Wiring Systems - Introduction: Removal & Installation Hummer H2 I

Terminal Removal

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

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. Re-form the locking device if you are going to reuse the terminal (1).
6. To repair the terminal, refer to Terminal Repair.

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

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.
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-187209-S06842425972005083100000) .
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.

Terminal Removal Procedure

1. Disconnect the connector from the component or separate the connector halves for in-line connectors.
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece.
4. Repeat the procedure for the other locking tab and remove the nose piece.
5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover.
9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector.

Follow the steps below in order to remove terminals from Micro 64 connectors.

1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece.
6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector.
7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used.
8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector.

Removal Procedure

1. Remove the electrical center cover.
2. Locate the relay. Refer to «Electrical Center Identification Views»(ref-187233-S03197999852005083100000) to locate the electrical center where the relay exists.
3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). See «Special Tools and Equipment»(ref-187209-S12984863662005083100000) .
4. Remove the relay (2) from the electrical center.

Installation Procedure

1. Install the relay (2) in the same position as removed.
2. Install the electrical center cover.

1. Locate the relay. Refer to the «Master Electrical Component List»(ref-187233-S38094684522005083100000) to locate the relay in the vehicle.
2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
4. Separate the relay (1) from the wire harness connector (2).

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.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-187208-S04260183982005083100000) in Engine Electrical.
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: Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in).
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: Tighten all connector bolts (1) to 9 N.m (80 lb in).
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: Tighten the 4 retaining bolts to 25 N.m (18 lb ft).
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-187208-S04260183982005083100000) in Engine Electrical.
14. Start vehicle and ensure all components function properly.

1. Remove the left side end panel.
2. Remove the knee bolster. Refer to «Trim Panel Replacement - Knee Bolster»(ref-187217-S19396169522005083100000) in Instrument Panel, Gauges and Console.
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 IP assembly till it clicks in place.
2. Install the wire harness block to the back of the fuse block.
3. Install the bolt. Tighten: Tighten the bolt to 6 N.m (53 lb in).
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. Refer to «Trim Panel Replacement - Knee Bolster»(ref-187217-S19396169522005083100000) in Instrument Panel, Gauges and Console.
8. Install the left side end panel.

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 IP wiring harness block from the vehicle.

1. Install the fuse block to the I/P wire harness block.
2. Install the retaining bolt. Tighten: Tighten the bolt to 6 N.m (53 lb in)
3. Install the fuse block to the I/P till it clicks in place.
4. Connect the wiring connectors to the fuse block. Refer to «Electrical Center Identification Views»(ref-187233-S03197999852005083100000) to ensure the right connections are made.
5. Install the right side end panel.