130089008B

Bulletin No.:
Service Bulletin
Date:
13-00-89-008B
August, 2019
INFORMATION
Subject:
GM Wiring Repair Strategy Information
Models:
2009-2020 GM Passenger Cars and Trucks — Excluding Chevrolet Low Cab Forward
Trucks
2019-2020 Chevrolet Silverado 4500HD, 5500HD, 6500HD
2009-2020 Holden Vehicles
Attention: This Bulletin applies to any of the above models that may be Export from
North America vehicles.
This Bulletin has been revised to add Model Years 2016-2020, add MY2009-2020 Holden
Vehicles, add an Important statement regarding the phasing out of the service terminals,
tray, core and insulation crimps, communicate Wiring, Connector and Terminal repair
changes, change CCA Parts to EPC, add a Coaxial Cable Repair section, add the process and
graphics to find the part number in SI and the process and graphics to find the part in the
Electronic Parts Catalog (EPC). Please discard Corporate Bulletin Number 13-00-89-008A.
Overview
Important: For newer GM Cars and Trucks, the
service terminals, tray, core and insulation crimps
are being phased out. The process to repair
machine crimped terminals cannot be duplicated
reliably in the Service environment and is no longer
a viable repair option. The use of a terminated lead
or a Pigtail (8-way or less connector) is the only
approved repair method going forward.
This bulletin provides a resource to find information,
processes and parts in order to perform wiring, terminal
and connector repairs.
Global Wiring Repair
Wiring Repair Strategy
The following is the global wiring repair strategy:
• Major Harnesses (Body, Engine, Instrument
Panel, Forward Lamp, etc.) are to be repaired
whenever possible.
• Minor Harnesses (door, seat, steering column,
etc.) are serviced as assemblies.
Copyright 2019 General Motors LLC. All Rights Reserved.
Strategy Consists of Four Different Repairs
The repairs consist of the following:
• Wire to Wire Repair
• Connector Assemblies (Pigtails)
• Connector Kits
• Terminated Lead Repair
This strategy was established to reduce the number of
individual part numbers needed to service GM vehicles,
as even small harnesses can have many different part
numbers for the individual connectors and terminals.
When new terminals or connectors are released within
the major harnesses they will be serviced through the
release of connectors, terminated leads, pigtails, kits,
etc., and are available through EPC.
For individual connectors that are 8-way or less, a fully
populated pigtail with the correct DuraSeal splice will
be available. For connectors that are 9-way or more,
the individual parts will be available via connector kits,
DuraSeal splices and terminated leads.
Page 2
August, 2019
Wiring Systems and Power
Management — Navigation — Repair
Instructions
Navigating to Repair Instructions
To navigate to the Repair Instructions section in Service
Information, enter a VIN then click ‘Next’. Go to >
Power and Signal Distribution > Wiring Systems and
Power Management > Repair Instructions
OR
To navigate to the Repair Instructions section in Service
Information without a VIN, Go to Year > Make > Model
> ‘Next” > Service Manual > Power and Signal
Distribution > Wiring Systems and Power Management
> Repair Instructions.
At the Repair Instructions screen a search can be
performed for a specific repair, for example: Flat Wire
Repair, Wire to Wire Repair etc.
Repair Instructions
The Repair Instructions contain the following types of
wiring repair information:
• Flat Wire Repairs
• Fold Over Wire Repair
• Serial Data Circuit Wiring Repairs
• High Temperature Wiring Repairs
• Heated Oxygen Sensor Wiring Repairs
• Wire to Wire Repair
• Splicing Twisted or Shielded Cable
• SIR/SRS Wiring Repairs
• Terminal Removal
• Serial Data Circuit Wiring Repairs (consists of the
following repairs):
– GMLAN Repairs
– GMLAN Connector Terminal Repairs
– GMLAN Wire Repairs
– Media Oriented Systems Transport (MOST)
Wiring Repair
– Ethernet Wiring Repair
Coaxial Cable Repairs
The coaxial (coax) cable repair strategy uses coaxial
cables, connectors and jumpers to repair coaxial
cables. The intent is to install the new service cable in
the vehicle, with removal of the old cable not being
necessary.
The following are several repair scenarios:
• New cables, jumpers, and connector housing are
required.
• Only new cables are required while it is possible to
reuse the existing connector housing in vehicle. A
jumper may or may not be needed.
•
•
Bulletin No.: 13-00-89-008B
Only new connector housing are required, while it
is possible to reuse the existing cable in the
vehicle.
A new cable would need to be installed from
source to destination and by-pass the inline
connector in some cases when an inline
connector is unrepairable. For example: a cracked
male end of a 1-way connector.
Antenna Coax Repair Kits
Different kits are available to repair some antenna
coaxial cables. Refer to Bulletin 17-NA-346
Information on Antenna COAX Repair Kit
Availability in SI for Kit part numbers.
Obtaining Service Parts Using SI
and EPC
Navigating to Connector End Views in SI
Go to > Service Manual > Power and Signal
Distribution > Wiring Systems and Power Management
> Component Locator > Master Electrical Component
List > Connector End View (last column on the right)
At the Master Electrical Component List a search can
be performed for the electrical component being
serviced, for example the: K20 Engine Control Module.
Bulletin No.: 13-00-89-008B
August, 2019
Page 3
Finding the Correct Service Part Number in SI —
8-Way or Less Connectors
5378389
B75C Multifunction Air Intake Sensor — Connector
End View 8-Way
The Connector End View provides a view of the
connector and the connector part information, which is
just below and to the left of the Connector End View
drawing.
The Connector End View is presented two ways — the
legacy format typically associated with TIFF
viewer-supported graphics and the new format typically
associated with the new CGM viewer-supported
graphics. Connector dissassembly videos may be
provided to assist with repairs.
The Service Connector part number will be the part
number that needs to be ordered, while the OEM
Connector part number is what the vehicle should have
been built with. If the connector Description indicates it
is an 8-way or less, the part number will be a pigtail.
Tables Following Connector End View
The Terminal Part Information Table following the
Connector End View provides useful information
including the Diagnostic Test Probes, Terminal
Removal Tools and Terminated Leads to use.
The second Table (Code and Component Name Table,
if Titled) provides the Pin, Size, Color, Circuit, Function,
Terminal Type ID and Option.
Page 4
August, 2019
Bulletin No.: 13-00-89-008B
Terminal Part Information
Terminal
Type ID
Terminated
Lead
Diagnostic
Test Probe
Terminal
Removal Tool
Service Terminal
I
Not
Required
J-35616-64B
(LT BU)
No Tool Required
Not Required
Tray
Name
Core
Crimp
Insulation
Crimp
Not
Required
Not
Required
Not
Required
B75C Multifunction Intake Air Sensor
Function
Terminal
Type ID
Option
6289
Induction Air Temperature Sensor Signal
I
—
I
I
I
LFV
LKN
LTG
Pin
Size
Color
Circuit
1
0.5
WH/BU
2
0.5
0.5
0.5
BU/RD
BK/YE
GY/RD
460
6014
3053
Engine Control Sensors 5 Volt Reference (1)
Barometric Pressure Sensor Low Reference
Turbo Intake Pressure Sensor High Reference
Bank 1
3
0.5
0.5
BK/YE
BK/VT
548
2760
Engine Control Sensors Low Reference (1)
Intake Air Temperature Sensor Low Reference
I
I
LFV
LTG/LKN
4
0.5
0.5
BU/GY
YE
433
3054
Barometric Pressure Sensor Signal
Turbo Intake Pressure Sensor Signal Bank 1
I
I
LKN
LTG/LFV
5
0.5
VT/BU
5294
Powertrain Main Relay Fused Supply 5
I
—
6
0.5
GN/WH
492
Mass Air Flow Sensor Signal
I
—
7
0.75
BK/WH
151
Signal Ground
I
—
8
0.5
BN/GY
4008
Humidity Sensor Signal
I
—
Bulletin No.: 13-00-89-008B
August, 2019
Page 5
Finding the Correct Service Part Number — 9-Way
or More Connectors
5379076
K9 Body Control Module X1 — Connector End View
26-Way
The Connector End View provides a view of the
connector and the connector part information, which is
just below and to the left of the Connector End View
drawing. A Click Image For Video arrow will be shown
under the Connector End View if it is available.
The Connector End View is presented two ways — the
legacy format typically associated with TIFF
viewer-supported graphics and the new format typically
associated with the new CGM viewer-supported
graphics.
The Service Connector part number will be the part
number that needs to be ordered, while the OEM
Connector part number is what the vehicle should have
been built with. If the connector Description indicates it
is a 9-way or more it will be a connector kit.
Tables Following Connector End View
The Terminal Part Information Table following the
Connector End View provides useful information
including the Terminated Lead, Diagnostic Test Probe,
Terminal Removal Tool, Service Terminal, Tray Name,
Core Crimp and Insulation Crimp to use.
The second Table provides the Pin, Size, Color, Circuit,
Function, Terminal Type ID and Option.
Page 6
August, 2019
Bulletin No.: 13-00-89-008B
Terminal Part Information
Terminal
Type ID
Terminated
Lead
Diagnostic
Test Probe
Terminal
Removal Tool
Service Terminal
Tray
Name
Core
Crimp
Insulation
Crimp
I
13582297
J-35616-64B
(LT BU)
J-38125-215A
Not Available
Not
Available
Not
Available
Not
Available
II
13582298
J-35616-64B
(LT BU)
J-38125-215A
Not Available
Not
Available
Not
Available
Not
Available
III
13582326
J-3561635 (VT)
J-38125-553
8100-4444
Sumitomo
22
2
A
Terminal Part Information
Color
Terminal
Type ID
Option
Ground
III
—
Battery Positive Voltage
III
—
III
—
Pin
Size
Circuit
Function
1
1
BK
1850
2
1
RD/BU
4540
3
1
RD/GN
4440
Battery Positive Voltage
Note: This Table is a representative view and does not include all 26 Connector Pins.
these parts to help in confirming the correct parts are
ordered. Battery cables, infotainment cables and hoses
are also listed in the EPC.
Tip: GM is now releasing washer hoses as a
subassembly to the main harness when a hose is
imbedded in the harness. For example: The chassis
harness has a hose going to the rear wiper.
Video
Ordering Parts
Process for ordering part(s) in the EPC:
1. Go to > Service Manual > Power and Signal
Distribution > Wiring Systems and Power
Management > Component Locator > Master
Electrical Component List > Connector End View
(last column on the right) in SI.
2. Select the Connector End View being serviced.
5380982
Connector Repair Video Opening Screen
The video (if available) will illustrate how to use the
tools for probing and releasing the terminals with a
demonstration on the exact connector.
Electronic Parts Catalog
Overview
Continual updates to the EPC will allow better
searchability for wiring repair components. In addition,
pictures will be added when available to the EPC for
5381355
Bulletin No.: 13-00-89-008B
August, 2019
Page 7
3. Locate the Service Connector Number which is just
below and to the left of the Connector End View
drawing.
5385197
5381448
6. Select the Part Group Index.
Select 02.530 CONNECTOR-CONNECTOR
KIT-SEAL-TAPE-WIRE, Chassis Electrical
4. In the Electronic Parts Catalog (EPC) enter the VIN
for the vehicle OR select the Make, Year and
Model.
5385460
5381500
5. At the Major Group screen, select:
02 – STARTER - GENERATOR IGNITION_ELECTRICAL - LAMPS
7. Copy and paste the Service Connector Number
into the Type To Narrow search box.
Page 8
August, 2019
Bulletin No.: 13-00-89-008B
Terminal Test Probe Kit J-35616-F (EL-35616 Global
Tool Number)
5386219
8. Typical view of 19352910 CONNECTOR KIT,
BODY WRG HARN (14V POWER MODULE X1)
(BLACK) (.75MM2) (8-WAY FEMALE)
(W/LEADS)
Click View Image to see the connector image to
verify the correct part is being purchased. If an
image is not available, there will be a generic
image in its place. Review the Description field to
determine if it matches application required for
repair.
9. Add the Service Connector to the Shopping List.
Terminal Tools and Kits
Overview
The metal piece soldered or crimped to the end of a
wire is called a terminal. It provides the electrical
connection between wires and components. Any
damage to the terminals could cause inaccurate test
results, difficult diagnosis and failures after the vehicle
has been returned to the customer.
When servicing a suspected wire/terminal issue, It is
important to inspect for the following conditions:
– Any signs of connector damage.
– Excessive wear to the terminal locking mechanism.
– Loose or backed out terminals.
– Damaged terminated lead due to improper probing
tool use.
Terminal Tools
The following Special Tools can be used for the
diagnosis, testing and removal of terminals. These
items can be ordered through Bosch or Kent-Moore. Be
advised that the kit and tool numbers are always
subject to change when they are updated by the
supplier.
5386340
When probing a terminal for testing procedures, it is
critical to use the appropriate size probe from the
J-35616-F Terminal Test Probe Kit. The probes in the
kit are sized to fit various terminal sizes and their
shapes properly.
Terminals are becoming increasingly smaller and more
complex in design. Using an improper test kit probe
may cause damage to the terminals being probed and
false readings during a diagnostic procedure. Using an
instrument other than the correct probe will, in most
cases, cause irreversible damage to the terminal by
enlarging or deforming it to the point that it will no
longer mate correctly.
Refer to Power and Signal Distribution > Wiring
Systems and Power Management > Diagnostic
Information and Procedures > Probing Electrical
Connectors in SI. Refer to the Test Adapter and
Description Table as a guide in selecting the correct
test adapter for front probing connectors.
Bulletin No.: 13-00-89-008B
August, 2019
Page 9
selection. Crimp nest selection is determined based on
wire size. Crimp nest selection is critical to splice crimp
quality.
Use the J-38125–580 Terminal Repair Kit with the
following tools:
– J-38125-6 Crimp Tool
– J-38125-7 Crimp Tool
– J-38125-8 Crimp Tool
– J-38125-64 Crimp Tool
– J-38125-101 Crimp Tool
– J-38125-641 Crimp Tool
– J-38125-642 Crimp Tool
– J-38125-643 Crimp Tool
Terminal Release Tool Kit: J-38125-550
(EL-38125-550 North America Only)
Splice Sleeve Crimp Tool — Special Tool Numbers
– J-38125-8 (North America Only)
– EL-38125–EU (Europe)
– EL-38125–10 (Non-North America/Non Europe)
5386378
This Terminal Release Tool Kit contains various tools
designed to release the terminals from the connector.
The terminals have a metal arm or tang that locks into
the connector body. When the release tool is inserted
into the canal, it moves the tang against the terminal.
This movement allows the connector body to be
released and moved outward. Tangless terminals are
released in a similar fashion with the only difference
being that the tool pushes the arm of the connector
body to release the terminal.
Splice Sleeve Crimp Tool
Best Practices
Some steps that should be considered as best
practices are:
1. Compress handles until the ratchet automatically
opens.
2. Determine the correct holder per the crimp matrix
section.
3. Crimp the core wings first. Lay the back of the
terminal core wings on the appropriate anvil. Be
sure the core wings are pointing toward the
forming jaws.
4. Gently apply pressure to the handles until the
crimpers slightly secure the terminal core wings.
5. Insert stripped cable through as needed.
Wire Repair Components
Overview
Note: GM DOES NOT recommend soldering of
terminals or connections unless specifically called
out in a repair procedure.
The following components are used to repair damaged
circuits. Each piece is used for a specific application
depending on which parts are damaged and how they
are damaged. Some pieces may also be used together
depending on the repair procedures.
5389158
J-38125-8 Splice Sleeve Crimping Tool (GMNA)
The splice sleeve crimp tools are part of the process
necessary for repairing terminals and connectors. It is
very important to use these tools in conjunction with the
information contained in the Service Manual. The
Service Manual contains information for crimp nest
Page 10
August, 2019
Terminated Lead
Bulletin No.: 13-00-89-008B
Connector Kit
5389168
Machine Crimped Terminated Lead
Replacement may be needed due to a spread terminal
condition, corrosion, or it will not stay retained in the
connector body.
Pigtail
5389320
8-Way or Less Pigtail
Used when replacing a damaged connector that has
8-circuits or less. This connector assembly has
terminated leads installed. The most common cause of
replacement could be terminal corrosion or body
damage.
5389332
9-Way and More Connector Kits
Used when replacing a plastic connector body that has
nine or greater circuits. These kits include the plastic
connector body, CPA, and TPA, but do not have
terminals or terminated leads included. The most likely
cause requiring replacement is a damaged retainer or
corrosion.
DuraSeal Splices
Important: Use only DuraSeal splice sleeves to
form a one-to-one splice on all types of insulation
except high voltage and specialty cables. Use
DuraSeal splice sleeves where there are special
requirements such as moisture sealing.
The use of DuraSeal splice sleeves is required to form
a one-to-one splice on all types of insulation, except
Tefzel® and coaxial. The current procedure helps to
install the DuraSeal splice sleeves once the wire or
circuit has been identified.
DuraSeal splice sleeves have the following 2 critical
features:
• A special heat shrink sleeve environmentally seals
the splice. The heat shrink sleeve contains a
sealing adhesive inside.
• A cross hatched (knurled) core crimp provides the
necessary low resistance contact integrity for
these sensitive, low energy circuits.
Bulletin No.: 13-00-89-008B
August, 2019
Page 11
DuraSeal Splice Colors and Sizes
5389895
Use the instructions in the Table below to splice copper
wire using DuraSeal splice sleeves.
Splice Sleeve Selection
Crimp Tool Nest Color
Splice Sleeve Color
3 Crimp Nests
4 Crimp Nests
Wire Gauge mm² / (AWG)
Salmon (Yellow-Pink)
19300089
Red (1) or Red/Green (1)
Red (2)
0.22–0.8/(18–26)
Blue
19168447
Blue (2)
Blue (3)
1.0–2.0/(14–16)
Yellow
19168448
Yellow (3)
Yellow (4)
3.0–5.0/(10–12)
Wire and Fuse Parts
GXL and TXL Wire Overview
There are overlapping qualities between GXL and TXL
wire and there are also some distinct differences. GXL
and TXL wire both consist of multi-stranded bare
copper core conductors, a temperature rating of -59°F
(-51°C) to 257°F (125°C), cross linked polyethylene
(XLPE) along with meeting the SAE specification
ratings. The two main distinct differences between the
two wires is their differences in weight and wall
thickness. GXL is a slightly heavier option due to its
slightly thicker outer wall. TXL on the other hand, is
lighter due to its more lightweight and extra-thin
outer wall.
It is important to use TXL wire to maintain GM factory
specifications for wire harness integrity. TXL wire is
available through the EPC within the Chemical Catalog
section.
Locating TXL Wire and Fuses in EPC
In the EPC the TXL wire and fuses are located in the
Chemicals – Fuses - Wire - book section. To locate this
section, select Make, Year, then under Model select
Chemicals – Fuses – Wire catalog. The TXL Wire will
be called out under Group 8.966 Wire, Primary wire.
Fuses are located under Group 8.965 Fuse.
In the EPC Next Generation the TXL wire and fuses are
in the Q – CHEMICALS – FUSES – WIRES – BULBS
section. To locate this section, select Make, Year, then
under Model select Q – CHEMICALS – FUSES –
WIRES – BULBS and then select 08 – Vehicles
Maintenance. The TXL Wire will be called out under
Group 08.966 WIRE, Primary Wire. Fuses are located
under Group 08.965 FUSE, Fuse.
Part Resource Matrix
Part Resource Matrix
Part Name
Part Number
Resource
Order
Through
Terminal
SI
Bosch
Automotive
Service
Solutions
Crimp Tools
SI
Bosch
Automotive
Service
Solutions
Page 12
August, 2019
Part Resource Matrix (cont'd)
Part Name
Part Number
Resource
Order
Through
Terminated Leads
SI
EPC
Connector w/Leads
SI
EPC
Connector
SI
EPC
Splice Sleeves
SI and EPC
EPC
Harness Assembly
EPC
EPC
Wire, Fuse and
Heat Shrink
EPC
EPC
Electrical Service Information
Reference
Circuit Testing
The Circuit Testing section contains the following
diagnostic testing information. Using this information
along with the diagnostic procedures will identify the
cause of the electrical malfunction.
To navigate to the Circuit Testing section in the Service
Manual, enter a VIN then click Next. Go to > Power and
Signal Distribution > Wiring Systems and Power
Management > Diagnostic Information and Procedures
> Circuit Testing
OR
Go to > Year > Make > Model > Next > Service Manual
> Power and Signal Distribution > Wiring Systems and
Power Management > Diagnostic Information and
Procedures > Circuit Testing
• Using Connector Test Adapters
• Probing Electrical Connectors
• Troubleshooting with a Digital Multimeter
• Troubleshooting with a Test Lamp
• Using Fused Jumper Wires
• Measuring Voltage
• Measuring Voltage Drop
• Measuring Frequency
• Testing Ground and Low Reference Circuits
• Testing for Continuity
• Testing for Short to Ground
•
•
•
•
•
•
•
•
Bulletin No.: 13-00-89-008B
Testing for a Short to Voltage
Testing for Intermittent Conditions and Poor
Connections
Inducing Intermittent Fault Conditions
Testing for Electrical Intermittents
Scan Tool Snapshot Procedure
Circuit Protection - Fuses
Circuit Protection - Circuit Breakers
Circuit Protection - Fusible Links
Supplier Connector Repair Reference List
In addition to connector disassembly videos, some
supplier connector disassembly instructions are found
in SI. The connector repairs are listed by the connector
manufacturer and then by connector type. Knowing the
connector manufacturer will assist in finding the correct
connector repair. If the technician cannot identify the
manufacturer of the connector, refer to Identifying
Connectors below.
To navigate to the Connector Repair Reference section
in the Service Manual, enter a VIN then click Next. Go
to > Power and Signal Distribution > Wiring Systems
and Power Management > Diagnostic Information and
Procedures > Connector Repairs
OR
Go to > Year > Make > Model > Next > Service Manual
> Power and Signal Distribution > Wiring Systems and
Power Management > Diagnostic Information and
Procedures > Connector Repairs
• Connector Position Assurance Locks
• Terminal Position Assurance Locks
• AFL/EPC Connectors
• Bosch Connectors
• Delphi Connectors
• FCI Connectors
• FEP Connectors
• JST Connectors
• Kostal Connectors
• Molex Connectors
• Sumitomo Connectors
• Tyco/AMP Connectors
• Yazaki Connectors
• Repairing Connector Terminals
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
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