Recall - Engine Wiring Harness Modification

Division: Automotive
Category: Technical

Section Title: Body Electrical
TSB No. TS 10 11253

SUBJECT:
SAFETY RECALL CAMPAIGN: EN, MODIFICATION TO ENGINE HARNESS AND ADDITION OF PROTECTION BRACKET

MODEL(S):
GRAND VITARA XL-7 (JA627)

YEAR:
2003

CONDITION:
Some Grand Vitara XL-7s have experienced a condition where the engine has shut off while driving.

CAUSE:
The engine wiring harness can rub against the intake manifold causing damage to wiring harness. This can cause a short in the ignition circuit which can cause the ignition fuse to blow.

CORRECTION:
Access engine harness and apply additional insulation to ignition protectors and splice caps relocate to backside of the engine harness. Install an engine harness protection bracket that is included in kit.





AFFECTED VIN RANGE








PARTS INFORMATION

PROCEDURE:

1. Record all radio station presets.

2. Disconnect negative battery cable.





3. Disconnect and remove canister purge valve.

4. Disconnect map sensor.





5. Disconnect throttle kick down cable assembly on automatic transmission vehicles only and move out of way.





6. Remove 6M retaining bolts from clamps A B C and clip as shown in illustration # 1





7. Pull engine harness up and out from behind intake manifold.





8. Remove the tape wrap from around the two protectors.





9. Place the two protectors to the butyl rubber sheet as shown leaving a small space between the two protectors in the middle of the sheet as shown.





10. Fold the butyl rubber sheet over the two protectors and pinch the sheet together between the two protectors.





11. Roll the butyl rubber sheet around the two protectors and rotate the protectors to the back side of the engine harness.





12. Wrap the harness and two protectors with black electrical tape.








13. Install bracket between the engine harness clamp A and intake manifold as illustrated in illustration # 2. Side view of harness protectors and bracket should be like illustration # 3





14. Install clamps B C and retaining clip. Connect MAP sensor and install canister purge valve making sure to attach the ground eyelet to the retaining bolt. Reinstall throttle kick cable on automatic transmission vehicles.

15. Attach negative battery cable and start vehicle. Warm up to operating temperature turn ignition switch to oft remove negative battery cable and touch it to the positive battery cable to relearn TPS settings. Re-attach negative battery cable. Set radio presets and clock.





16. Install the EN recall sticker to the radiator core support above the left headlamp.