions to GM...
Page 8 X-9276 For Adistra Use Only Order Number Date Filled Other GMC Truck Service Publications For Your Syclone, Typhoon or Sonoma GT: Price Each Form Description Form No. (U.S. Only) Qty. Total X-9237 $36.00 Light Duty Truck Unit Repair Manual X-9244 Electrical Diagrams and Diagnosis Manual $31.00...
Page 9 0A-1 SECTlON 0A GENERAL INFORMATION CONTENTS SUBJECT PAGE Regular Production Options (RPO’s) ............. . 0A-1 REGULAR PRODUCTION OPTIONS (RPO’S) The following RPOs are standard equipment on the Syclone, Typhoon and Sonoma GT models as indicated.
Page 11 0B-1 SECTION 0B MAINTENANCE AND LUBRICATION SYCLONE AND TYPHOON CONTENTS SUBJECT PAGE Maintenance Schedule ............... . . 0B-1 Section A-Scheduled Maintenance Services .
Page 12 0B-2 MAINTENANCE AND LUBRlCATION...
Page 13 MAINTENANCE AND LUBRICATION 0B-3 an accident should be inspected, and all needed repairs ELECTRONIC VACUUM REGULATOR VALVE (EVRV) INSPECTION* - Inspect filter for excessive should be done before operating your vehicle. Be sure to use the proper fluids and lubricants as shown in the Own- contamination or plugging.
Page 14 0B-4 MAINTENANCE AND LUBRlCATlON Light operation check - Check operation of license plate Drive axle service - Check rear/front axle fluid level and light, sidemarker light, headlights including high beams, add as needed. Check constant velocity joints and axle fog lights, parking lights, taillights, brake lights, turn sig- seals for leaking.
Page 15 MAINTENANCE AND LUBRICATION 0B-5 Lap and shoulder belts condition and operation - Accelerator control system - lubricate all pivot points Inspect belt system, including: webbing, buckles, latch with engine oil, except the throttle shaft. Do not oil any plates, retractors, guide loops and anchors. Have a belt accelerator or cruise control cables.
Page 16 0B-6 MAINTENANCE AND LUBRICATION SERVICE REPLACEMENT PART AND FlLTER RECOMMENDATIONS Charge Engine Spark Cooler Cleaner Valves (VIN) Plugs 4.3L (Z) A 1163C CR42TS 15637803** 8995909** V1851 **GM Part Number. WHEEL NUT TORQUE DESCRIPTION TORQUE All-Wheel Drive 100 ft. Ibs. (140 N•m) V1483 FUSES AND CIRCUIT BREAKERS Do not use fuses of higher amperage than those recom-...
Page 17 1A-1 SECTION 1A HEATING AND VENTILATION SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 18 1A-2 HEATING AND VENTILATION 19. Core Inlet Tube 20. Core Outlet Tube 32. Inlet Heater Hose 33. Outlet Heater Tube 33A. Hose 33B. Molded Hose 34. Screw V1740 Figure 1–Engine Heater Hose Assembly...
Page 19 HEATING AND VENTlLATlON 1A-3 SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS N•m In. Lbs. Outlet Hose Clamp ............Inlet Hose Clamp .
Page 21 1B-1 SECTION 1B AIR CONDITIONING SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener/s not available, a fastener of equal size and strength (or stronger) may be used.
Page 22 1B-2 AIR CONDITIONING 1. Hose Manifold 2. Compressor 3. Electrical Connector 4. Washer 5. Bolt 23. O-Ring V1491 Figure 1 – Compressor Mounting 4. Turbo water return pipe clip (22) onto upper compres- should be pressed into place with a tool that will sor mounting bolt (6).
Page 23 AIR CONDlTlONlNG 1B-3 2. Compressor 6. Upper Compressor Mounting Bolt 7. Turbo Water Return Pipe 8. Turbocharger 9. Lower Compressor Mounting Bolt 10. Nut 11. Mounting Bracket 18. Nut 19. Compressor Bracket 20. Bolt 21. Nut 22. Turbo Water Return Pipe Clip V1760 Figure 2 - Compressor Replacement...
Page 24 1B-4 AIR CONDITIONING EVAPORATOR TUBE Install or Connect (Figure 3) ASSEMBLY REPLACEMENT NOTICE: See “Notice” on page 1B-1 of this sec- tion. The procedure for removing the evaporator tube is the 1. Bolts (13). same as in the 1992 Service Manual Sonoma and Jimmy Models with the exception of first removing the battery tray.
Page 25 AIR CONDlTlONlNG 1B-5 SPEClFlCATlONS FASTENER TORQUE SPECIFICATIONS Ft. Lbs. In. Lbs. Compressor Mounting Nut ......... . Hose Manifold Bolt .
Page 27 2A-1 SECTlON 2A FRAME AND BUMPERS NOTICE: When fasteners are removed, a/ways reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 28 2A-2 FRAME AND BUMPERS Bracket Bolt Brace Bolt Bolt Washer 14. Fascia Washer 15. Front Support Electrical 16. Rivet Connector 20. Washer 26. Bolt Turn Signal/Parking Lamp 24. Brace 27. Bracket 31. Washer 25. Bolt 30. Washer 34. Washer Brace V1861 Figure 1 - Front Bumper...
Page 29 FRAME AND BUMPERS 2A-3 22. Fascia A. Frame B. Slot (Sonoma GT Only) 23. Support 28. Bracket 16. Rivet 17. Nut 29. Bolt 32. Washer 18. Washer 33. Washer 19. Bolt 21. Washer V1756 Figure 2-Rear Bumper REAR FASCIA REPLACEMENT Install or Connect (Figure 2) Remove or Disconnect (Figure 2) 1.
Page 31 2B-1 SECTION 2B SHEET METAL NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 32 2B-2 SHEET METAL A. Syclone 22. Bracket B. Typhoon 23. Rivet 1. Clip 24. Rivet 2. Rivet 28. Rocker Molding 21. Rocker Molding 31. Rivet V1752 Figure 1 - Rocker Molding and Brackets (Syclone and Typhoon)
Page 33 SHEET METAL 2B-3 GENERAL INFORMATION (SEC. 0A) in the 1992 Tighten Service Manual Sonoma and Jimmy Models. • Bolts (20) to 6.5 N•m (58 in. Ibs.). • Loosen bolt (36) on clamp (35) (5 places). • Lower vehicle. • Rocker molding (32) from vehicle. Disassemble (Figure 2) SONOMA GT •...
Page 34 2B-4 SHEET METAL 32. Rocker Molding 34. Bracket 35. Clamp 36. Bolt 37. Washer 38. Rocker Panel V1738 Figure 2 - Rocker Panel Molding (Sonoma GT)
Page 35 SHEET METAL 2B-5 A. Syclone and Typhoon B. Sonoma GT 13. Front Wheelhouse Molding 14. Bolt 15. Bolt 16. Brace 17. Bolt 18. Nut 19. Tape 20. Bolt 39. Front Fender Molding V1739 Figure 3 - Front Wheelhouse/Fender Moldings...
Page 36 2B-6 SHEET METAL A. Syclone Only 1. Clip 2. Rivet 3. Rear Wheel Opening Molding 10. Rear Box Molding 4. Screw 11. Bolt 5. Nut 12. Bracket 6. Bolt 24. Rivet 7. Rivet 27. Rivet 8. Bolt 29. Side Panel 9.
Page 37 SHEET METAL 2B-7 SONOMA GT Tighten Rear Box Molding • Bolts (6) to 1.4 N•m (12 in. Ibs.). 3. Screws (4) to rear wheel opening molding (3). Remove or Disconnect (Figure 5) Tighten • Raise and suitably support vehicle as described in GENERAL INFORMATION (SEC.
Page 38 2B-8 SHEET METAL 19. Tape 41. Bolt 36. Bolt 27. Rivet 42. Rear Box Molding 37. Washer 30. Bolt 43. Bolt 38. Rocker Panel 34. Bracket 44. Bracket 40. Front Box Molding 35. Clamp V1737 Figure 5 - Front and Rear Box Moldings (Sonoma GT)
Page 39 SHEET METAL 2B-9 SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS N•m In. Lbs. Front Wheelhouse Molding Bolt ..........Brace-to-Fender Bolt .
Page 41 3A-1 SECTION 3A FRONT END ALIGNMENT SYCLONE AND TYPHOON CONTENTS PAGE SUBJECT On-Vehicle Service ................3A-1 Trim Height Specifications .
Page 42 3A-2 FRONT END ALIGNMENT A. One revolution of bolt into nut increases front “Z” height by 6.0 mm (0.2”). B. 1 mm (0.04”) clearance must be provided D. “D” Height Average. “D” Heights to be between adjuster arm and nut after adjust- Trimmed at 100.2 ±...
Page 43 3B1-1 SECTION 3B1 POWER STEERING SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. ifs fastener needs to be rep/aced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 44 3B1-2 POWER STEERING 1. Bracket 2. Rear Bracket 3. Pump 4. Bolt 5. Nut 6. Pressure Hose Assembly 7. Return Hose Assembly 19. Bolt V1744 Figure 1 - Replacing Power Steering Pump Bolt Pot Joint Coupling Steering Shaft Intermediate Shaft Assembly Shield Bolt Flexible Coupling...
Page 45 POWER STEERING 3B1-3 STEERING GEAR REPLACEMENT Tighten • Nuts (5) to 45 N•m (33 ft. Ibs.). Remove or Disconnect (Figures 1 and 2) Pump (3) and rear bracket (2) to vehicle. • Place a drain pan below steering gear. Mounting bolts (4) to bracket (1). •...
Page 46 3B1-4 POWER STEERING • Refill charge air cooler radiator. Refer to TURBO- Tighten CHARGER (SEC. 6J) in this manual. • Bolt (14) to 36 N•m (27 ft. Ibs.). • Bleed power steering system as described in POWER STEERING (SEC. 3B1) in the 1992 Service 8.
Page 47 3D1-1 SECTION 3D1 ELECTRONIC LEVEL CONTROL TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 48 3D1-2 ELECTRONIC LEVEL CONTROL EXHAUST SOLENOID located at the left rear of the vehicle under body. The com- The exhaust solenoid is located in the compressor head pressor assembly is also coated with a weather sealant and assembly and provides two functions (figure 1): covered with a shield for protection (figure 1).
Page 49 ELECTRONIC LEVEL CONTROL 3D1-3 reliability of the air adjustable shocks/struts, a minimum (1 1/4 inch ± 1 inch), the sensor opens the compressor pressure of 48-97 kPa (7-14 psi) must be maintained in the relay circuit and shuts off the compressor. system at all times.
Page 50 3D1-4 ELECTRONIC LEVEL CONTROL connector on pump side and ground terminal “B” Tool Required (white wire) at same connector. J 22124-A Pressure Gage 1. Disconnect wiring from compressor motor and 4. When no more air can be exhausted, the gage should exhaust solenoid terminals.
Page 51 ELECTRONIC LEVEL CONTROL 3D1-5 16. Dryer “O” Ring Casting Bore 17. Dryer Cover 18. Cover Bolts 19. Head Casting Air Intake and Exhaust Opening 20. Solenoid Valve Terminal Housing V1795 21. Cover Gasket Figure 6 - Compressor Leak Test 5. Move metal sensor arm up. There should be a delay found in one of the connections, follow the procedure (8-15 seconds) before compressor turns “ON”...
Page 52 3D1-6 ELECTRONIC LEVEL CONTROL ON-VEHICLE SERVICE HEIGHT SENSOR ADJUSTMENT 6. Three compressor mounting bracket bolts (49) and remove bracket (52). The link should be properly attached to the sensor arm • If replacing compressor assembly, remove air dryer and rear axle when making the adjustment (figure 7). (34) and dryer bracket (33).
Page 53 ELECTRONlC LEVEL CONTROL 3D1-7 4. Compressor 23. Washer 24. Nut 25. Nut 27. Bolt 49. Bolt 50. Bolt 51. Shield 52. Bracket 53. Bolt 54. Electrical Connector V1797 55. Electrical Connector Figure 9 - Compressor Mounting COMPRESSOR HEAD ASSEMBLY Remove or Disconnect (Figure 11) 1.
Page 54 3D1-8 ELECTRONIC LEVEL CONTROL AIR DRYER 3. Head assembly (29). 4. Dryer assembly as explained later in this section. Remove or Disconnect (Figure 10) 1. Bolts connecting dryer bracket to compressor mount- ing. 2. Bolts connecting air dryer (34) to motor. •...
Page 55 ELECTRONlC LEVEL CONTROL 3D1-9 15. ELC Height Sensor 41. Sensor Bracket 42. Nut 43. Sensor Link Bracket 44. Sensor Link 45. Frame 46. Bolt 47. Bolt V1804 Figure 12 - Height Sensor Mounting...
Page 56 3D1-10 ELECTRONIC LEVEL CONTROL Install or Connect (Figure 12) 1. Height sensor bracket (41) to frame and install bolts (47). Tighten • Bolts (47) to 17 N•m (13 ft. Ibs.). 2. ELC height sensor (15) to sensor bracket (41) and install nuts (42).
Page 57 ELECTRONIC LEVEL CONTROL 3D1-11 SPECIAL TOOLS 1. J 34825 ELC Tester 2. J 22124-A Pressure Gage V1808...
Page 59 3E-1 SECTION 3E TIRES AND WHEELS SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 60 3E-2 TIRES AND WHEELS SPECIFICATIONS WHEEL AND TIRE SPEClFlCATlONS Bolt Circle Bolt Wheel Rating Diameter Size Width Tire Size Wheel Bolt (in.) (in.) Type (in.) kg/lbs kPa/psi Size Holes 0.437 P245/50R 16 96V 16 x 8.00 4.75 1 - piece 659/1453 240/35 V1856...
Page 61 4A-1 SECTION 4A PROPELLER SHAFT SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 62 4A-2 PROPELLER SHAFT 1. Front Axle 2. Front Propeller Shaft 3. Transfer Case 4. Bolt 5. Bolt V1749 Figure 1 - Front Propeller Shaft 2. Bolts (5) from flange at front axle (1). 1. Front propeller shaft (2). 3. Front propeller shaft (2). •...
Page 63 PROPELLER SHAFT 4A-3 A . Fitting B. Rear Flange 6. Double Cardan Joint V3219 Figure 2 - Lubricating Double Cardan Joint SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS N•m Ft. Lbs. Flange-to-Transfer Case Bolt ..........Flange-to-Front Axle Bolt.
Page 65 4C-1 SECTION 4C FRONT DRIVING AXLE SYCLONE AND TYPHOON CAUTION: Do not allow the vehicle’s weight to load the front wheels or attempt to operate the vehicle when the drive axle(s) or hub nut(s) are removed. To do so may cause the front wheel bearing inner races to separate, resulting In damage to front brake and suspension components and/or personal injury.
Page 66 4C-2 FRONT DRIVING AXLE A. Forward 80. Bolt 81. Drive Axle (Right Side) 82. Bolt 83. Drive Axle (Left Side) 150. Washer 151. Nut 152. Retainer F8613 153. Cotter Pin Figure 1 - Drive Axles and Components Inspect 5. Lower shock absorber nut and bolt as described in FRONT SUSPENSION (SEC.
Page 67 FRONT DRIVING AXLE 4C-3 • Insert a drift through the opening in the top of Inspect the brake caliper into the vanes of the brake rotor. This will keep the axle from turning. • Axle lubricant level, and add lubricant if necessary, as described in MAINTENANCE AND LUBRICATION Tighten (SEC.
Page 68 4C-4 FRONT DRIVING AXLE V1548 Figure 3 - Carrier Assembly and Components...
Page 69 FRONT DRIVING AXLE 4C-5 31. Insert 46. Nut 1. Shaft 32. Sleeve 47. Plug 2. Deflector 33. Side Bearing 48. Upper Bushing 3. Seal 4. Bearing 34. Bolt 49. Vent Hose 5. Tube 35. Differential Case 50. Vent 36. Bolt 51.
Page 70 4C-6 FRONT DRIVING AXLE 4. Axle vent hose (49). 5. Drive axle-to-output shaft bolts (80 and 62). 5. Tube 6. Tube-to-carrier bolts (6). 7. Drive axle (81) from output shaft (1) and support out of the way. 8. Drive axle (83) from output shaft (59) and support out of the way.
Page 71 FRONT DRIVING AXLE 4C-7 A. Front Axle B. Transfer Case 100. Front Propeller Shaft 101. Bolt 102. Bolt V1748 Figure 8 - Front Propeller Shaft Install or Connect (Figures 1 through 5, 8 and 9) • Remove the safety stands and lower the vehi- cle.
Page 72 4C-8 FRONT DRIVING AXLE Putting the transmission in PARK and applying the parking brake may not prevent the vehicle from moving. 1. Bolts (101) from propeller shaft flange to front axle. 2. Front propeller shaft (100). • Support the front propeller shaft (100) out of the way.
Page 73 FRONT DRIVING AXLE 4C-9 reference marked prior to disassembly. These com- ponents include the propshafts, drive axles, pinion flange, output shafts, etc. All components must be reassembled in the same relationship to each other as they were removed to maintain the factory bal- ance.
Page 74 4C-10 FRONT DRlVlNG AXLE 6. Bolts (101). • Align the marks made during removal. Compo- nents must be reassembled in the same relative position to maintain proper balance. Tighten • Bolts (101) to 70 N•m (52 ft. Ibs.). F1790 Figure 13 - Installing the Pinion Oil Seal SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS N•m...
Page 75 FRONT DRIVING AXLE 4C-11 SPECIAL TOOLS J 33693 J 29369-2 J 6614-01 J 33791 J 33782 J 33644 J 23907 4. Output Shaft Seal Installer 1. Axle Tube Bearing Remover 5. Flange Holder 2. Carrier Bushing Remover and 6. Pinion Oil Seal Installer Installer Set 7.
Page 77 5A-1 SECTION 5A HYDRAULIC BRAKES SYCLONE AND TYPHOON CAUTION: When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by cleaning wheel brake parts with a dry brush or with compressed air. (A water dampened cloth should be used.) Many wheel brake parts contain asbestos fibers which can become airborne if dust is created during servicing.
Page 78 5A-2 HYDRAULIC BRAKES 1. Combination valve (3) to booster (7). 2. Master cylinder mounting nuts (1). Tighten • Master cylinder mounting nuts(l) to 17 N•m (13 ft. Ibs.). 3. Warning switch connector (6) to combination valve (3). • Remove plugs from brake pipes (2). 4.
Page 79 HYDRAULIC BRAKES 5A-3 SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS N•m Ft. Lbs. Master Cylinder Mounting Nut..........Brake Pipe .
Page 81 5E1-1 SECTION 5E1 FOUR WHEEL ANTILOCK BRAKE SYSTEM SYCLONE AND TYPHOON CONTENTS PAGE SUBJECT Diagnostic Circuit Check ..............5E1-1 On-Vehicle Service .
Page 83 6A3-1 SECTION 6A3 4.3 LITER V6 SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 84 6A3-2 4.3 LITER V6 A. Left Side 3. Rocker Cover B. Right Side 4. Multi-Use Bracket 1. Rocker Cover 5. Coolant Inlet Pipe 2. Coolant Return Pipe Figure 1 - Valve Rocker Covers 6. Power brake hose (9). Install or Connect (Figures 1 and 2) 7.
Page 85 4.3 LITER V6 6A3-3 UPPER AND LOWER INTAKE MANIFOLDS Remove or Disconnect (Flgures 1 through 6) • Loosen wing bolt at air cleaner and move air cleaner and duct aside. • Drain engine radiator. • Drain charge air cooler radiator. 1.
Page 86 6A3-4 4.3 LITER V6 • Apply a 5 mm (3/16 inch) bead of RTV sealer, GM part Fuel injector electrical connectors. number 1052366 or equivalent, to the front and rear Fuel pipes (23 and 27) at fuel rail (21). of the cylinder block. Extend the bead 13 mm (1/2 inch) Fuel rail (21) and injectors (29) by removing bolts (28).
Page 87 4.3 LITER V6 6A3-5 Fuel Pipe (Inlet) Clip Bracket Clip V1509 Fuel Pipe (Return) Figure 5 - Fuel Lines 21. Fuel Rail 28. Bolt 29. Injector V1510 Figure 6 - Fuel Rail...
Page 88 6A3-6 4.3 LITER V6 EXHAUST MANlFOLDS Tighten • Exhaust crossover pipe nuts to 16 N•m (12 ft. LEFT EXHAUST MANIFOLD Ibs.). 6. Intermediate shaft. Remove or Disconnect (Figure 7) 7. Oil filter lines bracket to power steering pump. Negative (-) battery cable. 8.
Page 89 4.3 LITER V6 6A3-7 A. Left Side 31. Lock Tab B. Right Side 32. Bolt 30. Exhaust Manifold (Left) 33. Bolt 34. Stud 35. Washer 36. Heat Shield 37. Exhaust Manifold (Right) 38. Heat Shield V1511 Figure 7 - Exhaust Manifolds 11.
Page 90 6A3-8 4.3 LITER V6 Upper and lower radiator hoses. 13. Catalytic converter support bolts. Engine oil cooler lines from radiator. 14. Muffler(s) and tailpipe to catalytic converter. Heater and overflow hoses from radiator. Tighten Radiator. • Support bolts to 34 N•m (25 ft. Ibs.). Oil pipes at filter adapter.
Page 91 4.3 LITER V6 6A3-9 Tighten • Lower engine into engine compartment. Electrical connections to oil pressure and knock sen- • Crossmember nuts to 35 N•m (26 ft. Ibs.). sors and ground strap. Rear propeller shaft and bolts and nuts. Engine onto engine mounts. Tighten •...
Page 92 6A3-10 4.3 LITER V6 Tighten Tighten • Fan and pulley nuts to 24 N•m (18 ft. Ibs.). • Oil pipes bolt to 35 N•m (26 ft. Ibs.). 48. Upper fan shroud. 40. Radiator. 49. Turbocharger air inlet elbow. 41. Heater and overflow hoses to radiator. 50.
Page 93 4.3 LITER V6 6A3-11 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement 4.3L (262 Cu. In.) Bore 4.00 Stroke 3.48 Compression Ratio 8.35:1 Firing Order 1 - 6 - 5 - 4 - 3 - 2 Oil Pressure (Minimum) 6 psi @ 1000 RPM;...
Page 94 6A3-12 4.3 LITER V6 ENGINE SPECIFICATIONS (CONT) All specifications are in INCHES unless otherwise noted. DISPLACEMENT: 4.3L CRANKSHAFT: 2.4484-2.4493 #2, #3 2.4481-2.4490 Diameter 2.4479-2.4488 Production 0.0002 (Maximum) Main Taper Service Limit 0.001 (Maximum) Journal Out Of Production 0.0002 (Maximum) Round Service Limit 0.001 (Maximum) 0.0008-0.0020...
Page 95 4.3 LlTER V6 6A3-13 FASTENER TORQUE SPECIFICATIONS Ft. Lbs. In. Lbs. Valve Rocker Cover Bolt ..........Turbocharger Oil Feed Hose Fitting.
Page 97 6B2-1 SECTION 6B2 RADIATOR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 98 6B2-2 RADIATOR 1. Heater Hose 2. Heater Pipe 3. Clamp V1517 Figure 1 - Heater Hose 3. Clamp 4. Hose 5. Radiator 6. Hose V1518 Figure 2 - Radiator Hoses...
Page 99 RADIATOR 6B2-3 SPECIFICATIONS FITTING TORQUE SPECIFICATIONS N•m Ft. Lbs. Engine Oil Cooler Pipe Fitting ..........Transmission Fluid Cooler Pipe Fitting .
Page 101 6C-1 SECTION 6C FUEL SYSTEM ENGINE FUEL SYCLONE AND TYPHOON ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE REGULATIONS FOR THE CONTROL OF AIR POLLU- TION FROM NEW MOTOR VEHICLES. THIS CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO FACTORY STANDARDS.
Page 102 6C-2 FUEL SYSTEM Fuel Tank Purging Procedure ..............6C-9 Fuel Level Meter/Fuel Pump Assembly Replacement .
Page 103 FUEL SYSTEM 6C-3 FUEL TANK not receive reference pulses from the distributor/crank- shaft sensor after this time, the ECM opens the fuel pump relay ground circuit. The relay will once again activate the A baffle is installed in the tank to serve as a slosh baffle. fuel pump when the ECM receives distributor/crankshaft sensor reference pulses and grounds the fuel pump relay FUEL TANK FILLER PIPE (Figure 1)
Page 104 6C-4 FUEL SYSTEM If an element should ever become plugged, the engine amount of alcohol in fuel. The complaints may be due to will stop. An engine stoppage caused by a plugged filter fuel system corrosion and subsequent fuel filter plugging, element may be preceded by a hesitation or sluggish oper- deterioration of rubber components such as the O-ring ation.
Page 105 FUEL SYSTEM 6C-5 FUEL SYSTEM PRESSURE TEST 5. Drain any fuel remaining in gage into an approved container. The fuel system pressure test will be found in: DRI- FUEL SYSTEM INSPECTION VEABILITY AND EMISSIONS FUEL INJECTION (PORT) (SEC. 6E3) in this manual (Chart A7). It is necessary to relieve the fuel system pressure prior to Always check and replace any “O”...
Page 106 6C-6 FUEL SYSTEM DRAINING FUEL TANK 1. Drain tank. NOTICE: If vehicle is to be stored for any appre- CAUTION: To help avoid personal injury when a ciable length of time, the fuel should be drained vehicle is on a hoist, provide additional support from the complete system, including injector for the vehicle at the opposite end from which nozzle(s), fuel pump, all fuel pipes and the fuel...
Page 107 FUEL SYSTEM 6C-7 7. Nut - Tighten to 7 N•m (5 Ft. Lbs.) 1. Fuel Tank 2. Bolt - Tighten to 18 N•m (13 Ft. Lbs.) 8. Bolt - 17 N•m (13 Ft. Lbs.) 3. Strap 9. Bolt - 25 N•m (18 Ft. Lbs.) 4.
Page 108 6C-8 FUEL SYSTEM 1. Fuel Tank 2. Fuel Tank Meter Assembly 1. Fuel Tank Meter Assembly 3. Bolt - Tighten to 2 N•m (18 In. Lbs.) 2. Hose 4. Ground Wire 3. Pipe Clip 5. Washer 4. Frame 6. Frame 5.
Page 109 FUEL SYSTEM 6C-9 FUEL TANK PURGING CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support PROCEDURE for the vehicle at the opposite end from which components are being removed. This will reduce Relieve fuel system pressure - see “Fuel System the possibility of the vehicle falling off of the Pressure Relief.”...
Page 110 6C-10 FUEL SYSTEM • Anytime that the fuel or return pipes are discon- FUEL LEVEL METER REPLACEMENT nected, inspect the “O” rings for cut or other type of damage and replace as necessary (see “Fuel Line Remove or Disconnect (Figure 2) “O”...
Page 111 FUEL SYSTEM 6C-11 1. Fuel Pipe - Return 2. Nut - Tighten to 28 N•m (21 Ft. Lbs.) 3. Fuel Regulator 4. Nut 5. Bolt - Tighten to 35 N•m (26 Ft. Lbs.) 6. Bracket 7. Bolt - Tighten to 7 N•m (62 In. Lbs.) 8.
Page 112 6C-12 FUEL SYSTEM NOTICE: The TPS and IAC valve should NOT come in contact with solvent or cleaner, as they may be damaged. THROTTLE BODY Remove or Disconnect (Figure 11) 1. Negative battery terminal. • Loosen charge air cooler (CAC) mounting bolts and reposition CAC to gain access to throttle body.
Page 113 FUEL SYSTEM 6C-13 Install or Connect (Figure 11) 1. Throttle body assembly (2) with new flange gasket (1). NOTICE: See “Notice” on page 6C-1 of this section. 2. Throttle body attaching bolts (3). Tighten • Throttle body attaching bolts (3) to 24 N•m (18 ft. Ibs.).
Page 114 6C-14 FUEL SYSTEM GASKET - FLANGE SCREW ASSEMBLY - CLEAN AIR COVER ATTACHING THROTTLE BODY ASSEMBLY GASKET - CLEAN AIR COVER PLUG-IDLE STOP SCREW IACV/COOLANT COVER ASSEMBLY SCREW ASSEMBLY - IDLE STOP SCREW ASSEMBLY - IACV COVER ASSEMBLY TO THROTTLE BODY SPRING - IDLE STOP SCREW ASSEMBLY GASKET - IACV/COOLANT COVER TO THROTTLE BODY SENSOR - THROTTLE POSITION (TPS)
Page 115 FUEL SYSTEM 6C-15 Measure (If Installing a New IAC Valve) (Figure 14) • Distance between tip of IAC valve pintle and mount- ing surface. – If greater than 28 mm, use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve.
Page 116 6C-16 FUEL SYSTEM 2. Clean air cover (41) and gasket (43). • Distance between tip of IAC valve pintle and mounting surface. — Discard gasket (43). — If greater than 28 mm, use finger pressure to slowly retract the pintle. The force Clean required to retract the pintle of a new •...
Page 117 6D1-1 SECTION 6D1 BATTERY SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 118 6D1-2 BATTERY 10. Clip A. Radiator Support Ground 1. Transmission Filler Tube 12. Wire (Engine Ground) 2. Positive Cable 13. Bolt 3. Negative Cable 14. Nut 4. Starter Assembly 15. Nut 5. Exhaust Pipe Assembly 16. Bolt 6. Generator 17. Bolt 7.
Page 119 BATTERY 6D1-3 31. Battery Tray 36. Bolt 42. Bolt 32. Screw 37. Weld Nut 43. Retainer 33. Washer 38. Screw 44. Hex Flange Nut 34. Outlet Heater Hose 39. Cruise Control Vacuum Tank 45. Bolt 35. U-Nut 40. Radiator Support 41.
Page 120 6D1-4 BATTERY FASTENER TORQUE SPECIFICATIONS N•m Ft. Lbs. In. Lbs. Lower Wheelhouse-to-Battery Tray Screw......Battery Tray-to-Vacuum Tank Bolt.
Page 121 6D4-1 SECTION 6D4 IGNITION SYSTEM SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 122 6D4-2 IGNITION SYSTEM SPARK PLUG REPLACEMENT • If the distributor shaft won’t drop into the engine, insert a screwdriver into the hole for the distributor and turn the oil pump driveshaft. Remove or Disconnect Distributor hold-down clamp, washer and bolt. •...
Page 123 6D7-1 SECTION 6D7 ENGINE WIRING SYCLONE AND TYPHOON can result from wiring or harnesses becoming loose and When it is necessary to move any of the wiring, whether moving from their original positions or from being rerouted. to lift wires away from their harnesses or move harnesses to Refer to figures 1 through 4 for correct routing of Syclone reach some component, take care that all wiring is replaced and Typhoon engine wiring.
Page 124 6D7-2 ENGINE WIRING 1. A/C Compressor Connector 2. Wastegate Solenoid Connector 3. Heated Oxygen Sensor Connector 4. IAC Connector 5. TPS Connector 6. Generator Connector 7. IC Pump Fuse 8. Coolant Temperature Sensor Connector 9. Battery Power Leads to Alternator 10.
Page 125 ENGINE WIRING 6D7-3 1. MAT Sensor Connector 2. MAP Sensor Connector 3. Coil Lead Connector 4. EVRV Solenoid Connector 5. Coolant Temperature Sensor Connector for Gage 6. Generator Connector 7. IC Pump Fuse 8. A/C Compressor Connector 9. Boost Solenoid Connector 10.
Page 126 6D7-4 ENGINE WIRING 1. To Junction Block 10. IC Pump Extension Harness Connector 11. Fuel Pump Relay Connector 2. Fuel Pump Test Connector 3. Injector Subharness Connector 12. A/C Relay Connector 4. Injector Subharness Connector 13. Engine/4WAL Harness Connector 14. Knock Sensor Connector 5.
Page 127 ENGINE WIRING 6D7-5 1. Bolt 2. TCC Connector 3. Speed Sensor Connector 4. Harness 5. Fuel Lines 6. Strap V1773 Figure 4 - Engine Wiring at Transmission–4.3L Turbo Engine...
Page 129 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-1 SECTION 6E DRIVEABILITY AND EMISSIONS GENERAL INFORMATION SYCLONE AND TYPHOON When fasteners are removed, always reinstall them at the same location from which they NOTICE: were removed. If a fastener needs be replaced, use the correct part number fastener for that applica- tion.
Page 130 6E-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS * OPERATING CONDITIONS SENSED * SYSTEMS CONTROLLED A/C “On” or “Off” Exhaust Gas Recirculation (EGR) Engine Coolant “Temperature” Electronic Spark Timing (EST) Engine Crank Signal Fuel Control Exhaust Oxygen (0 ) Sensor Fuel Injectors Distributor Reference Idle Air Control (IAC)
Page 131 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-3 -ALWAYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS”. EXHAUST EMISSION SYSTEM V1874 Figure 2 - Vehicle Emission Control Information Label (Typical)
Page 132 6E-4 4.3 TURBO (VIN Z) DRIVEABILITY AND EMISSIONS “Driveability and Emissions,” Section “6E” You should be familiar with wiring diagrams, the provides general diagnostic procedures, Tech 1 meaning of voltage, ohms, amps, the basic theories of Diagnostic Computer use, wiring and terminal repair electricity, and understand what happens in an open procedures, and descriptions of special tools.
Page 133 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-5 The ECM performs a continual self-diagnosis on Reading Codes certain control functions. This diagnostic capability is complemented by the diagnostic procedures contained The provision for communicating with the ECM is i n t h i s m a n u a l . T h e E C M ’ s l a n g u a g e f o r the Assembly Line Diagnostic Link (ALDL) connector communicating the source of a malfunction is a system (See Figure 3).
Page 134 6E-6 4.3L TURBO VIN Z) DRIVEABILITY AND EMISSIONS To prevent ECM damage, the key must NOTICE: be “OFF” when disconnecting or reconnecting ECM power. TERMINAL IDENTIFICATION When using a hand-held Tech 1 Diagnostic Computer, or “Scan” tool to read the codes, clearing GROUND the diagnostic codes is done in the same manner as in DIAGNOSTIC...
Page 135 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-7 ALDL “SCAN” TOOLS The ECM can communicate a variety of informa- tion through ALDL connecter terminal “M”. This data is transmitted at a high frequency which requires a Tech 1 Diagnostic Computer (“Scan”) tool for interpre- tation.
Page 136 6E-8 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS The Tech 1 is also an easy way to compare the Factory Test Mode operating parameters of a poorly operating engine (Also Called Back-up or 3.9 K) with those of a known good one. For example, a sensor may shift in value but not set a trouble code.
Page 137 DRIVEABILITY AND EMISSIONS 4.3L TURBO VIN Z) 6E-9 METRI-PACK SERIES TOOL J 35689-A OR BT-8446 150 FEMALE TERMINAL CONNECTOR BODY LOCKING TANG SEAL V1706 Figure 6 - Metri-Pack Series 150 Terminal Removal With the low current and voltage levels found in Metri-Pack Series 150 Terminals the system, it is important that the best possible bond be made at all wire splices by soldering the splices as...
Page 138 6E-10 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Micro-Pack Connectors Micro-Pack terminal (Figure 8) replacement requires the use of special tool J 33095, J 38125-12, BT-8234-A or equivalent. TOOLS NEEDED TO SERVICE THE SYSTEM OPEN SECONDARY LOCK HINGE ON CONNECTOR The system requires a Tech 1 Diagnostic Computer or equivalent “Scan”...
Page 139 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-11 CABLE LOCKING TANG WITH TOOL IN PLACE, GENTLY PULL ON THE CABLE TO REMOVE TERMINAL. TERMINAL TOOL J 33095 OR J 38125-12 VISUALLY CHECK TERMINAL AND REPLACE IF GRASP CABLE AND PUSH TERMINAL TO TERMINAL CAVITY OR TANG IS DAMAGED.
Page 140 6E-12 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Figure 9 - Special Tools (1 of 4)
Page 141 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-13...
Page 142 6E-14 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Figure 11 - Special Tools (3 of 4)
Page 143 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-15 INJECTOR TESTER Used for energizing each fuel injector for a precise amount of time to perform injector balance test. Part of Diagnostic Kit J 34730-C. MASS AIR FLOW (MAF) SENSOR TESTER Used for static test of MAF Sensor on vehicles equipped with an AC type MAF Sensor.
Page 144 6E-16 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS ABBREVIATIONS AND GLOSSARY OF TERMS Abbreviations used in this manual are listed below - Containing CONV. - CATALYTIC CONVERTER in alphabetical order with an explanation of the platinum and palladium to speed up conversion of HC abbreviation.
Page 145 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-17 - Operates the same as ground and may, or may Used to sense ESC - ELECTRONIC SPARK CONTROL - not, be connected to chassis ground. detonation and retard spark advance when detonation occurs.
Page 146 6E-18 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS TPS - THROTTLE POSlTlON SENSOR - Device that tells QUAD DRIVER - A “chip” device that is capable of the ECM the throttle position. operating four separate outputs. Some have digital and some have pulse width modulated outputs. TVS - THERMAL VACUUM SWITCH - Used to control RESISTANCE - The ability of a circuit to limit current vacuum in relationship to engine temperature.
Page 147 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E-19 GENERAL SPECIFICATIONS Many of the specifications used in this section are located on the Vehicle Emission Control Information label under the hood. Listed on the chart below are locations of specifications used in this Section LOCATION OF INFORMATION SPECIFICATION Engine Timing...
Page 148 6E-20 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS...
Page 149 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-1 SECTION 6E3 DRIVEABILITY AND EMISSIONS FUEL INJECTION (PORT) THIS SECTION APPLIES TO: 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON CONTENTS 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON GENERAL DESCRIPTION ......... . . 4.3L (VIN Z) 6E3-2 DIAGNOSIS PROCEDURE.
Page 150 6E3-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO FACTORY STANDARDS.
Page 151 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-1 SECTION A DIAGNOSTIC CIRCUIT CHECK Blocking Drive Wheels The vehicle drive wheels should always be blocked The “Diagnostic Circuit Check” verifies that the while checking the system. engine control system is functioning correctly. Special consideration to observe while performing the “Diag- BASIC PROCEDURE nostic Circuit Check”...
Page 152 6E3-A-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS SYCLONE ENGINE CODE: 4.3L V6 EMISSION COMPONENTS COMPUTER COMMAND ECM INFORMATION CONTROL SENSORS (NOT ECM CONTROLLED) Manifold Absolute Pressure (MAP) N1 Crankcase Vent Valves (PCV) C1 Electronic Control Module (ECM) C2 ALDL diagnostic connector Exhaust Oxygen (O ) Sensor N15 Fuel Vapor Canister...
Page 153 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-3 V1819 Figure A-2 - ECM Wiring Diagram 4.3L TURBO (VIN Z) (1 of 3)
Page 154 6E3-A-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Figure A-3 - ECM Wiring Diagram 4.3L TURBO (VIN Z) (2 of 3)
Page 155 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-5 Figure A-4 - ECM Wiring Diagram 4.3L TURBO (VlN Z) (3 of 3)
Page 156 6E3-A-6 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS PORT FUEL INJECTION ECM CONNECTOR IDENTIFICATION This ECM voltage chart is for use with a digital voltmeter to further aid in diagnosis. The voltages you get may vary due to low battery charge or other reasons, but they should be very close. THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING: Engine at operating temperature Engine idling in “Closed Loop”...
Page 157 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-7 BLACK 32 PIN C-D CONNECTOR LIGHT GREEN 32 PIN E-F CONNECTOR * LESS THAN .5 VOLT LESS THAN 1 VOLT A/C. FAN OFF V1822 4.3L TURBO (VIN Z) (2 of 2) Figure A-6 - ECM Terminal Connector End View...
Page 158 6E3-A-8 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS DIAGNOSTIC CIRCUIT CHECK The Diagnostic Circuit Check is an organized approach to identifying a problem created by an electronic engine control system malfunction. It must be the starting point for any driveability complaint diagnosis because it directs the service technician to the next logical step in diagnosing the complaint.
Page 159 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-9 DIAGNOSTIC CIRCUIT CHECK 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V 1 8 7 5...
Page 160 6E3-A-10 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1561 CHART A-l NO “CHECK ENGINE” LIGHT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: There should always be a steady “Check Engine” light when the ignition is “ON” and the engine is “OFF.” Battery voltage is supplied directly to the light bulb.
Page 161 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-11 CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V1876...
Page 162 6E3-A-12 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1563 CHART A-2 WON’T FLASH CODE 12 “CHECK ENGINE” LIGHT “ON” STEADY 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: There should always be a steady “Check Engine” light when the ignition is “ON” and the engine stopped. Battery voltage is supplied directly to the light bulb.
Page 163 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-13 CHART A-2 WON’T FLASH CODE 12 “CHECK ENGINE” LIGHT “ON” STEADY 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT.
Page 164 6E3-A-14 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V3207 CHART A-3 (Page 1 of 2) ENGINE CRANKS BUT WON’T RUN 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: Before using this chart, battery condition, engine cranking speed, and fuel quantity should be checked and verified as being OK.
Page 165 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-15 CHART A-3 (Page 1 of 2) ENGINE CRANKS BUT WON’T RUN 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSE LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V1878...
Page 166 6E3-A-16 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V3208 CHART A-3 (Page 2 of 2) ENGINE CRANKS BUT WON’T RUN 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Disconnect ECM C-D connector and check injector Numbers below refer to circled Test Description: jumper circuits with a DVM.
Page 167 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-17 CHART A-3 (Page 2 of 2) ENGINE CRANKS BUT WON’T RUN 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT V1879...
Page 168 6E3-A-18 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS CHART A-5 FUEL PUMP RELAY CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: When the ignition switch is turned “ON,” the Electronic Control Module (ECM) will activate the fuel pump relay and run the in-tank fuel pump.
Page 169 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-19 CHART A-5 FUEL PUMP RELAY CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V 1 8 8 0...
Page 170 6E3-A-20 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V 1 5 7 1 CHART A-7 (Page 1 of 2) FUEL SYSTEM PRESSURE TEST 4.3 L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The fuel pump delivers fuel to the fuel rail and injectors, where the system pressure is controlled to 245 to 409 kPa (35 to 61 psi) by the pressure regulator.
Page 171 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-21 CHART A-7 N O T I C E : F U E L S Y S T E M I S U N D E R P R E S S U R E . T O A V O I D F U E L S P I L L A G E , R E F E R T O F I E L D (Page 1 of 2) S E R V I C E P R O C E D U R E S F O R T E S T I N G O R...
Page 172 AND EMISSIONS 6E3-A-22 4.3L TURBO (VIN Z) DRIVEABILITY V1571 CHART A-7 (Page 2 of 2) FUEL SYSTEM PRESSURE TEST 4.3 L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The fuel pump delivers fuel to the fuel rail and injectors, where the system pressure is controlled to 245 to 409 kPa (35 to 61 psi) by the pressure regulator.
Page 173 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-23 NOTICE; FUEL SYSTEM IS UNDER PRESSURE. TO AVOID FUEL SPILLAGE, REFER TO FIELD S E R V I C E P R O C E D U R E S F O R T E S T I N G O R REPAIRS REQUIRING DISASSEMBLY OF FUEL LINES OR FITTINGS.
Page 174 6E3-A-24 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1832 CODE 13 OXYGEN (0 ) SENSOR CIRCUIT (OPEN CIRCUIT) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ECM applies a bias voltage of approximately 450 millivolts (350-550 mV is normal bias voltage) between terminals “GE14”...
Page 175 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-25 CODE 13 OXYGEN (0 ) SENSOR CIRCUIT (OPEN CIRCUIT) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V 1 8 8 3 CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT.
Page 176 6E3-A-26 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1577 CODE 14 COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT (HIGH TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE (PORT) Circuit Description: The Coolant Temperature Sensor (CTS) uses a thermistor to control the signal voltage to the ECM. The ECM applies a voltage on CKT 410 to the sensor.
Page 177 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-27 CODE 14 COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT (HIGH TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V 1 8 8 4...
Page 178 6E3-A-28 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS CODE 15 COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT (LOW TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Coolant Temperature Sensor (CTS) uses a thermistor to control the signal voltage to the ECM. The ECM applies a voltage on CKT 410 to the sensor.
Page 179 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-29 CODE 15 COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT (LOW TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) DIAGNOSTIC AID COOLANT SENSOR TEMPERATURE TO RESISTANCE VALUES (APPROXIMATE) °F °C OHMS 1,800 3,400 7,500 13,500 25,000...
Page 180 6E3-A-30 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V 1 5 8 0 CODE 21 THROTTLE POSITION SENSOR (TPS) CIRCUIT (SIGNAL VOLTAGE HIGH) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Throttle Position Sensor (TPS) provides a voltage signal that changes relative to the throttle valve. Signal voltage will vary from less than 1.0 volt at idle to about 4.6 volts at wide open throttle (WOT).
Page 181 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-31 CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND ND “CHECK ENGINE” LIGHT. V 1 8 8 6...
Page 182 6E3-A-32 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1582 CODE 22 THROTTLE POSITION SENSOR (TPS) CIRCUIT (SIGNAL VOLTAGE LOW) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Throttle Position Sensor (TPS) provides a voltage signal that changes relative to the throttle valve. Signal voltage will vary from less than 1.0 volt at idle to about 4.5 volts at wide open throttle (WOT).
Page 183 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-33 CODE 22 THROTTLE POSITION SENSOR (TPS) CIRCUIT (SIGNAL VOLTAGE LOW) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V 1 8 8 7...
Page 184 6E3-A-34 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1584 CODE 23 MANIFOLD AIR TEMPERATURE (MAT) SENSOR CIRCUIT (LOW TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Manifold Air Temperature (MAT) sensor uses a thermistor to control the signal voltage to the ECM. The ECM applies a voltage (about 5 volts) on CKT 472 to the sensor.
Page 185 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-35 CODE 23 MANIFOLD AIR TEMPERATURE (MAT) SENSOR CIRCUIT (LOW TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND ND “CHECK ENGINE” LIGHT. V1888...
Page 186 6E3-A-36 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS *REFER TO ECM WIRING DIAGRAM IN THIS SECTION. V1586 CODE 24 VEHICLE SPEED SENSOR (VSS) CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ECM applies and monitors 12 volts on CKT 437. CKT 437 connects to the DRAC, which alternately grounds CKT 437, when receiving voltage pulses from Vehicle Speed Sensor (VSS) when drive wheels are turning.
Page 187 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-37 CODE 24 VEHICLE SPEED SENSOR (VSS) CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V1089 "AFTER REPAIRS," REFER TO CODE CRITERIA ON FACING PAGE AND CONFIRM CODE DOES NOT RESET.
Page 188 6E3-A-38 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1588 CODE 25 MANIFOLD AIR TEMPERATURE (MAT) SENSOR CIRCUIT (HIGH TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Manifold Air Temperature (MAT) sensor uses a thermistor to control the signal voltage to the ECM. The ECM applies a voltage (4-6 volts) on CKT 472 to the sensor.
Page 189 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-39 CODE 25 MANIFOLD AIR TEMPERATURE (MAT) SENSOR CIRCUIT (HIGH TEMPERATURE INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) NOTE: A “SCAN” TOOL MAY NOT BE USED TO DIAGNOSE THIS FAULT, DUE TO THE ECM TRANSMITTING “DEFAULT”...
Page 190 6E3-A-40 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1833 CODE 31 (Page 1 of 2) TURBO WASTEGATE OVERBOOST 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: On turbo charged engines, the exhaust gases pass from the exhaust manifold through the turbocharger, turning the turbine blades.
Page 191 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-41 CODE 31 (Page 1 of 2) TURBO WASTEGATE OVERBOOST 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V 1 8 9 1...
Page 192 6E3-A-42 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1835 CODE 31 (Page 2 of 2) TURBO WASTEGATE OVERBOOST 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: If the level of coolant in the charge air cooler (CAC) is low, the turbo boost cut-out relay will shut off all power to the wastegate solenoid.
Page 193 DRlVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-43 CODE 31 (Page 2 of 2) TURBO WASTEGATE OVERBOOST 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V1892...
Page 194 6E3-A-44 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS CODE 32 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ECM operates a vacuum solenoid to control the Exhaust Gas Recirculation (EGR) valve. This solenoid is normally closed.
Page 195 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-45 V1893...
Page 196 6E3-A-46 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1593 CODE 33 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH - LOW VACUUM) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The ECM receives this information as a signal voltage that will vary from less than 1.0 volt at closed throttle idle, to 4-4.5 volts at wide open throttle (low vacuum or boost).
Page 197 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-47 CODE 33 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH - LOW VACUUM) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V1894...
Page 198 6E3-A-48 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS CODE 34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE LOW - HIGH VACUUM) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The ECM receives this information as a signal voltage that will vary from less than 1.0 volt at closed throttle idle, to 4-4.5 volts at wide open throttle.
Page 199 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-49 CODE 34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE LOW - HIGH VACUUM) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V1895...
Page 200 6E3-A-50 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V 1 8 3 7 CODE 35 IDLE SPEED ERROR 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ECM controls engine idle speed with the IAC valve. To increase idle speed, the ECM retracts the IAC valve pintle away from its seat, allowing more air to bypass the throttle bore.
Page 201 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-51 CODE 35 IDLE SPEED ERROR 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) * IAC DRIVER AND NODE LIGHT REQUIRED KIT 222-L FROM: CONCEPT TECHNOLOGY, INC. J37027 FROM: KENT-MOORE, INC. CLEAR CODES, CONFIRM “CLOSED LOOP” OPERATION, NO “CHECK ENGINE”...
Page 202 6E3-A-52 4.3L TURBO WIN Z) DRIVEABILITY AND EMISSIONS CODE 42 ELECTRONIC SPARK TIMING (EST) CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ignition module sends a reference signal (CKT 430) to the ECM when the engine is cranking. While the engine speed is under 400 rpm, the ignition module will control ignition timing.
Page 203 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-53 CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V1897...
Page 204 6E3-A-54 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1651 CODE 43 ELECTRONIC SPARK CONTROL (ESC) CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The knock sensor is used to detect engine detonation and the ECM will retard the electronic spark timing based on the signal being received.
Page 205 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-55 CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V 1 8 9 8...
Page 206 6E3-A-56 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V 1 8 4 0 CODE 44 OXYGEN (0,) SENSOR CIRCUIT (LEAN EXHAUST INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ECM applies a bias voltage of approximately 450 millivolts (350-550 mV is normal bias voltage) between terminals “GE14”...
Page 207 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-57 CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V 1 8 9 9...
Page 208 6E3-A-58 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V 1 8 4 1 CODE 45 OXYGEN (0,) SENSOR CIRCUIT (RICH EXHAUST INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ECM applies a bias voltage of approximately 450 millivolts (350-550 mV is normal bias voltage) between terminals “GE14”...
Page 209 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-A-59 CODE 45 OXYGEN (0 ) SENSOR CIRCUIT (RICH EXHAUST INDICATED) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “SERVICE ENGINE SOON” LIGHT. V1900...
Page 210 6E3-A-60 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS CODE 51 PROM ERROR (FAULTY OR INCORRECT PROM) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET AND THAT PROM IS PROPERLY SEATED. IF OK, REPLACE PROM, CLEAR MEMORY, AND RECHECK.
Page 211 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-B-1 SECTION B SYMPTOMS CONTENTS Page B-1 Performing Symptom Diagnosis ........Page B-2 Intermittents .
Page 212 6E3-B-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS INTERMITTENTS Problem may or may not activate the “Check Engine” Definition: light or store a trouble code. Check for loss of trouble code memory. To DO NOT use the trouble code charts in Section check, disconnect the TPS and allow the engine “A”...
Page 213 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-B-3 TPS for sticking or binding. TPS voltage temperature, connect a vacuum gauge to should read less than 1.25 volts on a ‘Scan” any convenient vacuum port on intake tool. manifold. In-tank fuel pump check valve. A faulty 2.
Page 214 6E3-B-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS PCV valves for proper operation by placing 2. Run engine at 1000 rpm and record finger over inlet hole in each valve end sev- vacuum reading. eral times. Valve should snap back. If not, 3.
Page 215 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-B-5 POOR GAS MILEAGE Definition: Gas mileage, as measured by an actual road test, is noticeably lower than expected. Gas mileage is noticeably lower than it was during a previous actual road test. Perform careful visual and physical check as Coolant sensor for a shift in calibration.
Page 216 6E3-B-6 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS 5. Disconnect exhaust pipe from engine and Are tires at correct pressure? repeat Steps 3 & 4. If vacuum still drops Are excessively heavy loads being more than 3” Hg with exhaust discon- carried? nected, check valve timing.
Page 217 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-B-7 - For the possibility of an exhaust restriction or 4. If vacuum at 2500 rpm decreases more improper valve timing by performing the than 3” Hg from reading at 1000 rpm, the following test.
Page 218 6E3-B-8 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Transmission for proper shift points. See 4. If vacuum at 2500 rpm decreases more AUTOMATIC TRANSMISSION (Section 7A1) than 3” Hg from reading at 1000 rpm, the exhaust system should be inspected for in the 1992 Service Manual Sonoma and restrictions.
Page 219 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-B-9 PCV valves for proper operation by placing powdery coating and will cause a high but finger over inlet, hole in each valve end sev- f a l s e s i g n a l v o l t a g e ( r i c h e x h a u s t eral times.
Page 220 6E3-B-10 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS HESITATION, SAG, STUMBLE Momentary lack of response as the accelerator is pushed down. Can occur at all Definition: vehicle speeds. Usually most severe when first trying to make the vehicle move, as from a stop sign. May cause the engine to stall if severe enough. Perform careful visual and physical check as Oxygen sensor for silicone contamination described at the beginning of Section “B”.
Page 221 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-B-11 For worn or incorrect basic engine parts such Restricted air flow to radiator, or re- as cam, heads, pistons, etc. Also check for stricted water flow through radiator. bent pushrods, worn rocker arms, and broken Faulty or incorrect thermostat.
Page 222 6E3-B-12 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS BACKFIRE Definition: Fuel ignites in intake manifold or in exhaust system, making a loud popping sound. Perform careful visual and physical check as Ignition system for moisture, dust, cracks, described at the beginning of Section “B”. burns, etc.
Page 223 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C-1 SECTION C COMPONENT SYSTEMS Section “C” provides information on the following: General description of components and sub-systems. On-vehicle service. Part names and group numbers. Diagnostic charts. These include a functional check of the system as well as diagnosis of any problem found in the functional check.
Page 225 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-1 SECTION C1 ELECTRONIC CONTROL MODULE (ECM) AND SENSORS CONTENTS GENERAL DESCRIPTION ....C1-1 Oxygen (0 ) Sensor ....C1-5 ELECTRONIC CONTROL MODULE (ECM) .
Page 226 6E3-C1-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS The ECM controls output circuits such as the HANDLING ELECTROSTATIC injector(s), IAC, charge air cooler (CAC) pump relay, DISCHARGE SENSITIVE PARTS etc. by controlling the ground circuit through transistors or a device called a “quad-driver.” When handling an electronic part that has an ESD sensitive sticker (Figure C1-2) the service technician should follow these guidelines to reduce any possible...
Page 227 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-3 valve angle is changed (accelerator pedal moved), the By measuring the voltage, the ECM knows the manifold output of the TPS also changes. At a closed throttle air temperature. position, the output of the TPS is low (approximately 1 The MAT sensor is also used to control spark timing volt).
Page 228 6E3-C1-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS open throttle would produce a high output. Manifold A/C Request Signal Absolute Pressure (MAP) is the OPPOSITE of what you would measure on a vacuum gage. When manifold pres- This signal tells the ECM that the A/C selector sure is high, vacuum is low.
Page 229 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-5 The problem is intermittent. - This means that Coolant Temperature Sensor (CTS) the problem is not present at the time the system is being checked. In this case, refer to A “Scan” tool displays engine temperature in the “Symptoms”...
Page 230 6E3-C1-6 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Park/Neutral (P/N) Switch A “Scan” tool should read P/N when in park, or neutral, and R-D, L, when in drive or overdrive. This reading may vary with different makes of tools. Refer to CHART C-1A for P/N switch diagnosis.
Page 231 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-7 V1670 Figure C1-9 – ECM Location Important Important To prevent internal ECM damage, the ignition must When replacing the production ECM with a service be “OFF” when disconnecting or reconnecting ECM (controller), it is important to transfer the broadcast code and production ECM number to the power to ECM (for example;...
Page 232 6E3-C1-8 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS To prevent possible Electrostatic Discharge a. If not fully seated, press firmly on the ends NOTICE: of the Mem-Cal. damage to the Mem-Cal, Do Not touch the component leads, and Do Not remove b.
Page 233 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-9 New or service sensors will already have the Install or Connect compound applied to the threads. If a sensor is 1. Coat threads (only) with sealer P/N 1052080 or removed from an engine, and, if for any reason, it is equivalent.
Page 234 6E3-C1-10 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS PARTS INFORMATION PART NAME GROUP Controller, ECM ..... 3.670 Memory Calibration Unit, Mem/Cal ..3.670 Sensor, Coolant Temp .
Page 235 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-11 BLANK...
Page 236 6E3-C1-12 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS CHART C-1A PARK/NEUTRAL SWlTCH DlAGNOSlS 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Park/Neutral switch contacts are a part of the neutral start switch. They are closed to ground in park or neutral and open in drive ranges.
Page 237 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-13 CHART C-1A PARK/NEUTRAL SWITCH DIAGNOSIS 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V1726...
Page 238 6E3-C1-14 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1842 CHART C-1D MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The Manifold Absolute Pressure (MAP) sensor measures manifold pressure (vacuum) and sends that signal to the ECM.
Page 239 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C1-15 CHART C-1D MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V1727...
Page 240 6E3-C1-16 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS BLANK...
Page 241 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C2-1 SECTION C2 FUEL METERING SYSTEM CONTENTS lDLE AIR CONTROL (IAC) VALVE ..C2-4 GENERAL DESCRIPTION ... . C2-1 FUEL PUMP ELECTRICAL CIRCUIT .
Page 242 6E3-C2-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Run Mode The run mode has two conditions called “Open Loop” and “Closed Loop.” When the engine is first started, and rpm is above 400 rpm, the system goes into “Open Loop” operation. In “Open Loop,”...
Page 243 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C2-3 The injectors are controlled by the ECM. They deliver fuel in one of several modes, as described above. In order to properly control the fuel supply, the fuel pump is operated by the ECM through the fuel pump relay and oil pressure switch (see “Fuel Pump Electrical Circuit”).
Page 244 6E3-C2-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS switch which closes when oil pressure reaches about 28 kPa (4 psi). If the fuel pump relay fails, the oil pressure switch will close and run the fuel pump. An inoperative fuel pump relay can result in long cranking times, particularly if the engine is cold.
Page 245 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C2-5 Tool Required: J 34730-1 Fuel Pressure Gage 1. Disconnect negative battery terminal to avoid possible fuel discharge if an accidental attempt is made to start the engine. 2. Loosen fuel filler cap to relieve tank vapor pressure.
Page 246 6E3-C2-6 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Cleaning and Inspection Before disassembly, the fuel rail assembly may be cleaned with a spray type engine cleaner, such as AC Delco X-30A, or equivalent, following package instructions. The fuel rail should not be immersed in liquid solvent.
Page 247 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C2-7 Cleaning and Inspection Throttle body parts, except as noted below, may be cleaned in a cold immersion-type cleaner such as AC Delco X-55 or equivalent. The Throttle Position Sensor (TPS), Idle NOTICE: Air Control (IAC) valve, throttle body with cover and seals or gaskets in place, should NOT be soaked in liquid solvent or...
Page 248 6E3-C2-8 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS CHART C-2A INJECTOR BALANCE TEST The injector balance tester is a tool used to turn the injector on for a precise amount of time, thus spraying a measured amount of fuel into the manifold. This causes a drop in fuel rail pressure that we can record and compare between each injector.
Page 249 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C2-9 NOTE: If injectors are suspected of being dirty, they should be cleaned using an approved tool and procedure prior to performing this test. The fuel pressure test in Section “A,” Chart A-7, should be completed prior to this test. Step 1.
Page 250 6E3-C2-10 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS BLANK...
Page 251 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C3-1 SECTION C3 EVAPORATIVE EMISSION CONTROL SYSTEM (EECS) CONTENTS C3-1 On-Vehicle Service ....C3-2 General Description ....C3-1 Vapor Canister .
Page 252 6E3-C3-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS FUEL TANK VAPOR PIPE CANISTER HOSE THROTTLE BODY VAPOR RESTRICTION FUEL CAP VAPOR CANISTER V1708 Figure C3-2 - Evaporative Emissions Control System Schematic VISUAL CHECK OF VAPOR CANISTER ON-VEHICLE SERVICE Replace vapor canister if cracked or damaged. VAPOR CANISTER Replace vapor canister if fuel is leaking from bottom and check operation of the total system.
Page 253 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C3-3 VAPOR PIPE steel tubing and hose so that hose lengths will not be more than 10 inches (254mm). The vapor pipe is secured to the underbody with 2. Cut ends of pipe remaining on vehicle square clamp and screw assemblies.
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Page 255 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C4-1 SECTION C4 IGNITION SYSTEM/EST CONTENTS GENERAL DESCRIPTION ... . C4-1 DIAGNOSIS ....C4-1 PURPOSE .
Page 256 6E3-C4-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V3210 Figure C4-1 - HEI System With EST ON-VEHICLE SERVICE If the bypass line is open or grounded, the HEI module will not switch to EST mode. The EST voltage will be low, and Code 42 will be set. SETTING TIMING If the EST line is grounded, the HEI module will switch to EST, but because the line is grounded there...
Page 257 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C4-3 BLANK...
Page 258 6E3-C4-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V3211 CHART C-4C IGNITION SYSTEM CHECK (REMOTE COIL) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Numbers below refer to circled ule from the “BATT” to the “TACH” terminal. Test Description: numbers on the diagnostic chart. 5.
Page 259 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C4-5 CHART C-4C IGNITION SYSTEM CHECK (REMOTE COIL) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V1729...
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Page 261 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C5-1 SECTION C5 ELECTRONIC SPARK CONTROL (ESC) SYSTEM CONTENTS ON-VEHICLE SERVICE GENERAL DESCRIPTION ... . C5-1 ....C5-2 OPERATION .
Page 262 6E3-C5-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Code 43 to set. Spark retard without the knock sensor connected could indicate a noise signal on the wire to Install or Connect the ECM. 1. ESC sensor into engine block. Code 43 indicates that the ECM is receiving less Ensure that threads are clean, than 6 volts for a 4 second period with the engine running.
Page 263 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C5-3 BLANK...
Page 264 6E3-C5-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1671 CHART C-5 ELECTRONIC SPARK CONTROL (ESC) SYSTEM CHECK 4.3L TURBO WIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The ESC knock sensor is used to detect engine detonation and the ECM will retard the electronic spark timing based on the signal being received.
Page 265 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C5-5 CHART C-5 ELECTRONIC SPARK CONTROL (ESC) SYSTEM CHECK 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) V1731 CLEAR CODES AND CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT...
Page 266 6E3-C5-6 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS BLANK...
Page 267 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C7-1 SECTION C7 EXHAUST GAS RECIRCULATION (EGR) SYSTEM CONTENTS GENERAL DESCRIPTION ... . C7-1 DIAGNOSIS ....C7-2 PURPOSE .
Page 268 6E3-C7-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Positive backpressure EGR valves will have a “P” stamped on the top side of the valve, after the part number. When replacing an EGR valve, always check for correct part number in the parts catalog or supplemental bulletin.
Page 269 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C7-3 Tighten Bolts to 17 N•m (13 ft. lbs.). 3. Vacuum line to valve. EGR CONTROL SOLENOID Remove or Disconnect Negative battery cable. 2. Electrical connector at solenoid (See Figure C7-5). 3. Vacuum hoses. 4.
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Page 271 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C8-1 SECTION C8 TORQUE CONVERTER CLUTCH (TCC) SYSTEM CONTENTS ....C8-1 TCC System ....C8-1 General Description .
Page 272 6E3-C8-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS The electrical diagnosis of the TCC system is Models. For the replacement of the TCC solenoid covered in the appropriate “Torque Converter Clutch refer to 4L60 AUTOMATlC TRANSMlSSlON (SEC. Electrical Diagnosis” chart. 7A1) in the 1992 Service Manual Sonoma and If the ECM detects a problem in the VSS system, a Jimmy Models.
Page 273 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C8-3 BLANK...
Page 274 6E3-C8-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1674 CHART C-8A TORQUE CONVERTER CLUTCH (TCC) (ELECTRICAL DIAGNOSIS) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: The purpose of the automatic transmission Torque Converter Clutch (TCC) feature is to eliminate the power loss of the torque converter stage when the vehicle is in a cruise condition.
Page 275 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C8-5 CHART C-8A TORQUE CONVERTER CLUTCH (TCC) (ELECTRICAL DIAGNOSIS) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) “AFTER REPAIRS,” CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V1732...
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Page 277 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C10-1 SECTION C10 A/C CLUTCH CIRCUIT DlAGNOSIS CONTENTS General Description ....C10-1 Diagnosis C10-1 ..... . GENERAL DESCRIPTION DIAGNOSIS In order to improve idle quality and wide open...
Page 278 6E3-C10-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1845 CHART C-10A (Page 1 of 2) A/C CLUTCH CONTROL DIAGNOSIS (AUTOMATIC TRANSMISSION) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: ECM control of the A/C clutch improves idle quality and performance by: Delaying clutch apply until the idle air rate is increased.
Page 279 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C10-3 CHART C-10A (Page 1 of 2) A/C CLUTCH CONTROL DIAGNOSIS (AUTOMATIC TRANSMISSION) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) “AFTER REPAIRS,” CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V1733...
Page 280 6E3-C10-4 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1846 CHART C-10A (Page 2 of 2) A/C CLUTCH CONTROL DIAGNOSIS (AUTOMATIC TRANSMISSION) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) Circuit Description: ECM control of the A/C clutch improves idle quality and performance by: Delaying clutch apply until the idle air rate is increased.
Page 281 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C10-5 CHART C-10A (Page 2 of 2) A/C CLUTCH CONTROL DIAGNOSIS (AUTOMATIC TRANSMISSION) 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) “AFTER REPAIRS,” CONFIRM “CLOSED LOOP” OPERATION AND NO “CHECK ENGINE” LIGHT. V1734...
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Page 283 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C12-1 SECTION C12 CHARGE AIR COOLER (CAC) PUMP CONTENTS GENERAL DESCRIPTION ... . C12-1 ON-VEHICLE SERVICE ....C12-1 OPERATION .
Page 284 6E3-C12-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1848 CHART C-12 CHARGE AIR COOLER (CAC) PUMP SYSTEM CHECK 4.3L TURBO (VIN Z) SYCLONE (PORT) Circuit Description: Battery voltage to operate the CAC pump motor is supplied to relay terminal “D.” Ignition voltage to energize the relay is supplied to relay terminal “A.”...
Page 285 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C12-3 CHART C-12 CHARGE AIR COOLER (CAC) SYSTEM CHECK 4.3L TURBO WIN Z) SYCLONE AND TYPHOON (PORT) V1735...
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Page 287 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C13-1 SECTION C13 POSITIVE CRANKCASE VENTILATION (PCV) CONTENTS GENERAL DESCRIPTION FUNCTIONAL CHECK OF PCV VALVES . . C13-1 ... . C13-1 RESULTS OF INCORRECT OPERATION . . . C13-1 ON-VEHICLE SERVICE .
Page 288 6E3-C13-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS V1696 1. Check Valve Figure C13-2-PCV Valve Cross Section ON-VEHICLE SERVICE See Figure C13-3 for replacement of PCV system components. An engine which is operated without any 1. PCV Valve Hose crankcase ventilation can be damaged. Therefore, it is 2.
Page 289 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) 6E3-C14-1 SECTION C14 AIR INDUCTION SYSTEM NOTICE: When fasteners are removed, always reinstall them at the same location from which they were re- moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 290 6E3-C14-2 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS Figure C14-1 – Air Induction System...
Page 291 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) INDEX-1 SECTION PAGE SECTION PAGE Code 14 ......A-26 Code 15 .
Page 292 2-INDEX 4.3L TURBO (VIN Z) DRIVEABILITY AND EMISSIONS PAGE SECTION PAGE SECTION C4-1 EST/Ignition System ....Evaporative Emission Control System General Description, Diagnosis ..C3-1 MAP Sensor Exhaust Emissions Excessive (Odors).
Page 293 DRIVEABILITY AND EMISSIONS 4.3L TURBO (VIN Z) INDEX-3 SECTION PAGE PAGE SECTION Diagnosis ..... . . A-30 A-32 C1-5 Rough Idle ......Service .
Page 295 6 F - 1 SECTION 6F EXHAUST SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 296 6F-2 EXHAUST 1. Nut 2. Crossover Pipe 3 . Left Exhaust Manifold 4. Right Exhaust Manifold V1520 Figure 1 - Exhaust Crossover Pipe TURBOCHARGER OUTLET PIPE Tighten Nuts (19) to 55 N•m (41 ft. Ibs.). Remove or Disconnect (Figures 2 through 4) Catalytic converter clamp nuts to 57 N•m (42 ft.
Page 297 EXHAUST 6F-3 A. Frame 5. Oxygen Sensor 6. Converter 7. Muffler Assembly 8. Converter Support 9. Outlet Pipe 11. Bolt 12. Bolt 13. Nut 14. Retainer 15. Bolt 16. Hanger Assembly 17. Hanger Assembly 23. Clamp V3220 Figure 2 - Exhaust System (Syclone)
Page 298 6F-4 EXHAUST 5. Oxygen Sensor 6. Converter 8. Converter Support 9. Outlet Pipe 23. Clamp 26. Muffler Assembly 27. Bolt 28. Bolt 29. Hanger Assembly 30. Hanger Assembly V1781 Figure 3 - Exhaust System (Typhoon)
Page 299 EXHAUST 6F-5 5. Oxygen Sensor 9. Outlet Pipe 18. Turbocharger 19. Nut 20. Nut 21. Bracket 22. Bolt 25. Connector V1522 Figure 4 - Turbocharger Outlet Pipe Install or Connect (Figures 2 and 4) NOTICE: For steps 1, 2 and 3 see “Notice” on SYCLONE page 6F-1 of this section.
Page 300 6F-6 EXHAUST Install bolts (12), nuts (13) and hanger assembly 1. Bolts (24) from catalytic converter (6). (16) to retainer (14). 2. Muffler assembly (26). Remove bolts (27) from hanger assembly (30). NOTICE: See “Notice” on page 6F-1 of this Remove bolt (28) from hanger assembly (29).
Page 301 6J-1 SECTION 6J TURBOCHARGER SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 302 6J-2 TURBOCHARGER 1. Turbocharger Assembly 2. Connector 3. Gasket 4. Bracket 5. Solenoid 6. Nut 7. Bolt 8. Wastegate Actuator 9. Gasket 10. Connector 11. Stud V1527 Figure 1 - Turbocharger Components A. Air Inlet B. Exhaust Gas Outlet C. Exhaust Gas Inlet D.
Page 303 TURBOCHARGER 6J-3 CHARGE AIR COOLER NOTICE: A turbocharged engine is a finely tuned assembly. Any alteration to the air intake or exhaust system that upsets the air flow balance Before entering the combustion chambers, the air from may result in serious damage to the engine. the turbocharger is routed through an air-to-water charge air cooler.
Page 304 6J-4 TURBOCHARGER A turbocharger does not change the basic operating Check for loose duct connections from the air cleaner characteristics of an engine. It cannot correct or overcome to the turbo. malfunctions in the engine fuel system, timing, air cleaner or other systems.
Page 305 TURBOCHARGER 6J-5 A. Severely Bent C. Broken B. Cracked D. Nicked Figure 4 - Blade Damage From Foreign Material Figure 5 - Extreme Sand Erosion A. Heavy Rubbing on Turbine Wheel Blades B. Heavy Rubbing on Compressor Wheel Blades V1532 Figure 6 - Wheel Rub ON-VEHICLE SERVICE TURBOCHARGER...
Page 306 6J-6 TURBOCHARGER 1. Turbocharger Assembly 2. Connector 19. Oil Feed Line 20. Nut 21. Screw 22. Clip 23. Nut 24. Connector 25. Nut 26. Clip V1534 Figure 7 - Oil Feed Line Assembly...
Page 307 TURBOCHARGER 6J-7 Turbocharger Assembly Connector Elbow Clamp Coolant Return Line Assembly V1765 Figure 8 - Coolant Return Line Assembly 34. Hose 39. Nut A. Engine Block 40. Gasket 36. Nipple 1. Turbocharger Assembly 41. Bolt 37. Fitting Oil Return Pipe 38.
Page 308 6J-8 TURBOCHARGER 1. Turbocharger Assembly 2. Connector 42. Gasket 43. Bolt 44. Coolant Feed Line Assembly 45. Nut 46. Connector Figure 10 - Coolant Feed Line Assembly Install or Connect (Figures 1, 7, 8, 9, 10 and 11) NOTICE: For steps 2, 3, 4, 5 and 6 see “Notice” on page 6J-1 of this section.
Page 309 TURBOCHARGER 6J-9 2. Bolts (55) attaching the charge air cooler (50) to the Coolant return line clamp (28) to 1.8 N•m (16 in. Ibs.). mounting bracket. 3. Charge air cooler (50). 7. Turbocharger outlet pipe to turbocharger. Refer to EXHAUST (SEC. 6F) in this manual. Install or Connect (Figure 12) 8.
Page 310 6J-10 TURBOCHARGER 4. Bolts (60) and washers (61) from bracket (63). 2. Bolts attaching charge air cooler pump (67) to charge air cooler radiator bracket (63). 5. Charge air cooler radiator (64) and bracket (63) from truck. 3. Charge air cooler pump (67) from charge air cooler radiator bracket (63).
Page 311 TURBOCHARGER 6J-11 1. With the system at a cool temperature, remove the 3. Fill the charge air cooler radiator through the charge air cooler. charge air cooler cap and connect the gage. 4. Bleed the charge air cooler as explained later in this NOTICE: Do not apply more than 89 kPa (13 psi) of section.
Page 312 6J-12 TURBOCHARGER 6J-12 TURBOCHARGER A. Direction to push lever closed B. Half of diameter of hole on rod end covered by pin 1. Turbocharger Assembly 8. Wastegate Actuator 71. Rod End 72. Lever V1720 Figure 15 - Wastegate Actuator Adjustment Measure Install or Connect (Figure 14) Apply 31 to 34.5 kPa (4.5 to 5 psi) air pressure with...
Page 313 TURBOCHARGER 6J-13 WASTEGATE ACTUATOR Install or Connect (Figure 14) REPLACEMENT 1. Wastegate actuator (6) to turbocharger assembly (1). 2. Bolts (75). Remove or Disconnect (Figure 14) 3. Hose (76) to wastegate actuator (8). 1. Passenger side wheelhouse panel. 4. Rod end (71) to pin (74). 2.
Page 315 7A1-1 SECTION 7A1 4L60 AUTOMATIC TRANSMISSION NOTICE: When fasteners are removed, a/ways reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 316 7A1-2 4L60 AUTOMATIC TRANSMlSSlON PRELIMINARY CHECK PROCEDURE PRELIMINARY CHECK PROCEDURE CHECK TRANSMISSION FLUID LEVEL CHECK AND ADJUST T.V. CABLE CHECK OUTSIDE MANUAL LINKAGE AND CORRECT CHECK ENGINE TUNE INSTALL PRESSURE GAGE CONNECT TACHOMETER TO ENGINE (A) ATTACH PRESSURE GAUGE CHECK PRESSURE AS FOLLOWS: Minimum T.V.
Page 317 4L60 AUTOMATIC TRANSMISSION 7A1-3 ELECTRICAL WIRING DIAGRAM For electrical wiring diagram refer to figure 3. V1802 Figure 3 - Wiring Diagram - Type 4 ON-VEHlCLE SERVICE FLYWHEEL AND TORQUE Manual Sonoma and Jimmy Models after removing the CONVERTER VIBRATION TEST front propeller shaft (refer to PROPELLER SHAFT [SEC.
Page 318 7A1-4 4L60 AUTOMATIC TRANSMISSION SHIFT CONTROLS AND LINKAGE SHIFT CONTROL CABLE 2ND APPLY PISTON & HOUSING APPLICATION Remove or Disconnect (Figure 6) 1. Negative (-) battery cable. Raise and suitably support vehicle as described in GENERAL INFORMATION (SEC. 0A) in the 1992 Service Manual Sonoma and Jimmy Models.
Page 319 4L60 AUTOMATIC TRANSMISSION 7A1-5 1. Indicator 2. Bolt 3. Clip 4. Bracket 5. Oil Filler Tube 6. Seal 35. Transmission V1438 Figure 5 - Oil Filler Tube Replacement (Syclone and Typhoon) Tighten Important Floorshift control screws (16) to 10 N•m (69 in. Lever must be held out of “PARK”...
Page 320 7A1-6 4L60 AUTOMATIC TRANSMISSION A. Typhoon B. Syclone and Sonoma GT 7. Clip 8. Cotter Pin 9. Nut 10. Shift Control Cable 17. Floorshift Control 33. Clip 34. Retainer 35. Transmission 46. Speed Sensor Harness 49. Fuel Line 59. Guide 60.
Page 321 4L60 AUTOMATIC TRANSMISSION 7A1-7 6. Fog lamp relay as described in LIGHTING SYSTEMS (SEC. 8B) in the 1992 Service Manual Sonoma and Jimmy Models. Lower steering column by removing nuts. 7. Park/lock cable (19) from steering column switch (22) by slipping a screwdriver blade into the slot provided in the steering column switch (22) and depressing the cable latch.
Page 322 7A1-8 4L60 AUTOMATIC TRANSMISSION A. Carrier Tang 25. Neutral Start and Backup Lamp Switch 26. Gage Pin 27. Nut 28. Mounting Stud 29. Electrical Connector 30. Detent Plate V1780 Figure 9 - Neutral Start and Backup Lamp Switch 2. Console. Refer to INTERIOR TRIM (SEC. 10A4) in 1.
Page 323 4L60 AUTOMATIC TRANSMISSION 7A1-9 Move shift control lever out of “NEUTRAL” to shear Important plastic pin. After neutral start and backup lamp switch adjust- 3. Gage pin (26). ment, verify that engine will only start in “PARK” or 4. Console. Refer to INTERIOR TRIM (SEC. 10A4) in “NEUTRAL.”...
Page 324 7A1-10 4L60 AUTOMATlC TRANSMISSION 43. Strap 2. Bolt 44. Bolt 5. Oil Filler Tube 45. Vent Hose 35. Transmission 46. Speed Sensor Harness 38. Stud 47. Nut 39. Bolt 48. Oil Cooler Line 40. Nut 49. Fuel Line 41. Bracket 50.
Page 325 4L60 AUTOMATIC TRANSMISSION 7A1-11 2. Bracket (41). Install studs (38) through transmission (35) to engine. Tighten Studs (38) to 47 N•m (35 ft. Ibs.). Install bracket (41) over studs (38) and install nuts (40) over bracket (41). Tighten Nuts (40) to 30 N•m (22 ft. Ibs.). 3.
Page 326 7A1-12 4L60 AUTOMATIC TRANSMISSION 3. Screws (53) connecting indicator assembly to plate Tighten (51). Screws (53) to 2 N•m (18 in. Ibs.). Tighten 5. Plate assembly. Refer to INTERIOR TRIM (SEC. 10A4) in this manual. Screws (53) to 2 N•m (18 in. Ibs.). 4.
Page 327 7D-1 SECTION 7D TRANSFER CASE SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 328 7D-2 TRANSFER CASE IDENTIFICATION The identificaton tag is an aluminum tag attached under one of the self tapping case bolts. The tag provides the Borg Warner part number, the General Motors part number, serial number and the build date. The information on the tag is necessary when servicing this transfer case.
Page 329 TRANSFER CASE 7D-3 ON-VEHlCLE SERVICE FLUID CHANGE Fill the transfer case until the fluid level is at the bottom of the filler plug hole. Remove or Disconnect (Figure 2) 3. Fill plug (18). Raise and suitably support vehicle as described in Tighten GENERAL INFORMATION (SEC.
Page 330 7D-4 TRANSFER CASE Speed Sensor 9. Extension Housing 13. Breather Assembly 16. Vent Hose 19. Clip 20. Vent Tube 44. Fuel Line 45. Bracket Bolt Clip Bolt 57. Speed Sensor Connector 58. Brace 59. Strap Figure 3 - Vent Hose Replacement 9.
Page 331 TRANSFER CASE 7D-5 7. Speed Sensor Bolt 8. Speed Sensor 9. Extension Housing 10. Rear Case Half 9. Extension Housing 12. Extension Housing Bolt 14. Rear Output Shaft Oil Seal Seal 14. Rear Output Shaft Oil 25. Water Drain 20. Vent Tube 26.
Page 332 7D-6 TRANSFER CASE TRANSFER CASE BRACE AND Tighten BRACKET REPLACEMENT Extension housing bolts (12) to 47 N•m (35 ft. Ibs.). Remove or Disconnect (Figure 8) 3. Vent tube (20). Raise and suitably support vehicle as described in 4. Speed sensor (8) and speed sensor connector (57). GENERAL INFORMATION (SEC.
Page 333 TRANSFER CASE 7D-7 Inspect Install or Connect (Figure 8) Gasket surfaces making sure that they are NOTICE: See “Notice” on page 7D-1 of this sec- clean and free of grease and oil. tion for steps 4, 5, 7 and 8. 1.
Page 334 7D-8 TRANSFER CASE 4. Transfer case adapter (30). Rear propeller shaft as described in PROPELLER SHAFT (SEC. 4A) in the 1992 Service Manual 5. Transfer case adapter seal (29). Sonoma and Jimmy Models. Install or Connect (Figures 8 and 9) Fill the transfer case with the proper fluid as described in MAINTENANCE AND LUBRICATION (SEC.
Page 335 TRANSFER CASE 7D-9 1. Front Output Flange Nut 23. Planet Carrier Assembly Thrust Washer 2 . Steel Flat Washer 24. Output Shaft Assembly 3 . Rubber Sealing Washer 25. Extension Housing Bolts 4. Front Output Shaft 27. Output Shaft Bearing Snap Ring 5 .
Page 336 7D-10 TRANSFER CASE 19. Input Shaft 20. Viscous Clutch 21. Sun Gear Shaft Thrust Washer 22. Planet Carrier Assembly 23. Planet Carrier Assembly Thrust Washer 1. Front Output Flange Nut 24. Output Shaft Assembly 2. Steel Flat Washer 25. Extension Housing Bolts 3.
Page 337 TRANSFER CASE 7D-11 15. Magnet 18. Sun Gear Shaft 19. Input Shaft A. Tab Locations F7567 Figure 14 - Removing the Input Shaft Figure 12 - Tab Locations 24. Output Shaft Assembly 27. Output Shaft Bearing Snap Ring 28. Output Shaft Bearing 37.
Page 338 7D-12 TRANSFER CASE 16. Drive Sprocket Spacer 17. Drive Sprocket 18. Sun Gear Shaft 20. Viscous Clutch 24. Output Shaft Assembly 33. Sun Gear Shaft Bearing 38. Input Shaft Pilot Bearing F7603 V1420 Figure 16 - Removing the Input Pilot Shaft Bearing Figure 10 - Installing the Sun Gear Shaft Components 3.
Page 339 TRANSFER CASE 7D-13 24. Output Shaft Assembly 38. Input Shaft Pilot Bearing F7604 Figure 21 -installing the Output Shaft Bearing Figure 19 - Installing the Input Shaft Pilot Bearing Snap Ring 10. Rear Case Half 39. Output Shaft Rear Bearing F7607 Figure 22 - Installing the Output Shaft Rear Bearing 1.
Page 340 7D-14 TRANSFER CASE A. Water Drain B. Drain Groove F7610 Figure 25 - Alignment of the Oil Seal 10. Rear Case Half 24. Output Shaft Assembly 27. Output Shaft Bearing Snap Ring 28. Output Shaft Bearing 42. Oil Scoop F7608 Figure 23 - Installing the Output Shaft Bearing Snap Ring 21.
Page 341 TRANSFER CASE 7D-15 4. Front Output Shaft A. Sun Gear Shaft Assembly 12. Front Output Shaft Spacer 22. Planet Carrier Assembly V1474 F7612 Figure 29 - Installing the Front Output Shaft Spacer Figure 27 - Installing the Sun Gear Shaft Assembly 1.
Page 342 7D-16 TRANSFER CASE 16. Front cover (11) and front cover bolts (9) to the rear 19. Front output flange (5) to the front output shaft (4). case half (10). 20. Rubber sealing washer (3), steel flat washer (2) and a new front output flange nut (1).
Page 343 TRANSFER CASE 7D-17 SPECIAL TOOLS J 37668-A J 22912-01 J 23907 J 38216 J 2619-01 J 29369-1 1. Bearing Remover 2. Puller J 7079-2 3. Slide Hammer 4. Output Shaft Searing Remover 5. Driver Handle 6. Needle Bearing Installer 7. Seal Installer J 38212 8.
Page 345 8A-1 SECTION 8A CAB ELECTRICAL CONTENTS P A G E P A G E SUBJECT Cab Harnesses and Components ..............8A-1 Instrument Panel Harnesses.
Page 346 8A-2 CAB ELECTRICAL 90. Convenience Center 92. Fuse Block 99. Instrument Panel Lamp Dimmer Switch Connector 100. Headlamp Switch Connector 101. Parking Brake Switch Connector 105. AC/Heater Harness Connector 106. Stoplamp Switch 107. Left Door Harness Connector (For Jam Switch) 108.
Page 347 CAB ELECTRICAL 8A-3 108. Stoplamp Switch Connector 109. TCC Switch Connector 111. Windshield Wiper and Washer Switch Connector 122. Rear Window Defogger Switch 124. Rear Window Release Relay 127. Rear Speaker Connector 128. Brake Pedal Bracket 99. Instrument Panel Lamp Dimmer 129.
Page 348 8A-4 CAB ELECTRICAL 91. AC/Heater Control Panel 93. Compartment Lamp 94. Radio 95. Ash Tray Lamp 96. Cigar Lighter Connector 97. Cigar Lighter 98. AC/Heater Control Panel Lamp Connector 102. Console Harness Connector 103. Bus Bar Ground Terminal 104. DRAC Connector 107.
Page 349 CAB ELECTRICAL 8A-5 93. Compartment Lamp 131. Rear Speaker Connector 95. Ash Tray Lamp 132. Power and Front Speaker 104. DRAC Connector Connector 112. Courtesy Lamp 133. Clock Connector 113. Glove Box Lamp Connector 134. Rear Window Release 114. Engine Harness Connector 125.
Page 350 8A-6 CAB ELECTRICAL 92. Fuse Block 120. ALDL Connector 116. Steering Column 121. Safety Belt Retractor 117. Dimmer Switch Connector Switch Connector 118. Lap Cooler Duct 123. Ignition Switch Connector 119. Turn Signal Switch Connector V3212 Figure 5 - Instrument Panel Harness-Steering Column...
Page 351 8B-1 SECTION 8B LIGHTING SYSTEMS CONTENTS SUBJECT PAGE Description ................. . 8B-1 Backup Lamp System .
Page 353 8C-1 SECTION 8C INSTRUMENT PANEL AND GAGES NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 354 8C-2 INSTRUMENT PANEL AND GAGES TURBO BOOST GAGE gage receives a signal input from the manifold absolute pressure (MAP) sensor. The ECM also receives input from SYCLONE AND TYPHOON the MAP sensor, which is connected to the intake manifold. Turbo boost is controlled by a wastegate solenoid which is The boost gage displays intake manifold pressure.
Page 355 INSTRUMENT PANEL AND GAGES 8C-3 8. Odometer 9. Trip Odometer 15. Tachometer/ Turbo Boost Gage Case 20. Cluster Retaining Screw 21. Lens Retaining Screw V1783 Figure 2 - Instrument Cluster (Syclone and Typhoon) 8 . Odometer 9. Trip Odometer 16. Tachometer 20.
Page 356 8C-4 INSTRUMENT PANEL AND GAGES Install or Connect (Figures 2 through 5) 1. Instrument cluster (11). 2. Nuts (10) to instrument cluster (11). 3. Instrument cluster housing (12). 4. Nuts (10) to instrument cluster housing (12). 5. Filler panel (14). 6.
Page 357 INSTRUMENT PANEL AND GAGES 8C-5 1. Instrument Panel 10. Nut 11. Instrument Cluster 12. Instrument Cluster Housing 13. Screw 14. Filler Panel V1490 Figure 5 - Instrument Panel Components...
Page 359 9A-1 SECTION 9A AUDIO SYSTEMS CONTENTS SUBJECT PAGE Description ................. . 9A-1 On-Vehicle Service .
Page 361 9B-1 SECTION 9B CRUISE CONTROL SYCLONE AND TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 362 9B-2 CRUISE CONTROL Cruise Control Vacuum Hose Vacuum Tank Hose Battery Tray Vacuum Tank Servo V1742 Figure 1 - Cruise Control Vacuum Hose Routing...
Page 363 9K-1 SECTION 9K REMOTE KEYLESS ENTRY TYPHOON NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 364 9K-2 REMOTE KEYLESS ENTRY When the “END GATE RELEASE” symbol is depressed, TO LOCK DOORS Press the “DOOR KEY” symbol to lock all the doors at the rear glass is unlocked from the end gate. once. DlAGNOSlS OF THE KEYLESS ENTRY SYSTEM Refer to the Sonoma GT/Syclone/Typhoon Models Elec- trical Diagrams and Diagnosis Manual, the last section in this manual.
Page 365 REMOTE KEYLESS ENTRY 9K-3 20. Brace Assembly 29. Bolt Remote Keyless Entry Connector 30. Bolt 21. Bolt 38. Remote Keyless Entry Receiver 31. Plate Assembly Power Auxiliary Outlet 32. Bolt 41. Console Bin 33. Electrical Connector Screw 25. Bolt 34. Console Assembly Screw 26.
Page 366 9K-4 REMOTE KEYLESS ENTRY 2. Jumper program connector terminal “A”. (BLK/ WHT) to terminal “G” (PPL) on assembly line diag- nostic link (ALDL) connector (40). Door locks will lock and unlock in approximately two seconds (figure 4). 3. Press “UNLOCK” button on transmitter. Door lock will lock and unlock in approximately two seconds.
Page 367 9O-1 SECTION 9O TONNEAU COVER SONOMA GT AND SYCLONE NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener Is not available, a fastener of equal size and strength (or stronger) may be used.
Page 368 9O-2 TONNEAU COVER Large Bracket Short Bracket V1450 Figure 1 - Tonneau Frame and Brackets Position rear rail so that inside of rail is flush with inside of end gate. Position side rail so that the distance from side rail to outside edge of truck is approximately equal to dis- tance from rear rail to outside edge of end gate.
Page 369 TONNEAU COVER 9O-3 2. Bow 3. Hairpin 4. Bolt 5. Large Bracket 6. Short Bracket 7. Spacer 8. Nut V1452 Figure 3 - Brackets...
Page 370 9O-4 TONNEAU COVER 12. Cover. ends, put slight pressure outward in the center of rail and tighten all bolts. Front and rear rails Stretch cover over bows (2) to rear of vehicle. should have a slight outward bow of 3.2-6.4 mm Snap 2 snaps on each corner.
Page 371 10A1-1 SECTlON 10A DOORS SYCLONE AND TYPHOON NOTICE: When fasteners are removed, a/ways reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener Is not available, a fastener of equal size and strength (or stronger) may be used.
Page 372 10A1-2 DOORS 1. Molding 2. Retainer 3. Clip 4. Rivet 5. Door V1751 Figure 1 - Door Molding (Left Door Shown, Right Door Similar)
Page 373 10A2-1 SECTION 10A2 SEATS SYCLONE AND TYPHOON CONTENTS PAGE SUBJECT On-Vehicle Service ................10A2-1 Lumbar Component and Seatback Cover Replacement .
Page 374 10A2-2 SEATS 10A2-2 SEATS A. Zipper 1. Bulb/Valve Assembly 2. Lumbar Hose 3. Seat Cushion Cover 4. Retainer Ring 5. Bladder 6. Seat Cover 7. Rod 8. Retainer Ring V1810 Figure 1 - Lumbar Components...
Page 375 10A4-1 SECTION 10A4 INTERIOR TRIM NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 376 10A4-2 lNTERlOR TRIM 20. Brace Assembly 21. Bolt 22. Nut 23. Nut 24. Nut 25. Bolt 26. Floor Pan 27. Cable 28. Console Assembly 29. Bolt 30. Bolt 31. Plate Assembly 32. Bolt 33. Electrical Connector 35. Floor Patch Assembly V1768 Figure 2 - Console Assembly (Sonoma GT and Syclone)
Page 377 INTERIOR TRIM 10A4-3 20. Brace Assembly 21. Bolt 25. Bolt 26. Floor Pan Cable 29. Bolt 30. Bolt 31. Plate Assembly 32. Bolt 33. Electrical Connector 34. Console Assembly 35. Floor Patch Assembly 36. Power Auxiliary Outlet Connector 37. Remote Keyless Entry Connector 38.
Page 378 10A4-4 INTERIOR TRIM 15. Snap ring (3). Install or Connect (Figures 1, 2 and 3) 16. Shifter button (1) with spring (2). NOTICE: For steps 2, 3, 8, 9 and 13 see “Notice” on page 10A4-1 of this section. POWER AUXILIARY OUTLETS Brace assembly (20) to floor pan (26).
Page 379 lNTERlOR TRIM 10A4-5 SPECIAL TOOLS 1. Door Trim Pad and Garnish Clip Remover V1460...
Page 381 INDEX-1 PAGE SECTION PAGE SECTION A/C Clutch Circuit Diagnosis... 6E3-C10-1 Cab Electrical ..... 8A-1 A/C Request Signal .
Page 382 2-INDEX SECTION PAGE SECTION PAGE Differential Carrier Assembly Replacement. 4C-3 Electronic Level Control Residual Air Check 3D1-3 Differential Carrier Bushing Replacement . . 4C-7 Electronic Level Control Shield, Differential Fluid Fill and Check ..4C-1 Compressor and Bracket.
Page 383 INDEX-3 SECTION PAGE SECTION PAGE Fluid Capacities....0B-5 Fuel System Inspection ....6C-5 Fluid Change, Transfer Case.
Page 384 4-INDEX SECTION PAGE SECTION PAGE Information Sensors ....Meter, Fuel Level....6C-3 6E3-C1-2 Inspections and Services, Owner .
Page 385 INDEX-5 SECTION PAGE SECTION PAGE Pressure Regulator, Fuel, On-Vehicle Starting Mode..... 6E3-C2-1 Service ......6E3-C2-6 Steering Gear Replacement .
Page 386 6-INDEX SECTION PAGE SECTION PAGE Trim, Interior..... . 10A4-1 Vapor Pipe, On-Vehicle Service..6E3-C3-3 Tube Assembly Replacement, Evaporator .
Page 387 SONOMA GT SYCLONE TYPHOON ELECTRICAL DIAGRAMS DIAGNOSIS MANUAL The information provided in this supplement includes the complete engine wiring harness and a partial instrument panel wiring harness for the 1992 Syclone and Typhoon models. Also included are the Typhoon- specific power door lock, remote keyless entry and electronic level control harnesses. All of the components and harnesses shared by the Sonoma GT, Syclone or Typhoon and the Sonoma or Jimmy may not appear in this supplement.
Page 389 1992 SONOMA GT/ SYCLONE/TYPHOON Page Symptom lndex ................General Description .
Page 390 BLANK...
Page 391 S Y M P T O M I N D E X REMOTE KEYLESS ENTRY (TYPHOON) Some or all transmitter functions are SYMPTOM PAGE inoperative......18 Interior lamps do not turn on with C H A R G I N G transmitter unlock function .
Page 392 BLANK...
Page 393 CIRCUIT OPERATION The circuit operation for the starting and charging circuits is the same as described in the 1992 Electrical Diagrams and Diagnosis Sonoma and Jimmy Models Manual. DIAGNOSIS - STARTING AND CHARGING BATTERY IS UNDERCHARGED OR OVERCHARGED TEST RESULT ACTION Disconnect generator connector Battery voltage.
Page 394 ENGINE DOES NOT CRANK AND STARTED SOLENOID DOES NOT CLICK TEST RESULT ACTION 1. Place transmission in PARK. Battery voltage. GO to step 2. Connect a voltmeter from PPL (6) No voltage. GO to step 3. wire at starter motor solenoid to ground.
Page 395 CIRCUIT OPERATION The circuit operation for the digital ratio adapter controller (DRAC) is the same as described in the 1992 Electrical Diagrams and Diagnosis Sonoma and Jimmy Models Manual. DIAGNOSIS - DIGITAL RATIO ADAPTER CONTROLLER SPEED SENSOR COMPONENTS DO NOT OPERATE PROPERLY TEST RESULT ACTION...
Page 396 CIRCUIT OPERATION This time limit is necessary to prevent continuous compressor operation in case of a severe system leak or ELECTRONIC LEVEL CONTROL continuous vent. Turning the ignition switch to “OFF” (TYPHOON) and back to “RUN” resets the 3½ minute maximum run The Electronic Level Control (ELC) keeps the rear of time.
Page 397 DIAGNOSIS - ELECTRONIC LEVEL CONTROL (TYPHOON) PRELIMINARY CHECKS: 1. Check to see that the ELC fuse is not blown. Replace 3. Remove load from passenger compartment. After 8 if blown. to 15 seconds the ELC system should vent and lower 2.
Page 398 ELC SYSTEM DOES NOT VENT TO LOWER REAR OF VEHICLE RESULT ACTION TEST 1. Disconnect connector C472 from Solenoid clicks and vents air. CHECK for poor connections at C473. Connect a fused jumper connector C472 and Actuator from WHT (320) at connector Arm for binding or damage.
Page 399 CIRCUIT OPERATION VOLTMETER The voltmeter indicates battery voltage with the igni- CLUSTER ILLUMINATION tion switch in RUN and the engine not running. With the The cluster illumination lamps are powered by the engine running, the voltmeter indicates generator panel and interior lamps control switch through the INST output.
Page 400 BRAKE INDICATOR FASTEN SAFETY BELT WARNING Ground to light the BRAKE indicator is provided in INDICATOR one of four ways. When the ignition switch is turned to Battery voltage is applied to the FASTEN SAFETY RUN, the antilock brake module provides a ground to BELT warning indicator for four to eight seconds when the indicator for about two seconds through the TAN/ the ignition switch is in RUN, BULB TEST or START, by...
Page 401 DIAGNOSIS - INSTRUMENT PANEL CLUSTER The instrument panel cluster is not serviceable. If PRELIMINARY CHECKS: any component is defective, the entire cluster must be 1. CHECK condition of IGN/GAUGES fuse. Replace if replaced. blown. For diagnosis of the Fuel Gage, Coolant Tempera- 2.
Page 402 CIRCUIT OPERATION provided at the Remote Keyless Entry Module terminal C through internal contacts. Ground for the other door POWER DOOR LOCKS/REMOTE KEYLESS lock motor is provided through the contacts of the ENTRY (TYPHOON) UNLOCK Switch, inside the Door Lock Relay. All door The power door locks/remote keyless entry control lock motors run to lock all doors.
Page 403 DIAGNOSIS - POWER DOOR LOCKS (MANUAL OPERATION) (TYPHOON) PRELIMINARY CHECK: 1. CHECK to see that PWR/ACC circuit breaker is reset- ting. Replace if not resetting. POWER DOOR LOCK/UNLOCK FUNCTION INOPERATIVE TEST RESULT ACTION 1. Disconnect connector C345 from Test lamp does not light. LOCATE and REPAIR open in door lock relay.
Page 404 LH OR RH DOOR LOCK SWITCH DOES NOT OPERATE TEST RESULT ACTION 1. Connect a test lamp from Test lamp does not light. LOCATE and REPAIR open in ORN/BLK (60) wire at LH or RH ORN/BLK (60) wire from affected door lock switch connector C502 door lock switch to fuse block.
Page 405 LH OR RH DOOR LOCK MOTOR DOES NOT UNLOCK TEST RESULT ACTION 1. Connect a test lamp from TAN Test lamp does not light at RH GO to step 2. (294) wire at LH or RH door lock door lock motor. motor connector C503 or C603 to Test lamp does not light at LH GO to step 3.
Page 406 DIAGNOSIS - REMOTE KEYLESS ENTRY (TYPHOON) 4. REPLACE batteries in non-functioning transmitter. PRELIMINARY CHECKS: CHECK transmitter functions. If transmitter functions 1. CHECK manual operation of the lock and unlock do not operate, OBTAlN a known functioning trans- functions of BOTH the right and left power door locks. mitter.
Page 407 INTERIOR LAMPS DO NOT TURN ON WITH TRANSMITTER UNLOCK FUNCTION TEST RESULT ACTION LOCATE and REPAIR open in 1. Disconnect connector C386 from Interior lamps do not turn on. WHT (156) wire. remote keyless entry receiver. Using a jumper wire, jumper GO to step 2.
Page 408 BULB DATA Quantity Trade No. Lamp Usage Fog Lamps Direction Signal Indicator Lamp Hi Beam Indicator Lamp Brake Indicator Lamp Low Turbo Coolant Indicator Lamp (Syclone/Typhoon) Antilock Indicator Lamp (Syclone/Typhoon) I/P Illumination Lamp PRNDL Illumination Lamp Fasten Safety Belt Indicator Lamp Check Engine Indicator Lamp Check Gages Indicator Lamp 20 BULB DATA...
Page 409 COMPONENT LOCATION Page-Figure A/C Compressor....... . RH front side of engine, at AC compressor..20-7 A/C Compressor Control relay .
Page 410 COMPONENT LOCATOR INDEX RH side of intake manifold ....23-9 C170 ........RH side of dash panel (engine compartment).
Page 411 COMPONENT LOCATOR INDEX Engine Control Module (ECM) ..... Behind RH side of I/P ..... . .25-11 Four-Wheel Antilock Brake Module .
Page 412 COMPONENT LOCATOR INDEX S123 ........Center rear of engine, near distributor .
Page 413 CIRCUIT WIRE COLOR C A V I T Y DESCRIPTION SIZE NOT USED NOT USED NOT USED 5V MAP REFERENCE 5V TPS REFERENCE PNK/BLK 12V IGNITION (FUSED) NOT USED NOT USED ALDL SERIAL DATA NOT USED GRN/WHT FUEL PUMP RELAY CONTROL BLK/WHT SYSTEM GROUND 12V BATTERY (FUSED)
Page 414 CIRCUIT WIRE C A V I T Y C O L O R DESCRIPTION SIZE NOT USED NOT USED NOT USED NOT USED NOT USED DRAC SIGNAL TAN/BLK EST BY PASS EST CONTROL DK GRN A/C SIGNAL NOT USED INJECTOR 2, 4, 6 DRIVER INJECTOR 1, 3, 5 DRIVER BLK/WHT INJECTOR GROUND...
Page 415 CIRCUIT WIRE C O L O R C A V I T Y DESCRIPTION SIZE NOT USED NOT USED LT GRN/WHT IAC COIL B LOW LT GRN/BLK IAC COIL B HIGH BLU/BLK IAC COIL A LOW LT BLU/WHT IAC COIL A HIGH GRA/WHT CHECK ENGINE LAMP CONTROL CAC CONTROL...
Page 416 1. Throttle Position Sensor (TPS) 2. Idle Air Control (IAC) 3. Injector-4 4. Injector-2 5. Fusible Links 6. 10 AMP Fuse (In Line) 7. Coolant Temperature Sensor for ECM 8. Waste Gate Solenoid 9. To Starter Motor 10. Oxygen Sensor V1865 Figure 4 - Right Front Engine Harness-4.3L Turbo (Syclone and Typhoon) 28 COMPONENT LOCATOR VIEWS...
Page 417 1. 10 AMP Fuse 2. Manifold Absolute Temperature (MAT) Sensor 3. Manifold Absolute Pressure (MAP) Sensor 4. Coil 5. Electronic Vacuum Regulator Valve (EVRV) Solenoid 6. Coolant Temperature Sender for Gage 7. Fusible Links 8. Coolant Temperature Sensor for ECM Figure 5 - Left Front Engine Harness-4.3L Turbo (Syclone and Typhoon) COMPONENT LOCATOR VIEWS 29...
Page 418 1. Oil Pressure Switch 2. Coil 3. Charge Air Cooler (CAC) Pump Relay 4. Turbo Boost Cut-Out Relay 5. To Junction Block 6. Electronic Spark Timing (EST) Distributor 7. Electronic Spark Control (ESC) Knock Sensor V1793 Figure 6 - Rear Engine Harness-4.3L Turbo (Syclone and Typhoon) 30 COMPONENT LOCATOR VIEWS...
Page 419 1. A/C Compressor 2 . Generator 3 . Battery 4. Starter Motor Solenoid 5. To Positive Battery Terminal 6. To Fusible Links 7. To 10 AMP Fuse V1857 Figure 7 - Battery Cable Routing-4.3L Turbo (Syclone and Typhoon) COMPONENT LOCATOR VIEWS 31...
Page 420 1. Transmission Converter Clutch Solenoid 2. Vehicle Speed Sensor V1626 Figure 8 - Rear Engine Harness at Transmission-4.3L Turbo (Syclone and Typhoon) 1. Injector-5 2. Injector-3 3. Injector-1 4. Injector-2 5. Injector-4 6. Injector-6 V1627 Figure 9 - Injector Sub Harness-4.3L Turbo (Syclone and Typhoon) 32 COMPONENT LOCATOR VIEWS...
Page 421 1. Parking Brake Switch Convenience Center TCC/Stoplamp Switch V1750 Figure 10 - Instrument Panel Harness-Left Side (Sonoma GT and Syclone) COMPONENT LOCATOR VIEWS 33...
Page 422 1. Parking Brake Switch 2. Convenience Center 3. TCC/Stoplamp Switch 4. Brake Pedal Bracket 5. Cigar Lighter 6. AC/Heater Control Panel 7. Rear Speaker Connector 8. Rear Window Defogger Relay 9. Rear Window Defogger Switch V3202 Figure 11 - Instrument Panel Harness-Left Side (Typhoon) 34 COMPONENT LOCATOR VIEWS...
Page 423 1. Courtesy Lamp 2 . I/P Compartment Lamp 3. Ash Tray Lamp 4. A/C Heater Control 5 . Busbar Ground 6 . Digital Ratio Controller Adaptor (DRAC) 7. Engine Control Module (ECM) 8 . Clock Connector 9 . Rear Speaker Connector 10.
Page 424 1. Courtesy Lamp 2. I/P Compartment Lamp 3. Ash Tray Lamp 4. Rear Speaker Connector 5. Power and Front Speaker Connector 6. Digital Ratio Controller Adaptor (DRAC) 7. Engine Control Module (ECM) 8. Rear Window Release Connector 9. AC/Heater Harness Assembly 10.
Page 427 ENGINE WIRING HARNESS (SYCLONE/TYPHOON) 37...
Page 428 38 ENGINE WIRING HARNESS (SYCLONE/TYPHOON)
Page 429 ENGINE WIRING HARNESS (SYCLONE/TYPHOON) 39...
Page 430 40 ENGINE WIRING HARNESS (SYCLONE/TYPHOON)
Page 431 ENGINE WIRING HARNESS (SYCLONE/TYPHOON) 41...
Page 432 42 ENGINE WIRING HARNESS (SYCLONE/TYPHOON)
Page 433 ENGINE WlRlNG HARNESS (SYCLONE/TYPHOON) 43...
Page 434 44 INSTRUMENT PANEL WIRING HARNESS (SYCLONE)
Page 435 INSTRUMENT PANEL WIRING HARNESS (SYCLONE) 45...
Page 436 46 INSTRUMENT PANEL WIRING HARNESS (SYCLONE)
Page 437 INSTRUMENT PANEL WIRING HARNESS (SYCLONE) 47...
Page 438 48 INSTRUMENT PANEL WIRING HARNESS (SYCLONE)
Page 439 INSTRUMENT PANEL WIRING HARNESS (TYPHOON) 49...
Page 440 50 INSTRUMENT PANEL WIRING HARNESS (TYPHOON)
Page 441 INSTRUMENT PANEL WIRING HARNESS (TYPHOON) 51...
Page 442 52 INSTRUMENT PANEL WIRING HARNESS (TYPHOON)
Page 443 INSTRUMENT PANEL WIRING HARNESS (TYPHOON) 53...
Page 444 54 INSTRUMENT CLUSTER WIRING HARNESS (SONOMA GT)
Page 445 LEFT DOOR HARNESS (TYPHOON) 55...
Page 446 56 LEFT DOOR HARNESS/CROSS-BODY HARNESS (TYPHOON)
Page 447 CROSS-BODY HARNESS (TYPHOON) 57 CROSS-BODY HARNESS (TYPHOON) 57...
Page 448 58 CROSS-BODY HARNESS/RIGHT DOOR HARNESS (TYPHOON)
Page 449 RIGHT DOOR HARNESS (TYPHOON) 59...
Page 450 60 REMOTE KEYLESS ENTRY HARNESS (TYPHOON)
Page 451 ELECTRONIC LEVEL CONTROL HARNESS (TYPHOON) 61...
Page 452 WASTEGATE SOLENOID ENGINE VACUUM HARNESS (SYCLONE/TYPHOON)
Page 454 X-9276...

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Typhoon 1992 Sonoma gt 1992