Safety Recall Campaign: En, Modification To Engine Harness And Addition Of Protection Bracket (TS 10 11253)

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

TECHNICAL SERVICE BULLETIN

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

All 2003 Grand Vitara XL-7
JS3TX92V_34100030	~	JS3TX92V_34116055
JS3TY92V_34100002	~	JS3TY92V_34106458

PARTS INFORMATION

Part #	Part Name	Model(s)	Contents
36600-65820	EN Recall Bracket Set, Engine Harness	Grand Vitara XL7	Bracket, Engine Harness Protection (1) and Sheet, Harness (1)

PROCEDURE:

1. Record all radio station presets.
2. Disconnect negative battery cable.
3. Disconnect and remove canister purge valve.
4. Disconnect map sensor.
   Fig 2: Locating Canister Purge Valve & Map Sensor

   
5. Disconnect throttle kick down cable assembly on automatic transmission vehicles only, and move out of way.
   Fig 3: Disconnecting Throttle Kick Down Cable Assembly

   
6. Remove 6M retaining bolts from clamps A, B, C, and clip as shown in Fig 4 .
   Fig 4: Removing Retaining Bolts From Clamps A, B, C, And Clip

   
7. Pull engine harness up and out from behind intake manifold.
   Fig 5: Pulling Engine Harness Up And Out From Behind Intake Manifold

   
8. Remove the tape wrap from around the two protectors.
   Fig 6: Removing Tape Wrap From Around 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.
   Fig 7: Placing Protectors To Butyl Rubber Sheet

   
10. Fold the butyl rubber sheet over the two protectors and pinch the sheet together between the two protectors.
    Fig 8: Folding Sheet Over Protectors

    
11. Roll the butyl rubber sheet around the two protectors and rotate the protectors to the back side of the engine harness.
    Fig 9: Rotating Protectors To Back Side Of Engine Harness

    
12. Wrap the harness and two protectors with black electrical tape.
    Fig 10: Wrapping Harness And Protectors With Black Electrical Tape

    
13. Install bracket between the engine harness clamp A and intake manifold as illustrated in Fig 11 . Side view of harness, protectors, and bracket should be like Fig 12 .
    Fig 11: Installing Bracket Between Engine Harness Clamp A And Intake Manifold

    
    Fig 12: Identifying Side View Of Harness, Protectors, And Bracket

    
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.
    Fig 13: Attaching Ground Eyelet To Retaining Bolt

    
15. Attach negative battery cable and start vehicle. Warm up to operating temperature, turn ignition switch to off, 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.
    Fig 14: Installing EN Recall Sticker