Part # 2
34. Compress handles until the ratchet mechanism automatically opens the J-38125-8 Splice Crimp Tool. Place a yellow DuraSeal splice sleeve in nest (3) as indicated above. Position the sleeve so that the crimp falls midway between the end of the barrel and the stop. Close the tool handles slightly in order to firmly hold the splice sleeve in the proper nest (3).
35. Insert the Cooling Fan - Left Low Reference circuit wire (1) into the barrel (2) of the splice sleeve until the wire hits the barrel stop (3).
36. Compress handles until the ratchet mechanism automatically releases in order to obtain a secure crimp.
37. Repeat steps 35 and 36 for the opposite end of the splice.
38. Use a heat torch to apply heat to the center area of the sleeve while rotating and gradually moving to the open ends of the tubing. The tubing will shrink completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinkage has occurred.
39. Repeat steps 34 through 38 for the:
- Cooling Fan - Right Supply Voltage Circuit
- Cooling Fan - Left Supply Voltage Circuit
40. Reinsert the High and Low Speed Cooling Fan Relay Control Circuit wires coming from the ECM back into the respective conduit for the harness and tape as needed.
41. Route the new spliced High Speed and Low Speed Cooling Fan Relay Control Circuit wires under the fuse block and toward the RH fender flange.
42. Insert any excess wire length for the Cooling Fan Low Reference Circuit, Right Supply Voltage Circuit and Left Supply Voltage Circuit back into the conduit (1) from which it was extracted in the area by the RH fender flange and tape as needed.
43. Install the ground wire grommet from the revised harness assembly at the existing G 100 ground location (1) as shown.
Tighten
Tighten the fastener to 7 Nm (62 lb in).
44. Install and seat the X1 and X3 electrical connectors into the fuse block. Verify the proper positioning of all four connectors in the fuse block.
45. Install the electrical center board (2). Ensure that the tabs have locked in place.
Install the fasteners (1).
Tighten
Tighten the fasteners to 7 Nm (62 lb in).
46. Install the forward lamp battery supply harness terminal and the fusible links (1) to the LH and RH fuse block battery studs in their original positions and orientations.
47. Route the shortest Maxi-Fuse ring terminal lead (2) to the RH fuse block stud (2). Maintain sufficient clearance.
Route the longest Maxi-Fuse ring terminal lead (1) over the top of the fuse block to the LH fuse block stud (1). Maintain sufficient clearance.
Tighten
Tighten the fasteners to 7 Nm (62 lb in).
48. Install the fuse block underhood electrical center cover (1).
49. Enclose as much as possible of the revised harness assembly in protective conduit and tape as needed.
Note
Do not tip the battery more than 40 degrees during installation.
50. Install the battery.
51. Install the battery hold down and bolt.
Tighten
Tighten the bolt to 18 Nm (13 lb ft).
52. Install the battery insulator.
Note
Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal.
53. Install the positive battery cable terminal to the battery.
54. Tighten the positive battery cable terminal nut.
Tighten
Tighten the nut to 15 Nm (11 lb ft).
55. Snap closed the positive battery cable terminal cover.
Note
Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal.
56. Install the negative battery cable terminal to the battery. Refer to Battery Negative Cable Disconnection and Connection in SI.
57. Tighten the negative battery cable.
Tighten
Tighten the nut to 15 Nm (11 lb ft).
58. Install the screw at the top of the windshield washer solvent container filler neck at the RF fender flange.
Tighten
Tighten the screw to 1Nm (9 lb in).
59. Install the retainer that secures the wiring harness to the bottom of the brace (2), then install the upper diagonal brace.
Install the RH front fender upper diagonal brace bolts (1).
Tighten
Tighten the bolts to 10 Nm (89 lb in).
60. Connect the electrical connector to the headlamp.
1. While installing the headlamp, guide the lock pin into the RH fender flange lock pin retainer.
2. Install the headlamp bolt.
Tighten
Tighten the bolt to 2Nm (18 lb in).
3. Secure the inner headlamp retainer.
61. Use the scan tool to clear any existing DTCs.
62. Use the scan tool output controls to command the Fan Relay 1, Fan Relay 2 & 3, and Fan Relays 1, 2 & 3 ON and OFF. Visually inspect both of the cooling fans for the correct ON/OFF actions when activated. Refer to Engine Control Module Scan Tool Output Controls in SI.