AMP RESEARCH POWER STEP – GMC / CHEVROLET INSTALLATION . - Free Download PDF

25d ago
1 Views
0 Downloads
2.24 MB
15 Pages
Transcription

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ EAPPLICATIONMODEL YRChevrolet Silverado / GMC Sierra1999–2006PART #(Crew Cab)(Extended Cab)Chevrolet Tahoe / SuburbanChevrolet Avalanche2001-20062001-2006(without cladding)(with cladding)GMC Yukon / Yukon XLCadillac Escalade Ext / 75115-01A75114-01A75115-01A75115-01AINSTALLATION TIME3:00 hrsSKILL LEVEL12 344 ExperiencedTOOLS REQUIREDqqqqqqqqqqqqqqqqqqqqqqSafety gogglesMeasuring tapeFlat blade screwdriverPhillips head screwdriverRight angle drill1/8” drill bit q 3/16” drill bit9/32” drill bit q 21/64” drill bit17mm socket13 mm socket10 mm socket q 7 mm socketT 20 Torx driverRatchet wrench and extension13mm end wrenchWire crimpersWire stripper / cutterVise grip pliersCorrosion inhibiter3/16” hex key wrench (allen wrench)5mm hex key wrench (allen wrench)4mm hex key wrench ( allen wrench )Electrical tapeWeather proof caulking (siliconesealer)AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 6:00 AM - 5:00 PM PSTDesigned and manufactured by AMP Research . Patent Number 6,830,257; 6,641,158; 6,834,875; 6,938,909; 6,942,233; 7,007,961; 7,055,839; 7,163,221;7,367,574; 7,380,807; 7,398,985; 7,413,204; 7,487,986. Other US and Worldwide patents pending. Made in USA 2010 AMP Research5-year limited warranty. Professional installation is recommended.www.amp-research.com1/11IM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ EINSTALLATION GUIDEAttaching motor to linkage assemblyThe motors must be attached to the linkage assemblies before continuing theinstallation process.EXPLODED 79-90Socket cap screw19-03133-90WasherIM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ EANote: Some Applications require modification.ApplicationCrew CabExtended CabCut Length79” (No Modification Required)72” (Trim 7”)Cut dimensionCD1E(A) 19-03225-11 End cap left (x1)(B) 19-03225-12 End cap right (x1)(C) 19-02663-90 T-nut insert (x2)(D) 19-03236-90 Socket cap screw (x2)(E) 19-03237-90 Nut plate (x2)Bx220-03314-XXRunning board 8-11 TruckIdler linkage assemblyUSED ON SILVERADOAND SIERRAHEAVY DUTIES ONLY.6x216-03079-90Cable 59-12 TruckMotor linkage assembly(10-03058-12 Shown)4519-03297-93Controller19-03067-93 SUV19-03067-91 TruckWire harnessBRACKET(SUV SHOWN)USED ON SILVERADOAND SIERRAHEAVY DUTIES ONLY.97819-03088-90Brake Cable Ring19-03044-90Drill Template3/11x416-03055-90-TRUCKMounting Bracket19-03149-90-SUVMounting BracketIM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ E1210x819-02812-90Hex HeadSheet Metal Screw14x819-02634-90Button Head Bolt1811x419-03037-90 SUV19-03248-90 TruckHex Flange Bolt15www.amp-research.comx819-02802-90Socket Cap Screw1919-02805-90Cable tie (7”)x819-03021-90Hex Nut(for Truck only- Step 8)16x219-03339-90Cable tie (11”)x2521x419-03032-90Upper Sill Mountwith 19-03033-90Stud13x410-00115-60Nylock Nut1719-02992-90Tubing (Installation Tool)20x419-03354-90Posi-Tap (Red/Grey)19-02640-90Grommet2322x819-02989-90Butt Connectorx480-03302-90LED Lamp4/11IM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ ESteps 1-3 for Heavy Duty Trucksonly! For all other vehicles skipto Step 4.6HD - Short Bed: Remove forward most brakecable guide.HD - Long Bed: Remove first and third brakecable guide.12Install replacement brake cable guides.Rear linkage assembly. Template position forTahoe and Yukon shown in hidden lines.67SILL DRAIN8Clamp drill template about 1/16” forward of therearmost sill drain.HD - Long Bed: Install plastic brake cable guidein forward hole of rear body mount.34Tahoe and Yukon: Clamp Template 1/8”behind second rearmost sill drain.Tahoe and Yukon: Clamp Template 1/8”behind second rearmost sill drain.With drill template secured with vise grips,drill 1/8” starter holes. Remove template anddrill holes to 21/64”.Front linkage assembly. Template position forSUV driver side shown in hidden lines.8MOUNTING TABSILL DRAINFOR SUV856www.amp-research.com5/11Clamp drill template to pinch weld about 1/8”behind the forward most mounting tab.Then repeat Step 5.SUV’s: On driver side only, clamp template1/8” in front of forward most mounting tab.IM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ ECAUTION: Remove step plates on inside of cab and move vehiclewire harnesses out of the way before drilling in Steps 8 & 9.READ THE ABOVE CAUTION NOTE!Center the upper support mount and drill 1/8”starter holes, then remove mount and drill 3/16”holes. Drill through first layer of sheet metalonly. Attach with #14 sheet metal screws.10AVOIDDRILLINGTHROUGHWIRES.Use a straight edge to make a vertical linecentered between drilled mounting holes.7813IMPORTANT NOTE:AVOIDDRILLINGTHROUGHWIRES.99For Truck and HD Avalanche:The motorized linkageassembly goes to the frontlocation on the drivers sideand to the rear location onthe passenger side.10File down any exposed screw tipsfrom inside and cover with silicone.File down any exposed screw tipsfrom inside and cover with silicone.Mount linkage assembly and upper bracket andfinger tighten all fasteners.READ CAUTION NOTE AT TOP OF PAGE!Repeat Steps 7 & 8 for rear mount. Drill throughfirst layer of sheet metal only. This mountsupport will mount partially behind framesupport and will require only one sheet metalscrew.121211For SUV & 1500 Avalanche:The motorized linkageassembly goes towards the 14front on both sides.10Tighten button head fasteners and upper nut to16 ft-lbs. Then adjust the bottom edge tohorizontal and tighten hex bolt to 16ft-lbs.Slide mounting T-nut into position. Mountboard and tighten fasteners to 10 ft-lbs. Alignthe end of the board with the rear edge of theback door.2TIGHTEN AFTERADJUSTMENT11116ADJUST EDGE TOHORIZONTAL1112www.amp-research.com6/11IM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ EUsing the two 11” cable ties, mount controller tofactory wire conduit above brake booster ondrivers side of truck.Remove power fuse. Attach power lead REDwire to positive lead in the junction box.CAUTION: Do not ground wrench whenengaged with nut.15445Plug in wire harness.(Ensure that lockingtabs engage.)1314Route long end of wire harness above engineand down through passenger side wheel well.Zip tie harness to cowling clips on fire wall.Route short end down drivers side.Attach ground lead to junctionbox mounting bracket.Route wire harness along the frame. Securewith zip ties.415Secure with zip ties.416Poke hole through rubber grommet nearfront door on underside of floor panel withsmall phillips screwdriver. Push both wiresthrough hole.(See Step 19 for passenger side notes.)Pop off the threshold cover with screwdriver andremove the kick panel. The panel will slide outfrom under the seat after fasteners give way.4Plug wireharness intomotors.31817www.amp-research.com7/11IM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ EIMPORTANT: Steps 20 and 21 are for Crew Cabs and SUV’s only. Light blue and Greenwires will not be used otherwise. See wire diagrams for model years previous to 2003.On Crew Cab’s and SUV’s carefully remove wirewrap and find LIGHT BLUE wire with BLACKSTRIPE (on passenger side find GREEN wire withBLACK STRIPE rear of the “T” junction wherewires cross under the front seat).Pull up the carpet and thread both wiresthrough the floor panel (same steps on passenger side EXCEPT drill 9/32” hole in metal andadd rubber grommet).419Seal holes with silicone glue.20Remove plastic trim on doornear mirror attachment.Using supplied Posi-Taps splice shorter trigger wire into wire found in step 20.42119Note: Crew Cab and SUV’s only; Tapeoff these extra wires otherwise.22Pry off door handle plate and any remainingpanel fasteners. Then remove door panel.To remove door, first pry off door locktab. Remove door bolts.2324www.amp-research.comSee wire diagrams for modelyears previous to 2003.8/11NOTE: Remove door lightwhile removing door panel.IM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ EPull back the door weather guard. Pry offspeaker and unplug. Thread plastic tubethrough accordion.Feed longer wire of Step 19 through tube intodoor and pull out plastic tube on door side.1717425426Using supplied Posi-Taps splice triggerwire into door ajar wire (Driver side: Graywith Black Stripe; Passenger side: Black withWhite Stripe). The wire leads to the connector with a cam-release lever.Route wire along harness going to switch plate.41927428Secure all wires with zip ties and electrical tape.29Make sure that plug lever is fully opened beforereinstalling. Failure to do this will adverselyaffect the operation of the powerstep andwindow controls.30www.amp-research.com9/11Reinstall door panel.IM3419 rev 03.25.10

A M P R E S E IA NRCR TS ITOE PN – GGMCHEVROLETSHT PAOLWLEAU CI D/ EReplace power fuse.31Check that both doors activate the powerstep. Reinstall any remaining trim panels.Repeat the adjustments of Step 12 if the stowed step position is not even.332www.amp-research.com10/11IM3419 rev 03.25.10

Wiring InstructionsRESEARCHGM POWERSTEP ('03-'05) Truck and SUVDRIVER SIDEPASSENGER SIDEInsulated SpadeConnectorABDAT-TapConnectorCBL-Blue / Black wirefrom PowerstepHarnessGrey / Black wirefrom PowerstepHarnessL-Blue/ Black fromVehicle HarnessRear of TruckFront of TruckDRIVER SIDE WIRING1. After removing the front door step plate, lift carpet and pullPowerstep trigger wires through floor of truck.2. Open wire bundle located under front door step plate and locatethe 18Ga. rear door-ajar signal wire (light blue with a black stripe).3. Apply T-Tap connector to the above found wire. Make sure thatthe T-Tap latches completly.4. Attach shorter trigger wire of step-1 to spade connector thenattach spade to T-tap. Make sure that the spade is center within theinsulation before attaching to the T-tap connector.D5. After removing the door panel, you will access the wire bundle atthe black cam-plug from window control panel (Area-A). Undo wirewrap and locate the 18Ga. door-ajar signal wire (grey with a blackstripe).6. Apply T-Tap connector to the above found wire. Make sure thatthe T-Tap latches completly.7. The longer of the two wires from step-1 will be routed to the doorpanel through front door accordian. Attach routed wire fromPowerstep harness to spade connector then attach spade to T-tap.Make sure that the spade is center within the insulation beforeattaching to the T-tap connector.CPasses underfront seat.Green / Black wirefrom PowerstepHarnessGreen / Black fromVehicle HarnessRear of TruckBlack/White wirefrom PowerstepHarnessFront of TruckPASSENGER SIDE WIRING1. After removing the front door step plate, lift carpet and pullPowerstep trigger wires through floor of truck.2. Open wire bundle located under front door step plate and locatethe 18Ga. rear door-ajar signal wire (green with a black stripe).3. Apply T-Tap connector to the above found wire. Make sure thatthe T-Tap latches completly.4. Attach shorter trigger wire of step-1 to spade connector thenattach spade to T-tap. Make sure that the spade is center within theinsulation before attaching to the T-tap connector.5. After removing the door panel, you will access the wirebundle at the black cam-plug from window control panel (Area-C). Undo wire wrap and locate the 18Ga. door-ajar signalwire (black with a white stripe).6. Apply T-Tap connector to the above found wire. Makesure that the T-Tap latches completly.7. The longer of the two wires from step-1 will be routed tothe door panel through front door accordian. Attach routedwire from Powerstep harness to spade connector then attachspade to T-tap. Make sure that the spade is center within theinsulation before attaching to the T-tap connector.Notes:1. All of the signal wires tapped into will be 18Ga. Do not tap into anything with a thicker gage than this.2. Occassionally the wire colors do not match the wire schematics. Under these circumstances you will need to locate the door-ajar signal wires.3. Make sure to secure all wires after install. Loose wires can be damaged and may cause a failure in the Powerstep's function.Revision - 11/11/04

Wiring InstructionsRESEARCHGM POWERSTEP1999-2002 Truck & SUV - LUXURY & UP LEVELSingle Diode Harness - Qty: 4(Call 800-315-9705 to receive diodes free of charge.)ATTENTION: Pay close attention to theorientation of the diode harnesses. ThePower-Step will not work with a incorrectlyinstalled diode harness.Leads to Front door Panel.DiodePower StepTrigger WireADiodeFigure A-1Power StepTrigger WireLeads towardrear of vehicle.DRIVER SIDE WIRINGFigure A-3Figure A-25. Locate the front door-ajar signal wire (tan) on large connectorlocated behind the connector of step 2.6. Cut this wire and install Single Diode Harness as oriented inFigure A-3.7. After timming to correct length, connect the grey with blackstripe trigger wire from step one to the blue connector of SingleDiode Harness installed in previous step.8. Wrap all connections with electrical tape and secure any loosewires.1. After removing the front door step plate and kick plate, lift carpetand pull Powerstep trigger wires through floor of truck.2. Locate the rear door-ajar signal wire (dark blue with white stripe)on black connector below the hood-release lever (Area-A in Figure A-1). There should be two wires of this color; use the wire located onthe row closest to the plug release.3. Cut this wire and install Single Diode Harness as oriented inFigure A-2.4. After timming to correct length, connect the light blue with blackstripe trigger wire from step one to the blue connector of SingleDiode Harness installed in previous step.DiodeDiodeBFigure B-1Figure B-2PASSENGER SIDE WIRING1. After removing the front door step plate, lift carpet and pullPowerstep trigger wires through floor of truck.2. Locate the two wire bundles running up along kick panel areaunderneith glove compartment as shown in the above figures.3. Open wire wrap of the bundles and locate the front and rear doorajar signal wires (dark blue with white stripe), one found in eachbundle.4. Cut each wire and install the Single Diode Harnesses asoriented in Figure B-2. Make certain that the leg with thediode is towards the top.5. Wrap all connections with electrical tape and secure anyloose wires.Notes:1. All of the signal wires tapped into will be 18Ga. Do not tap into anything with a thicker gage than this.2. Occassionally the wire colors do not match the wire schematics. Under these circumstances you will need to locate the door-ajar signal wires.3. Make sure to secure all wires after install. Loose wires can be damaged and may cause a failure in the Powerstep's function.Revision - 11/11/04

Wiring InstructionsRESEARCHGM POWERSTEP1999-2002 Truck & SUV - BASE LEVELSingle Diode Harness- Qty: 4(Call 800-315-9705 to receive diodes free of charge.)ATTENTION: Pay close attention to theorientation of the diode harnesses. ThePower-Step will not work with a incorrectlyinstalled diode harness.Leads to Front door Panel.DiodePower StepTrigger WireADiodeFigure A-1Power StepTrigger WireLeads towardrear of vehicle.DRIVER SIDE WIRINGFigure A-2Figure A-35. Locate the front door-ajar signal wire (tan) on large connectorlocated behind the connector of step 2.6. Cut this wire and install Single Diode Harness as oriented inFigure A-3.7. After timming to correct length, connect the grey with blackstripe trigger wire from step one to the blue connector of SingleDiode Harness installed in previous step.8. Wrap all connections with electrical tape and secure any loosewires.1. After removing the front door step plate and kick plate, lift carpetand pull Powerstep trigger wires through floor of truck.2. Locate the rear door-ajar signal wire (orange) on black connectorbelow the hood-release lever (Area-A in Figure A-1). There shouldbe two wires of this color; use the wire located on the row closest tothe plug release.3. Cut this wire and install Single Diode Harness as oriented inFigure A-2.4. After timming to correct length, connect the light blue with blackstripe trigger wire from step one to the blue connector of SingleDiode Harness installed in previous step.DiodeDiodeBFigure B-1Figure B-2PASSENGER SIDE WIRING1. After removing the front door step plate, lift carpet and pullPowerstep trigger wires through floor of truck.2. Locate the two wire bundles running up along kick panel areaunderneith glove compartment as shown in the above figures.3. Open wire wrap of the bundles and locate the front and rear doorajar signal wires (dark blue with white stripe), one found in eachbundle.4. Cut each wire and install the Single Diode Harnesses asoriented in Figure B-2. Make certain that the leg with thediode is towards the top.5. Wrap all connections with electrical tape and secure anyloose wires.Notes:1. All of the signal wires tapped into will be 18Ga. Do not tap into anything with a thicker gage than this.2. Occassionally the wire colors do not match the wire schematics. Under these circumstances you will need to locate the door-ajar signal wires.3. Make sure to secure all wires after install. Loose wires can be damaged and may cause a failure in the Powerstep's function.Revision - 11/11/04

Wiring InstructionsRESEARCHGM POWERSTEP1999-2002 Sierra Denali OnlySingle Diode Harness- Qty: 4(Call 800-315-9705 to receive diodes free of charge.)ATTENTION: Pay close attention to theorientation of the diode harnesses. ThePower-Step will not work with a incorrectlyinstalled diode harness.Leads to Front door Panel.DiodePower StepTrigger WireADiodePower StepTrigger WireLeads towardrear of vehicle.Figure A-1Figure A-2DRIVER SIDE WIRINGFigure A-35. Locate the front door-ajar signal wire (light green with blackstripe) on large connector located behind the connector of step 2.6. Cut this wire and install Single Diode Harness as oriented inFigure A-3.7. After timming to correct length, connect the grey with black stripetrigger wire from step one to the blue connector of Single DiodeHarness installed in previous step.8. Wrap all connections with electrical tape and secure any loosewires.1. After removing the front door step plate and kick plate, lift carpetand pull Powerstep trigger wires through floor of truck.2. Locate the rear door-ajar signal wire (dark blue with white stripe)wire on black connector below the hood-release lever (Area-A inFigure A-1). There should be two wires of this color; use the wirelocated on the row closest to the plug release.3. Cut this wire and install Single Diode Harness as oriented inFigure A-2.4. After timming to correct length, connect the light blue with blackstripe trigger wire from step one to the blue connector of SingleDiode Harness installed in previous step.DiodeDiodeBFigure B-1Figure B-2PASSENGER SIDE WIRING1. After removing the front door step plate, lift carpet and pullPowerstep trigger wires through floor of truck.2. Locate the two wire bundles running up along kick panel areaunderneith glove compartment as shown in the above figures.3. Open wire wrap of the bundles and locate the rear door-ajar signalwire (dark blue with white stripe) in one bundle and the front doorajar signal wire (light green with black stripe) in the other bundle.4. Cut each wire and install the Single Diode Harnesses asoriented in Figure B-2. Make certain that the leg with thediode is towards the top.5. Wrap all connections with electrical tape and secure anyloose wires.Notes:1. All of the signal wires tapped into will be 18Ga. Do not tap into anything with a thicker gage than this.2. Occassionally the wire colors do not match the wire schematics. Under these circumstances you will need to locate the door-ajar

AMP RESEARCH POWER STEP – GMC / CHEVROLET IMPORTANT: Steps 20 and 21 are for Crew Cabs and SUV’s only. Light blue and Green wires will not be used otherwise. See wire diagrams for model years previous to 2003. 4 Pull up the carpet and thread both wires through the floor panel (same steps on passen-ger side EXCEPT drill 9/32” hole in metal and