Service Procedure

1. Disconnect negative battery cable.

2. Disconnect positive battery cable at battery then disconnect leads to alternator and junction block on fender well.





3. Remove and save screws from # 1 and # 2 clips (see Figure 2) on starter lead of old cable.

4. Route new cable so starter terminal can be reached from below.

5. Raise vehicle and disconnect old cable from starter. Old cable will not be reused.

6. Attach starter terminal of new cable to starter. Torque to 17 N-m (12 lb.ft.).

7. Lower vehicle.





8. Copy and cut out template in Figure 1.





9. Referencing Figure 3. locate the two existing holes (one oblong and one round) in the area of frame rail where the "new hole" is to be drilled. Using these two existing holes as locating points, install template and tape in place. Use a punch to mark hole location, then drill a 5.6 mm (7/32 inch) hole. This hole will be used for # 3 clip shown in Figures 2 and 4.





10. Install new retainer in # 2 clip location as shown in Figure 3. Use new screw (P/N 11508995) to attach retainer to frame. Torque to 4.8 N-m (40 lb.in.).

11. Route starter lead of cable as shown in Figure 4.

12. Attach clips # 1 and # 3 using screws removed in step 3, above. Torque screws to 4.8 N-m (40 lb.in.).

13. Attach clip # 2 to retainer installed in step 10 with new screw (P/N 11508154). Torque screw to 3.0 N-m (18 lb.in.).

Notice:
Make certain that any slack is removed from cable to insure cable is positioned as far away from exhaust manifold as possible.

14. Connect new positive battery cable to battery and attach lead ends to alternator and junction block.

15. Connect negative battery cable.

16. Install Campaign Identification Label.

Notice:
This campaign is to be performed on all involved vehicles in conjunction with campaign 92C31, "Engine Mounted Fuel Pipe Fracture". Some involved vehicles may also require campaign 92C33, "Crankcase Vent Tube Disconnection", to be performed.