Procedures A, B, C and D
PROCEDURE "A" - HARNESS INSPECTION1. Lift vehicle on hoist to access the undercover.
2. Remove the fasteners (A) and bolts (B) to remove the undercover from the vehicle.
3. Carefully inspect the harness (A) in the area closest to the engine starter housing (B).
DOES THE HARNESS TOUCH THE ENGINE STARTER HOUSING?
^ YES - Go to next step.
^ NO - Go to PROCEDURE "B"
4. Inspect the vehicle's harness and compare to the illustration below to determine procedure.
^ Starter contacts area of corrugated sheath (A) - Go to PROCEDURE "B".
^ Starter contacts area of tape (B) with no corrugated sheath - Go to PROCEDURE "C".
PROCEDURE "B" - EMISSION HARNESS PROTECTOR CLIP / SPACER INSTALLATION
NOTE:
The installation procedure and parts differ depending on the type of transmission the vehicle is equipped with. Please verify you have the correct parts for the transmission type, and then follow the proper installation instructions.
VEHICLES WITH AUTOMATIC TRANSMISSIONS
NOTE:
Some harnesses may be routed very close to the starter housing which could make the following procedures difficult to perform. Refer to PROCEDURE "D" - INCREASING WORK SPACE.
1. Install the spacer (A) on the emission harness by positioning it over harness in area shown, then squeeze together until tight.
2. Install the protector clip (B) on the emission harness by positioning it on the harness as shown, then squeeze the clip together until it snaps.
IMPORTANT:
MAKE SURE TO PLACE PROTECTOR CLIP WITH THE FLAT SIDE SHOWING "25" CLOSEST TO THE STARTER CONTACT AREA (C).
3. Refasten the lower harness anchor if unfastened in PROCEDURE "D" - INCREASING WORK SPACE.
VEHICLES WITH MANUAL TRANSMISSIONS
1. Add the rubber pad to the protector clip as shown.
2. Install the protector clip on the emission harness by positioning it on the harness at the point shown (A), then squeeze the clip together until it snaps.
IMPORTANT:
MAKE SURE TO PLACE PROTECTOR CLIP WITH THE FLAT SIDE SHOWING "22" CLOSEST TO THE STARTER CONTACT AREA (B).
PROCEDURE "C" - WATERPROOFING HARNESS
NOTE:
This procedure prevents water entry if harness tape was damaged by engine starter housing contact.
IMPORTANT:
IF VEHICLE IS EXPERIENCING MILS, BLOWN FUSES OR DRIVEABILITY CONCERNS THE EMISSION HARNESS WIRING MAY BE WORN THROUGH TO BARE COPPER CONDUCTER WIRE AND TOUCHING THE ENGINE STARTER HOUSING.
IS THE VEHICLE CURRENTLY EXPERIENCING MILS, DRIVEABILITY CONCERNS, BLOWN FUSES ETC..?
^ YES - Carefully inspect the emission harness for damage resulting in bare copper wire contact with engine starter housing. If you confirm wires are shorted, contact the NATIONAL TECHNICAL ASSISTANCE HOTLINE for further instructions.
^ NO - Go to step 1.
NOTE:
Some harnesses may be routed very close to the starter housing which could make the following procedures difficult to perform. Refer to PROCEDURE "D" - INCREASING WORK SPACE.
1. Note the area of harness at the engine starter housing contact point (A) to be waterproofed as shown (B).
2. Apply butyl tape in this area by following these steps.
- a. Remove the backing paper of one side of the butyl tape (PN 0000-99-TAPE).
- b. Apply butyl tape to contact area of the emission harness.
- c. Remove the remaining paper backing of the butyl tape.
3. Using 35 inches of electrical tape, wrap the harness to completely cover the butyl taped area as shown.
TIP: The work space for taping the harness is limited and may be difficult using a full roll of tape. Precutting 35 inches of tape, then wrapping it onto a 9 mm or 10 mm socket (A), allows easier application of the tape to the harness.
4. Perform PROCEDURE "B" - INSTALL EMISSION HARNESS PROTECTOR CLIPS.
PROCEDURE "D" - INCREASING WORK SPACE
NOTE:
There may be limited space to perform some procedures, especially on vehicles with an automatic transmissions. More work space can be obtained by temporarily releasing the lower harness anchor and moving the harness.
1. Release the anchor (A) of the main emission harness.
2. Pull the harness away from the AT Shifter cable bracket (B) to gain more work space.
C. CAMPAIGN LABEL INSTALLATION
1. Fill out a blue "Campaign Label" (9999-95-065A-06) with Campaign No: "5409D", your dealer code, today's date, and affix it to the vehicle's bulkhead or hood as shown in "A VEHICLE INSPECTION PROCEDURE".
2. Return vehicle to customer.