Proper Terminal Removal Procedures for the Delphi .64 Connection System

If you’ve been following the various stories in TechLink about electrical terminals, you know that over the past few years, numerous new types of terminal and connector systems have been introduced (TechLink, Sept. 2002, June 2003, Feb. 2004 and Jan. 2005).

In the January issue of TechLink, we reviewed the various suppliers of .64 terminals now in use in GM vehicles, and the slight differences between them.

We reviewed the J-35616-64A and the J-35616-65 test probes and the fact that the J-35616-64A (male) and J-35616-65 (female) test probes are correctly sized to work with both the round and square styles of .64 terminals.

We reviewed various connector types from various suppliers that use .64 terminals.

This article is about the proper terminal removal process for Delphi .64 connector systems (fig. 1), of which there are five different types. Type 4 (not shown) is not used in North America at this time.
Type 1
Type 2
Type 3 (hybrid)
Type 5 (Saturn only)

The Wire Dress Cover
On all but Type 1, start the disassembly process by removing the wire dress cover (if used), which requires a small screwdriver. There are two popular versions, with one tab (fig. 2) or two (fig. 3).

After loosening the tab(s), simply rock the cover up and off (fig. 4).

Terminal Position Assurance (TPA)
The next step is removal of the comb style TPA (Terminal Position Assurance). Be very careful, because the TPA can break very easily (fig. 5), particularly if you try to pry the head of the TPA out of the connector.

On Type 1 connectors, push the TPA from the end of the connector opposite the head (fig. 6). This will get the TPA past the detent that retains it in the connector. Then grasp the head and pull the TPA out of the connector.

On the other types, use a prying tool to reach inside the connector to push the TPA loose from the end opposite the head (fig. 7). Once the TPA is loosened, you can use the tool to extract it through the hole in the connector body (fig. 8).

TIP: On the Type 3, there is no access hole for loosening the TPA. Instead, use the tool as a lever to pry the TPA loose (fig. 9).

Nose Piece (Type 5 only)
In the Saturn LS only, a 64-way Delphi .64 connection system is used on a Bosch ECM. For this application only, the Type 5 connector uses a nose piece that covers the release holes for the terminals (fig. 10).

Pry the nose piece off for access to the TPA, which is similar to the Type 3. Once it is removed, you can remove the terminals.

TIP: The Type 5 connection system uses a .64 terminal p/n 15410621 found in tray 4 position 24. This is slightly different from all other .64 terminals, which are p/n 15359541.

Terminal Removal
For all four connector types, use the 15381651-2 terminal release tool. Push it into the small hole positioned between the two terminal cavities (fig. 11). In some small .64 connectors with one row of terminals, the terminal release hole is just to the side of the terminal cavity.

Assembly
After replacing the terminal, assemble the connector in the order opposite to disassembly.

TIP: The TPA has an lug which must be aligned with the corresponding depression in the connector (fig. 12). This assures that the detents on the TPA contact the detents in the connector body, to retain the TPA.

Recovery
TIP: Do not disassemble the Delphi connector body beyond removing the dress cover, the TPA and the nose piece (if equipped).

If for some reason a Delphi .64 connection system has been dissembled incorrectly (fig. 13), this is the process for getting it all back together.

Remove all the wires with their terminals from the connector. Reassemble the connector, leaving the TPA and wire dress cover off. Using the Connector End View information in SI, reassemble the wires into the connector, starting with the shortest wires and ending with the longest. Once the circuits have been correctly placed into the connector, replace the TPA and dress cover.

A Final Word About Testing a Round .64 Terminal
The .64 terminal is very small and will not withstand excessive probing, especially with an incorrect tool (fig. 14).

A J-35616-6 probe with 100 terminal
B J-35616-64A probe with .64 terminal

The ability of the J-35616-64A Test Probe to “hang” in a round type .64 terminal will be minimal. The drag that you feel is much less than you’re accustomed to in a larger terminal.

TIP: Square style .64 terminals will have a much better test probe feel relative to their size than the round style.

- Thanks to John Roberts

This information applies to 2002-04 GMT 360/370 (TrailBlazer, Rainier, Envoy and Bravada).

If replacing TBC (Truck Body Controller) part number 09352135 with a TBC part number 15065293, 15114669 or 15122670, you MUST contact Techline Customer Support Center (800.828.6860) for assistance or the TBC will be permanently damaged.

TIP: Before programming, remove LGM/DSM (Liftgate Module/Driver Seat Module) fuse 6 from the rear fuse block, or programming errors may result.

- Thanks to Craig Jones

A new, more-robust Tech 2 DLC cable is now available for purchase. It can be obtained from GMDE by ordering GM p/n 3000095.

TIP: Warranty replacement cables are available on exchange from Vetronix.

These are the improvements:
- Added a "dog-ear clamp" on both connectors to help prevent the cable from detaching from the connector.
- Improved strain relief by strengthening ribs.
- Reduced hardness of the cable's PVC material. The new cable is more flexible and forgiving, putting less stress on a given point.
- A new wire “lay” results in a more flexible cable.

- Thanks to Mark Stesney

When changing the engine oil on the following vehicles, it is necessary to replace the oil pan drain plug sealing washer. The drain plug sealing washer, which is part number 94525114, is not reusable. Reusing the old washer may result in an oil leak.

- Thanks to John Bowman

Owners of some 2000-05 LeSabre, DeVille, Aurora, or Bonneville vehicles may comment on corrosion in the floor pan in the area where the battery is located. This may be caused by acid weeping from the battery, or from a dislodged battery vent tube. A new repair floor pan kit p/n 88948594 has been released to assist in the repair of this condition. Refer to Bulletin 05-08-61-002 for repair procedures and part number information.

TIP: Clean the area of the floor pan where acid may have been present, using a solution of baking soda and water. Rinse and dry the area thoroughly.

- Thanks to Bill Denton

There are two manual transmissions used in the 2005 Cobalt. The transmission in the base vehicle (fig. 15) and the transmission in the SS Supercharged vehicle (fig. 16) require different lubricants.

- Thanks to Jerry Garfield

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2005 GM gasoline engines require the use of an engine oil that has the American Petroleum Institute (API) Starburst AND states that it meets GM Standard GM 6094M (non-synthetic) or GM4718M (synthetic). Failure to use the recommended engine oil can result in engine damage not covered by warranty.

Figure 17 is the list of engine oil brands that meet GM Standard GM 6094M and 4718M as of February 4, 2005.This list will be updated and will be in the Techlink Reference Guide available at http://service.gm.com.

- Thanks to Robert Stockwell and Matthew Snider

Driver Information Center Language Choice

The procedure for changing the DIC language on the Colorado/Canyon is correct in the owner’s and service manuals but some owners apparently are omitting the last step, which is critical. This has led to unnecessary warranty claims.

TIP: This information will also apply to the upcoming Hummer H3.

Before servicing the system, be sure the owner is following this procedure.
1. With the engine off, turn the key to ON.

TIP: You can't get to the LANGUAGE screen if there are messages on the DIC.

2. Close all doors. Ensure that NONE of the following messages is displayed in the DIC:
DOORS
PORTES
PUERTAS.

If so, check the doors again.

3. For 2004-05 vehicles, disengage the park brake. Ensure that NONE of the following messages is displayed in the DIC (Colorado/Canyon only):
PARK BRK
FREIN A MAIN
FRENO DE MANO.

4. Press and release the reset stem until the language is shown on the DIC display.

5. To view the next available language, press and hold the reset stem for approximately 2 seconds. Release the reset stem and press and hold again to view each language. You can choose from English (default), Spanish or French.

TIP: For 2004-05 vehicles, not all languages are available. You can choose from English (default) and Spanish for clusters with miles as the major speedometer scale, or English (default) and French for clusters with Km as the major speedometer scale.

6. Once the desired language is displayed on the DIC, briefly press the reset stem to set your choice.

Users are not performing step 6 and are just cycling the ignition once the language of their choice is displayed.

- Thanks to Anna West

The hydraulic clutch bleeding procedure has been changed for the SSR. Follow the improved bleeding procedure in SI document 1550985.

The procedure involves using Mity Vac J-35555 and adapter J-43485 to apply a vacuum to the clutch reservoir. This draws air from the system. Refer to the document for specifics.

TIP: This procedure applies to all 2005 and prior passenger cars, light duty trucks, and T-Series MD Tilt Cab models.

- Thanks to Dan Oden

HomeLink Transmitter

Unlike other GM vehicles, the 2005 LaCrosse (Allure in Canada) must have the engine running or the ignition key in the run position before the HomeLink transmitter can be programmed or operated.

TIP: This is normal operation, and no repair is required.

- Thanks to Wayne Zigler

Debris in Spacer Plate

According to bulletin 01-07-30-036D, there are several reasons for a 4L60E (RPO M30) or 4L65E (RPO M32) transmission to set a DTC P0756 (2-3 Shift Solenoid Performance).

Two possible causes described in the bulletin are a cracked, broken or leaking 2-3 shift solenoid and a stuck or hung-up 2-3 shift valve.

Another possible cause is chips or debris (fig. 18) plugging the filtered AFL oil at orifice 29 on the top of the spacer plate. Because this orifice is so small, it can be plugged by a very small amount of foreign material.

Remove the spacer plate and inspect orifice 29 (fig. 19) and the immediate area for the presence of chips or debris. Also, inspect the transmission case passage directly above this orifice and the valve body passage directly below. Clean the area of any chips or debris found.

- Thanks to Mike Johnson

The Chevrolet Aveo/Pontiac Wave automatic transmission prevents 4th gear upshifts when the transmission fluid temperature is below 15°C (59°F). This is intended to improve vehicle emissions and heater performance.

No corrective action is necessary. Replacing the ECM or TCM will not correct this condition. Refer to SI document 1339794 for additional information.

- Thanks to John Bowman

An article in the December 2004 TechLink explained how to repair center caps that are loose and rotate, then do not align with the wheel spokes.

This involves adding pieces of polyurethane tape to two opposing legs of the center cap 180° apart (fig. 20).

According to PIT3196A, the tape is now available by filling out the template at the bottom of the PI and faxing it to the WPC. The WPC will send out a service kit that consists of 8 pieces of polyurethane tape (2 pieces per wheel). The part number of this kit is TAC 306.

- Thanks to Dan Oden

figure 20

Bulletin 04-06-01-029 was recently released to reinforce GM’s position on system-flushing tools, equipment and procedures.

Please read the bulletin in detail and observe its contents. Highlights are mentioned here.

Flushing Not in Maintenance Schedule
In normal usage, GM vehicles do not require additional procedures or additives beyond what’s presented in the former Vehicle Maintenance Schedules and the current Simplified Maintenance Schedules. Maintenance schedules do not call for flushing of engine crankcases, fuel injectors, A/C lines, radiators, transmission coolers, brake systems, or power steering systems as a part of regular scheduled maintenance.

TIP: Do not confuse aftermarket flushing machines with the fluid-changing equipment available from Kent-Moore/SPX. Fluid-changing equipment is designed to aid and accelerate fluid changing when required, as part of a specific repair performed, or when directed to do so in the former Vehicle Maintenance Schedule or current Simplified Maintenance Schedule.

GM Service Instructions
If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document specifying the procedure, machine, tool or chemical needed to accomplish the proper vehicle servicing.

An example of this is fuel injector cleaning, which may be necessary due to fuel quality in different parts of the country. Under normal circumstances, though, this is not part of the scheduled maintenance requirements.

Crankcase Flushing
Crankcase flushing is not endorsed or recommended for any GM gasoline or diesel engine. Some aftermarket materials for this purpose may be incompatible with engine components, and may damage some engine seals and bearings. Damage of this sort is not covered under the new vehicle warranty.

Other Systems
Other subsystems, such as power steering, A/C, or cooling systems may be flushed after catastrophic failure or extreme corrosion. Specific bulletins or procedures in SI exist to cover these conditions. Routine flushing of these systems is not part of the scheduled maintenance requirements.

These cars don't have rear compartment (trunk) lid lock cylinders:
2004 1/2 - 05 Monte Carlo
2005 LaCrosse/Allure
2005 Grand Prix
2005 Cadillac STS

The following procedures explain how to open the lid on these vehicles in case of an electrical fault that prevents opening the lid with the remote keyless transmitter or the interior release switch.

With fold-down rear seat back:
Fold down the seat back. Using a long tool that will reach the rear compartment latch, operate the release handle and open the lid.

With rear seat back-to-rear compartment access door:
Fold down the access door. Using a long tool that will reach the rear compartment latch, operate the release handle and open the lid.

Without fold-down rear seat back or access door:
Remove the rear seat cushion, seat back and rear compartment-to-seat back panel. Using a long tool that will reach the rear compartment latch, operate the release handle and open the lid.

- Thanks to the GM SPO Interior Partition

On the 2005 Buick LaCrosse (Allure in Canada), the instrument panel trim plate bezel is retained by four clips, one nut and one screw (fig. 21). These are shown in SI document 1538590.
A Trim plate
B Clip
C Nut
D Hidden screw (access behind striker)

Open the IP compartment door and release the check strap. Refer to SI document 1538593 for procedures.

Use a 10mm socket and extension to remove the hidden screw through the access hole behind the door latch striker (SI document 1538602, item 4).

TIP: If this hidden screw is not removed, the trim plate bezel will be damaged.

- Thanks to Wayne Zigler

A 2003-05 Chevrolet or GMC Full Size Truck equipped with VYU option (Snow Plow Provision Package) may not have the roof beacon light connected. If the customer inadvertently presses the roof beacon switch to the ON position, the roof beacon indicator will illuminate on the switch.

If the ignition is turned off and the beacon switch is left on, a battery draw (140 Ma) will occur, evantually causing battery discharge.

The roof beacon switch indicator will not illuminate when the key is turned off. However, the roof beacon relay is still energized. It's suggested that the roof beacon switch be turned off before turning the ignition off to avoid a battery drain.

TIP: If the roof beacon is not being used, pull the SEO B1 fuse to disable the relay. This can be done on all vehicles with VYU option except vehicles equipped with option 8S8 (Speedometer Security) or have an overhead universal garage door opener.

- Thanks to Jim Will

Owners of some 2003 -05 GMC Sierra Denali, Yukon Denali/XL and Cadillac Escalade/EXT/ESV may comment that the center console cupholder and ashtray lid will not close.

When opening the cover, customers may be incorrectly pulling up on the cover as opposed to pushing down on the cover to let the automatic release work properly. During the pull-up motion of the cover, an over-design force is applied, causing the latch to be pulled out of the retainer while it is in the lock position.

Replace the latch assembly with p/n 89040109, as well as both the ashtray door and cupholder door latches. This will eliminate the customer returning with the same condition.

TIP: Do not re-use any latch that has become loose. Do not replace the lower bezel assembly. If the latch is missing during diagnostics, inspect the area inside the lower console and remove the broken latches, to prevent squeaks and rattles.

- Thanks to Jim Will

Owners of some 2005 Chevrolet Equinoxes may comment that intermittently the dome light does not turn on when the liftgate is opened. This will usually happen after the vehicle sits for an extended period of time. If the liftgate is opened after all the modules go to sleep, the dome light will not come on. The liftgate ajar switch input to the BCM will not wake up the BCM once it has gone to sleep, so the dome light will not come on. Once the BCM gets an input to wake it up (from RKE or door handle), the dome light will turn on when the liftgate is opened.

This is normal operation and no repairs should be made.

- Thanks to Ron Erman

Some customers may comment that their instrument panel voltmeter is fluctuating between 12 and 14 volts on their new 2005 model year light duty full size pickup/utility vehicle.

For 2005 model year, light duty full size pickups and utilities, are equipped with a new Regulated Voltage Control (RVC) system, covered in the September 2004 TechLink. The RVC system allows changes to vehicle voltage, up or down, under various scenarios. Battery state of charge and the vehicle’s present electrical needs are only two of numerous conditions taken into account.

This will cause the voltmeter to fluctuate between 12 and 14 volts. By comparison, conventional systems usually maintain a more consistent reading of 14 volts.

This fluctuation with the RVC system is normal system operation and no repairs should be attempted.

- Thanks to Jim Will

The 2004-05 Chevrolet Silverado and GMC Sierra C/K 1500 Crew Cab with 5' 8" bed is not recommended for fifth wheel trailering.

With a cab-to-axle (CA) distance of 32 inches, there is no available fifth wheel hitch that will allow the truck and trailer to approach 90° articulation. This means that in parking lot maneuvers and sharp turns, there will eventually be contact between cab and trailer, and damage will result to one or both vehicles.

TIP: A CA distance of at least 52 inches is best (with 8 foot box) for fifth wheel trailing. The extended pins and sliding 5th wheels were developed in the 1990s to accommodate short box (6' 6") models with 38 inch CA lengths, but that is the lower limit.

- Thanks to Jim Will

On some 2004-05 Chevrolet Express and GMC Savana vehicles, the upper radiator hose may have a coolant leak, because it has rubbed through on the fan shroud.

If the upper radiator hose (p/n 25757841) needs to be replaced, it will be necessary to cut 50mm (1.9 in.) off the radiator end of the hose. This will prevent the upper radiator hose from rubbing on the fan shroud.

- Thanks to Ron Erman

Owners of some 2005 Corvettes may comment that the I/P compartment door appears warped and extends outward near the center IP. This may be caused by the torque sequence when the door is installed by the plant.

To correct the condition, loosen the attaching screws at the bottom of the door. Then retighten the screws, beginning with the outboard screw, the one on the right side and then the inboard screws.

- Thanks to Paul Radzwilowicz

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