Color-Coded Wire Repair Only

Repair Procedure (color-coded wires only)

Order the harness service kit (P/N 24299-0L725) from the Parts Information table.





1. Remove and discard all four clips (A through D) from the EGI harness (see Figure 3-1). You can cut clips C and D. Pull, but DO NOT CUT clips A and B from their brackets.

2. Cut away the tape and remove the star-shaped support braces from the harness (see Figure 3-2). Discard these braces.





3. Remove the bracket for clip A from the strut tower (see Figure 4).

CAUTION : Be extremely careful not to cut into any wires within the harness.





4. Cut and unwrap the tape from around the corrugated tube surrounding the harness (see Figure 5). Remove and discard the corrugated tube.

5. If a wire is accidentally cut, you must repair it (perform steps 10-12).

6. Unwrap the tape from around the harness that was covered by the corrugated tube.





7. Push the zipper tube (near the bulkhead) down at least 2 inches to gain access to the wires (see Figure 6).

8. Remove the tape to expose the hard plastic cover at the harness intersection (see Figure 5).

9. Visually inspect each wire for breakage within the harness bend that is the color identified in the Diagnosis Procedure. Typically it is a wire that is near the outside which has been stressed against a larger wire. It may be broken inside the insulation.

A. If the broken wire cannot be identified, then wiggle each wire of this color in the harness bend while checking the continuity of the identified incident circuit.





10. Cut the broken wire 1-1/2 inches rearward from the hard plastic cover at the intersection of the harness (see Figure 7).





11. Cut the broken wire 1-1/2 inches up from the top of the zipper tube (see Figure 8).





12. Replace the broken wire with an equivalent gauge wire. Splice the bulkhead side of the wire first. Then lay the wire along the harness up to the harness intersection to determine the correct length for the replacement wire (see Figure 9).

IMPORTANT Make sure the replacement wire finished length is 1 inch longer than the section you cut out of the harness. If it is too short or too long, it may stress and break again after installation.

A. Solder the bare wire connection.

B. Wrap the solder connection with mechanic's Dumm Dumm to make it watertight.

C. Wrap with electrical tape.

NOTE: Perform this procedure to both ends of the replacement wire. Only the top splice is




13. After completing the wire repair, tape the exposed harness wire bundle at two intermediate points with electrical tape (see Figure 10).




14. Install the countermeasure corrugated tube around the wire bundle (see Figure 11). Tape the ends of the corrugated tube securely to the harness at either side of the bend with electrical tape.

15. Re-tape the hard plastic cover at the harness intersection.

16. Tape loosely a few turns around the length of the corrugated tube prior to installation of the clips.

17. Install the bracket for clip A back on to the strut tower (see Figure 3).

18. Install countermeasure clip A and clip B to their respective metal brackets.

19. Attach clips A and B around the harness.

20. Securely tape the clips and the harness.

21. Install countermeasure clips C and D to the engine, then secure them to the harness (see Figure 3).