Engine Electrical - Melted Wire Harness Conduit

9217chevy01

Number: 91-401-6D

Section: 6D

Date: AUGUST 1991

Corporate Bulletin No.: 136404 ASE No.: A6


Subject:
MELTED WIRE HARNESS CONDUIT


Model and Year:
1990-91 CORSICA, BERETTA AND CAVALIER WITH 2.2L ENGINE


Condition:
Some 1990 and 1991 "L" cars built prior to:

Wilmington MY150568

Linden ME132551

and 1990 through 1991 "J" cars may experience a melted engine wiring harness conduit above the starter motor as a result of engine manifold heat.





Cause:
Under certain conditions where high ambient and engine operating temperatures are experienced, engine harness conduit may appear melted above the starter motor.

Correction:
A revised routing, retention, and higher temperature conduit package, P/N 12125390 should be installed as follows:

Part is currently available from GMSPO.

WITH AIR CONDITIONING (C60)

Remove Or Disconnect:

1. Raise hood and install fender covers.
2. Negative battery cable.
3. Oil fill tube bolt and oil fill tube.
4. Oxygen sensor connector and oxygen sensor.
5. Wiring harness clamp above starter.
6. Release (2) harness clips.
7. Tape from harness near starter fusible links.
8. Carefully cut conduit approximately 1O mm (3/8 in.) under lower alternator retainer and discard conduit.
9. Remove and discard retainer from upper air conditioning bracket.
10. Remove and discard conduit from pressure switch on compressor.


Install Or Connect

1. 100 mm (4 in.) piece of 6 mm (1/4 in.) diameter conduit on A/C pressure switch harness.
2. 555 mm (22 in.) piece of 16 mm (5/8 in.) diameter conduit on engine harness from under alternator to starter.
3. Tape both harness conduit ends securely.
4. Place original harness clamp on harness conduit 170 mm (6 3/4 in.) from fusible links near starter.
5. Place metal retainer from service package 370 mm (14 1/2 in.) from harness clamp onto harness conduit.
6. Secure with kit supplied push-in retainer.
7. Harness clamp bolt. Tighten to 13 N-m (10 lbs.ft.).
8. Coat oxygen sensor threads with anti-seize compound, P/N 5613695 or equivalent and tighten to 41 N-m (30 lbs.ft.).
9. Oil fill tube and bolt. Tighten bolt to 25 N-m (18 lbs.ft.)
10. Negative battery cable.
11. Hood.

Without Air Conditioning (C41)

Remove Or Disconnect

1. Raise hood and install fender covers.
2. Negative battery cable.
3. Oxygen sensor.
4. Oil fill tube bolt and oil fill tube.
5. Wiring harness clamp next to starter.
6. Release harness clips.
7. Tape from harness near starter fusible links.
8. Carefully cut conduit approximately 1O mm (3/8 in.) under lower alternator retainer.
9. Remove conduit section from cut end to starter and discard.

Install Or Connect

1. Kit supplied 555 mm (22 in.) piece of 16 mm (5/8 in.) diameter conduit on engine harness from starter to lower alternator bracket.
2. Tape both harness conduit ends securely.
3. Place original harness clamp on harness conduit 170 mm (6 3/4 in.) from fusible links near starter.
4. Place metal retainer from service package 330 mm (13 in.) from harness clamp onto harness conduit.
5. Secure with push-in retainer supplied with kit.
6. Harness clamp bolt. Tighten to 13 N-m (10 lbs.ft.).
7. Coat oxygen sensor threads with anti-seize compound, P/N 5613695 or equivalent and tighten to 41 N-m (30 lbs.ft.).
8. Oil fill tube and bolt. Tighten to 25 N-m (18 lbs.ft.).
9. Negative battery cable.

Labor Operation Number: T1753

Labor Time .6 Hours

Trouble Code 92