Recall - 98V170 Engine Ground Wire Harness Replacement: Overview
BULLETIN NUMBER:SB98-04-L006
ISSUE DATE:
AUGUST 1998
GROUP:
ELECTRICAL
1998 RODEO (UE) & AMIGO (UA)
ENGINE GROUND WIRE HARNESS REPLACEMENT
SAFETY CAMPAIGN 98V-170
CAMPAIGN IDENTIFICATION NUMBER
Number 98V-170 has been assigned to this campaign. This number will appear on all communications and documentation of any nature dealing with this campaign.
AFFECTED VEHICLES
1998 Rodeo (UE), Amigo (UA) V6 models
with production dates before March 1, 1998.
^ 1998 Rodeo (UE): Start of Production up to VIN 4S2CK58W3W4346921
^ 1998 Amigo (UA): Start of Production up to VIN 4S2CM57W6W4346908
SERVICE INFORMATION
Condition:
On some affected vehicles, the engine wire harness ground connection terminal may fracture due to improper crimping. In a case where the terminal is fractured, the powertrain control module (PCM) may misinterpret it as a signal indicating a high vehicle speed. The PCM will then cut the fuel causing a "no-start" condition or an engine stall.
Correction:
To prevent this condition from occurring, Isuzu dealers will replace the existing wire harness with a new harness (Part Number 8-97211-283-0).
DEALER RESPONSIBILITY
Isuzu dealers must service all affected vehicles at no charge to the owner, regardless of mileage, age of vehicle, or ownership.
Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a dealership for service, the dealer must take the necessary steps to ensure that this campaign correction has been made before selling or releasing the vehicle.
All unsold new vehicles in dealer's possession and subject to this campaign must be held and repaired per the service procedure in this Campaign Bulletin before customers take possession of their vehicles.
OWNER NOTIFICATION
American Isuzu Motors Inc. (AIMI) will send a notification letter to owners of affected vehicles already retailed (See Enclosed Copy). Dealers should follow up with vehicle owners by sending a Campaign Reminder Notice (AIMI SVCF-1052) to all vehicle owners listed in the AIMI Campaign Report AWS 123-1A. Dealers may obtain these postcards from their Regional Office.
SERVICE PROCEDURE
Refer to the 1998 Rodeo (UE) ELECTRICAL TROUBLESHOOTING MANUAL for detailed information of the vehicle electrical system.
Removal
1. Record any radio presets and disconnect the negative terminal of the battery.
2. Using access through the right fender well, disconnect the wire harness at the following locations:
^ (P-10) Ground terminal, on the alternator support bracket (Figure 1)
^ (P-7) Ground terminal, near the alternator, on the frame (Figure 2)
^ Push the release tab of the band clip near the alternator and remove from harness for later use. Do not cut or discard this original band clip.
^ (P-8) Harness connector at the side of alternator (Figure 3)
^ (P-9) B+ ring terminal with two (WHT) wires at the rear of alternator (Figure 3)
3. From under the hood, disconnect the wire harness at the following locations:
(Figure 4)
^ (P-6) Ground terminal, near the fuse box
^ (H-3) Harness connector near the fuse box
^ (H-2) Harness connector near the fuse box
4. Remove the harness from the vehicle.
^ Remove the harness clip behind the battery tray. (Figure 4)
^ Remove the harness clip under the battery tray. (Figure 5)
5. * If Service Campaign 9804L2 (Refer to SB98-04-L002 for details) was performed on this vehicle, the installed pigtail harness (P/N 5-86698-014-0) cannot be removed from the (H-2) connector socket of the vehicle. The new harness must be reconnected to this pigtail harness to maintain proper operation. If equipped, do not remove. (Figure 6)
Installation
1. Using connector-to-clip distance of the old harness as a guide, reposition the harness clip of the new harness (Part Number 8-97211-283-0) to match the old harness. (Figure 7)
2. Position the new wire harness to its approximate position in the engine compartment, and attach the harness clip under the battery tray.
3. Using access through the right fender well, connect the new wire harness at the following locations:
^ (P-8) Harness connector at the side of alternator
^ Route the existing harness (leading to E-27 connector) in between the (P-8) and (P-9) connections and away from the exhaust manifold. (Figure 8)
^ (P-9) B+ ring terminal with two (WHT) wires, at the rear of alternator
^ (P-7) Ground terminal, near the alternator, on the frame
NOTE
Clean the ground area and fastening bolt with a wire brush. Replace the bolt if heavily corroded.
4. Install one band clip near the alternator. (Figures 9 & 10)
NOTE
The harness must be secured from surrounding components with the band clip to prevent possible damage to harness due to chafing.
5. From under the hood, connect the new wire harness at the following locations:
^ Attach the harness clip behind the battery tray.
^ Loosely attach (P-6) ground terminal, near the fuse box
NOTE
Clean the ground area and fastening bolt with a wire brush. Replace the bolt if heavily corroded.
^ (H-3) Harness connector near the fuse box
^ (H-2) Harness connector near the fuse box
* NOTE
If previously equipped, inspect the proper connection of the Rear Defogger ACG (pigtail harness) into the (H-2) socket. (Refer to Step 5 Removal)
^ Torque the (P-6) ground terminal to (14 N.m) 10 lb.ft.
6. Install the (P-6) ground terminal on the alternator support bracket, with 90° bend at top. (Figure 11)
NOTE
Clean the ground area and fastening bolt with a wire brush. Replace the bolt if heavily corroded.
7. Install the new band clip to the harness under the battery tray. (Figure 12)
NOTE
The excess slack of the harness must be secured from surrounding components with the band clip to prevent possible damage to harness due to chafing.
8. Reconnect the new wire harness to the battery and reset the radio presets and the clock.
APPLYING THE CAMPAIGN LABEL
1. Using a ball-point pen, fill out the following information on a campaign label (Part # 2-90028-700-0). (Figure 13)
^ This safety campaign number: 98V-170
^ Dealer Code
^ Repair Date: (Month/Day/Year)
2. Affix the campaign label adjacent to the manufacturer's identification label located on the driver's side B-pillar.
PARTS INFORMATION
Part Number Description Quantity Required
8-97211-283-0 HARNESS, Cable 1
5-09707031-0 CLIP, Band *1
2-90028-700-0 LABEL, Campaign 1
* The existing band clip near the alternator must be reused along with one new band clip.
WARRANTY CLAIM INFORMATION
Use the new labor operation as shown.
Use Trouble Code 07 for all campaign operations.
Labor Time includes diagnosis time and administrative time allowance.