GMC Safari resurrection

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GMC Safari resurrection

Here you can follow the progress, as we aim to restore a 1994 GMC Safari back to its full glory.

01/11/2026

Put the 'lid' back on today. Set off to test drive - ABS light came on. Feeling defeated I decided to check if the codes had changed etc. Terminals A-H, ignition on.... New loud noise - never heard before. Panic sets in.
More research done, turns out when you check for codes it cycles the ABS module, but I wasn't hearing it before as the pump wasn't cycling. Having found this out, I tried to clear the codes, and I did. It wouldn't let me clear them previously as it couldn't 'find' the module.
Took the van around the estate.... No ABS warning light, no new codes. Happy bunny!
All because of ONE 32 year old solder joint. 💪

01/11/2026

As someone commented the other day.... My sole purpose appears to be to find and publish every single problem imaginable, related to these vans.
After much research and advice, I came to the conclusion that such a catastrophic quantity of codes all happening at once meant an electrical issue rather than a sensor issue. Many owners stated the Kelsey-Hayes ABS module are well known for cracked solder joints being the source of a major code dump.
So yesterday (following a fantastic write up/tutorial, someone sent me as reference), I took the 'lid' off the ABS module. This was the easiest part of the job tbh, a bunch of T25 torx screws and a gentle prise and the lid came away. They electrical connectors were crudded up with 32 years of engine muck, but managed to find the locking tabs, which I wouldn't have been able to do if I hadn't removed the lid first and was able to tilt it for a better view.
The first thing I found (which was suggested I looked for), was a poor solder joint on the relay underneath the rubber boot on the remaining part of the unit.
The longest job was removing the PCB from the lid as it's well and truly fastened in with heatsink clips and sealant around the connectors. A couple of dodgy looking solder joints on the underside, which I redid.
I ran out of daylight and time yesterday, but hopefully I can refit the 'lid' today and find out if all that hard work yesterday has any effect on my problem. 🤷🤞

28/10/2026

Triple check all fluid levels today, checked for leaks etc. finally refit the upper radiator cowl and airhorns etc.
Happy bunny with the coolant/radiator/starting/running etc.

Then onto my new ABS light fault. So I checked my ABS codes today (jumper A to H on OBD1).... Got a list of faults back.

Code...
14 (AWD base code, 12 if you have the 2wd)
36 - missing vss signal
41 - open solenoid (front right)
42 - open PWH (front right)
45 - open solenoid (front left)
46 - open PWH (front left)
51 - EBCM control valve circuit fault
52 - control valves circuit fault
65 - open or shorted pump motor relay
67 - open motor circuit or shorted BPMV output

However because there was such a big list of codes it suggests a fuse or ground issue rather than a multiple amount of failures. Especially as it's a common fault, following a radiator replacement.
So I've checked the fuse under the dash (fine). I've found the ground point for the ABS, but that's tomorrow's job. If I still have the ABS light and codes after that I've got to find the main fuse (possibly in a plastic inline pod) or it could be a fusible link, (apparently somewhere in the main wiring loom).
If anyone has any advice on the Gen1, AWD, ABS system and where else to check for fuses/fusable links, please let me know.

24/10/2026

Update - new engine coolant temp sensor fitted. No change.
Did a full chase round of the 12v system from the beginning, through the starting process. Everything checked out as it should, all the way up to the brand new GM Genuine ICM.
Dead!
Threw on a spare I had knocking about (found in the van when I first bought it). Surprise surprise it started first time. And every time since. Rock auto are replacing the ICM allegedly. I won't hold my breath.
Next issue was the stalling when pulling up at junctions (found when I test drive round the block). Obviously the ECU needed to relearn the settings to keep the engine running under load at standstill.
Short test run went well, no stalling and no failing to start.
Just need to build up my trust in Blue again. Baby steps.
Just a dodgy ABS light to deal with now 🤦.

17/10/2026

Turns out the spare I had was for the side sensor (gauge) not the front one 🤦.
Luckily I managed to find the right part on Amazon. Try again tomorrow 🤷.

16/10/2026

Short lived victory.
Crank but no start from cold today.
Only thing left to change is the engine coolant temperature sensor.
The research suggests that a combination of the ECT sensor and the ECU makes the decision based on temp as to how much fuel it gives for start up. Like an automatic choke.
Learning new things every day here.
Luckily I bought a spare one last year. So tomorrow's job.
Fingers crossed this solves it. If not, I'm outta ideas and parts to replace.

15/10/2026

Well, the old radiator is out and finally new one in. So far so good, twice round the block and the idle has sorted itself thanks to the ECU relearning. A few local test runs needed next. Check fluids again. I need to regain my trust in him again.
Spraying the fittings earlier this week, for the oil cooler and trans cooler helped... They actually came undone without too much stress. Only issue was a seized bolt on the bottom fan cowl, but that was a minor hindrance in comparison to what could have gone wrong.
Safe to say, the old rad was knackered.

04/10/2026

Positive news to start with, RA are sending me a replacement radiator.
Removed the IAC yesterday, cleaned it and refitted. No change. The van starts but won't idle without a tickle of throttle.
So now everything is on hold till the new radiator is here and fitted. Can't run the engine up to temp for the computer to potentially relearn the idle settings until I have a working coolant system.
But the problem now either seems to be that the IAC valve has failed internally or I am yet again chasing a mystery problem around the engine like a headless chicken .

02/10/2026

Plugs removed and cleaned today. Starts up ok again. Still need to sort the low idle/stalling.... IAC and EGR clean next I think.

New radiator arrived from America today.
Couldn't make this up. 😔
Waiting on RA response for a replacement. ⏰

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Barnsley

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