8804 - Driveability -- Manual Transmission Equipped Models

Correction requires installation of an Oxygen Sensor Module Kit, P/N 83505116 (8983 505 116).

Note: Some of the vehicles may already have the module kit installed. If you determine that the kit must be installed, proceed as follows:

^ Kit Installation Procedure

1. Open the hood.

2. Disconnect the battery cables.

3. Remove the battery holddown bracket.

4. Remove the battery.

FIGURE 1:

5. Mount the module (A of Figure 1) on the headlight panel as follows:
a. Mark a spot on the panel ledge (F) 4 inches to the left of the oval opening (G) and 3/8 inch up from the bottom of the ledge.

b. Drill a 3.9 mm (0.1535 inch) hole at the marked spot for the module mounting screw.

c. Apply dielectric grease, P/N J8126688 (812 6688), to the threads of the module mounting screw supplied in the kit.

d. Attach the module (A) and the ground wire eyelet (B) to the panel ledge with the mounting screw.

FIGURE 2:

8804 - Driveability -- Manual Transmission Equipped Models

^ Kit Installation Procedure (Continued)

6. Remove the Oxygen Sensor connector (H of Figure 2) from the retainer clip on the engine block.

FIGURE 3:

7. Disconnect the Oxygen Sensor wire connector and install the new harness connectors (C & D of Figure 3).

FIGURE 4:

8. Route the voltage source wire (E of Figure 4) along the radiator upper cross-member to the driver side of the engine compartment. Position the end of wire (L, Figure 4) in the area shown.

FIGURE 5:

8804 - Driveability -- Manual Transmission Equipped Models

^ Kit Installation Procedure (Continued)

9. Remove the wing nut (J of Figure 5) and remove the ECU cover (K).

FIGURE 6:

10. Locate the green wire (N of Figure 6) leading to terminal "C" of the MAP sensor connector (M).

11. Cut the green wire (N) 1-1/2 inches from the connector.

12. Remove 1/2 inch of insulation from each end of the cut wire
(N) with a wire stripper tool.

FIGURE 7:

13. Slide the heat shrink tubing from the kit onto the voltage source wire (E of Figure 7). Then slide the tubing back from the wire end about two inches to avoid heating the tubing when the wire is soldered.

14. Twist the ends of wire (N) together. Then twist the end of wire (E) around wires (N) to ensure a strong connection (Figure 7).

FIGURE 8:

8804 - Driveability -- Manual Transmission Equipped Models

^ Kit Installation Procedure (Continued)

15. Solder wires (E) and (N )together with rosin core solder (Figure 8).

16. Slide the heat shrink tubing over the soldered connection. Be sure that the tubing completely covers the solder joint and any sections of bare wire.

FIGURE 9:

17. Shrink the tubing with a heat gun (R, Figure 9).

FIGURE 4:

18. Secure the new harness wire (E, Figure 4) to the radiator cross-member with tie straps (P).

FIGURE 3:

19. Coil any excess wire at the Oxygen Sensor and secure it with a tie strap (Q, Figure 3).
20. Install the ECU cover and wing nut.

21. Install the battery holddown bracket. Then install and connect the battery.