Wiring Systems (General Information): Removal & Installation Chevrolet Silverado 2500

Terminal Removal

Follow the steps below in order to repair push to seat connectors.

Scheme 1

Scheme 2

Scheme 3

1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock.
2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Reform the locking device if you are going to reuse the terminal (1).
6. To repair the terminal, refer to «Terminal Repair»(ref-175672-S25063055702005042500000) .

If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced.

Follow the steps below in order to repair pull-to-seat connectors.

Scheme 4

1. Remove the connector position assurance (CPA) device and/or the secondary lock.
2. Disconnect the connector from the component or separate the connectors for in-line connectors.
3. Remove the terminal position assurance (TPA) device.
4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3).

Terminal Installation

1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to «Splicing Copper Wire Using Splice Sleeves»(ref-175672-S02573968642005042500000) .
3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector.
4. Install the TPA, CPA and/or the secondary locks.

Installation Procedure

1. Connect the relay (1) to the wire harness connector (2).
2. Install any connector position assurance (CPA) devices or secondary locks.
3. Install the relay using any fasteners or tape that originally held the relay in place.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. Disconnect the negative battery cable.
2. Remove the left fender upper brace.
3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs.
4. Remove all fuses and relays.
5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2).
6. Remove all connectors by removing the bolt (1) for each connector.
7. Disconnect all connectors from the electrical center block.
8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing.
9. To replace the engine electrical center bracket remove the 4 retaining bolts (1).
10. Remove the engine electrical center bracket assembly from the fender.

1. Install the engine electrical center bracket assembly to the front fender.
2. Install the 4 retaining bolts (1). Tighten the 4 retaining bolts (1) to 9 N.m (80 in lbs).
3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place.
4. Connect the wire connectors to the lower portion of the electrical center block.
5. Connect the wire connectors with the bolts to the electrical center block. Tighten all connector bolts (1) to 9 N.m (80 in lbs).
6. Ensure all wire connectors are securely connected.
7. Set the electrical center block in its resting position till the tabs (3) locks in place.
8. Install the lower part of the cover (1).
9. With the cover (2) off, use the fuse location information to install all fuses and relays.
10. Install the cover.
11. Install the fender upper brace.
12. Install the 4 fender upper brace bolts. Tighten the 4 retaining bolts to 25 N.m (18 ft lbs).
13. Connect the negative battery cable.
14. Start vehicle and ensure all components function properly.

Scheme 10

1. Remove the left side end panel.
2. Remove the knee bolster.
3. Disconnect all the wiring connectors from the fuse block.
4. Remove all the fuses.
5. Remove the turn signal relay from the back of the fuse block.
6. From behind the fuse block, remove the retaining bolt.
7. Insert a screw driver between the fuse block and the wire harness block to separate.
8. Push on the retainers in order to remove the fuse block.
9. Remove the fuse block from the vehicle.

1. Install the fuse block onto the I/P assembly until it clicks in place.
2. Install the wire harness block to the back of the fuse block.
3. Install the bolt. Tighten the bolt to 6 N.m (53 in lbs).
4. Install the turn signal relay to the back of the fuse block.
5. Using the wiring diagram on the cover of the fuse panel, install the fuses.
6. Install the electrical connectors.
7. Install the knee bolster.
8. Install the left side end panel.

Scheme 11

1. Remove the right side end panel.
2. Push in the tabs in order to remove the fuse block.
3. Pull out the fuse block out of the I/P in order to remove the retaining bolt.
4. Loosen the bolt.
5. Insert a screw driver between the wire harness block and fuse block in order to separate.
6. Separate the fuse block from the I/P harness block.
7. Remove the I/P wiring harness block from the vehicle.

1. Install the fuse block to the I/P wire harness block.
2. Install the retaining bolt. Tighten the bolt to 6 N.m (53 in lbs)
3. Install the fuse block to the I/P until it clicks in place.
4. Connect the wiring connectors to the fuse block.
5. Install the right side end panel.

Scheme 12

Scheme 13

1. Remove the cover retaining nut.
2. Remove the cover by pushing in the tabs.
3. Remove the harness from the front of the junction block.
4. Remove the junction block from the bracket by pressing to release the tabs.
5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts.
6. Remove the retaining bolts.
7. Separate the wire harness block from the junction block by inserting a screw driver in between.
8. Remove the junction block from the vehicle.

1. Install the wire harness block to the junction block.
2. Install the retaining bolts. Tighten the bolts to 6 N.m (53 in lbs).
3. Install the junction block to the bracket.
4. Push on the top part until it clicks in place.
5. Connect the harness to the front of the junction block.
6. Install the cover to the junction block until it clicks in place.
7. Hand tighten the retaining nut until seated.