B. Wiring Harness Repair

NOTE:
This kit applies only to those vehicles with damage to the convolute and/or wiring as determined the inspection in Section A. Very few vehicles are expected to require this repair.

1. Pull apart the reflective convolute and pull the wires out for inspection.

> If no heat damage (melted) is found on the insulation of any of the four wires to the oxygen sensor connector, continue with Step 21.

> If heat damage is found (melted) on the insulation of any of the four wires to the oxygen sensor connector, continue with Step 2.





2. Disconnect the left rear oxygen sensor (Figure 2).

3. Disconnect the 4-way connector fastener from the cross member. Make sure the hole in the crossmember is free of debris.

4. Remove the entire damaged 3/8" reflective convolute tube (from the powertrain wire harness to the left rear oxygen sensor connector).

5. Note the wire colors and terminal locations of each wire in the oxygen sensor connector.

6. Using a small screw driver, remove the lock plate from the oxygen sensor connector. (Figure 2)





7. Remove the four wire terminals from the 4-way connector by disengaging the latch for each wire terminal, then pulling back on the wire. (Figure 3).

8. Discard the lock plate and the old 4-way connector.

9. Slide one heat shrink tube over the damaged area of the wire and center it.

10. Using a heat gun, apply heat along the entire length of the heat shrink tube until the tube shrinks tightly on the wire and sealant comes out of both ends.

11. Repeat Steps 9 and 10 for the other damaged wires as needed.





12. Install the 1/2" reflective convolute over the four oxygen sensor wires (Figure 4).

13. Noting the wire positions as recorded in Step 5 insert the four wire terminals into the new 4-way connector until they are securely latched.

NOTE:
Do not remove the lock plate from the connector.

14. Confirm the lock plate is fully seated into the harness connector by pushing on the yellow connector lock plate with a small screwdriver.

15. Wiggle the wires at the back of the connector to ensure proper seating of the wire to connector seal.

16. Insert the new connector fastener onto the new connector.

17. Attach the 4-way harness connector to the oxygen sensor and push the connector fastener into the cross member.

18. Tie strap the end of the 1/2" reflective convolute nearest to the connector. Cut off the excess tie strap leader.

19. Tie strap the excess length of the repaired oxygen sensor wiring to the main trunk of the powertrain harness just above the mounting bracket of the transmission as shown in Figure 4.

20. Lower the vehicle from the hoist and return the vehicle to the customer.

21. Cut away only the damaged section of the reflective convolute.

22. Insert the four oxygen sensor wires back into the two reflective convolute tubes.

23. Cut a new piece of 1/2" reflective convolute tube to a length 1" longer than the four exposed oxygen sensor wires.

24. Starting at the connector end, install the new 1/2" reflective convolute tube over the existing 3/8" reflective convolute tube end leaving a 1/2" overlap at each end.

25. Pull the repaired powertrain harness oxygen sensor wiring towards the transmission leaving a slight droop to allow for engine/transmission movement.





26. Tie strap the excess length of the repaired oxygen sensor wiring to the main trunk of the powertrain harness just above the mounting bracket of the transmission as shown in Figure 5.

27. Lower vehicle from the hoist.