I30 EGI HARNESS WIRE BREAKAGE

Transcription

1 Classification: Reference: Date: EC01-031A ITB01-072A January 9, I30 EGI HARNESS WIRE BREAKAGE ATTENTION: This bulletin Amends the Claims Information section of ITB Please discard all paper copies of ITB APPLIED VEHICLES: I30 (CA33) SERVICE INFORMATION If a I30 has any of the following symptoms: MIL 'On' and/or Diagnostic Trouble Code (DTC) stored in Self-Diagnosis, Engine no start, Other system malfunctions such as A/C inop, A/C idle up inop, rough idle, oil pressure light inop, The cause may be wire breakage in the engine control harness where it bends over the right rear of the engine next to the right strut tower (see Figure 1). See the Engine/Transmission DTC Charts on page 5 through page 7 for the possible DTC that may be caused by this incident, if it should occur. See the Symptom Chart on page 7 for possible symptoms that that may be caused by this incident, if it should occur. Right strut tower Harness bend Figure 1 TC /8

2 These repair procedures may apply to your DTC or symptom if it is specifically listed on the charts. Please note the following: Only incidents and circuits listed on the charts are applicable to this bulletin. All of the incident possibilities are circuits contained in wiring that pass through the bend in the engine control harness. For each DTC or symptom listed there can be more than one circuit to check. SERVICE PROCEDURE Diagnosis Procedure DTC Stored Use this procedure when the vehicle has come in with a DTC stored in Self-Diagnosis memory. 1. Use CONSULT-II to display 'Self-Diagnosis Results.' 2. Compare the DTC displayed by CONSULT-II to the following DTC charts: Engine DTC Charts # 1 and #2 on pages 5 and 6 Transmission DTC Chart on page After identifying possible affected circuits, CONSULT-II can be used in Data Monitor mode as a preliminary check. 4. Check for intermittent open or short circuits by aggressively wiggling the EGI harness side to side and up and down at the specified harness bend (see Figure 1, on page 1) while watching the results on CONSULT-II Data Monitor. If the Data Monitor readings change significantly or a DTC sets when you wiggle the harness, then wire damage has been confirmed. Replace the harness (see the PARTS INFORMATION section for additional information). If the readings do not change significantly, proceed to step 5, below. 5. Perform further diagnostics on the harness. Use the following references along with this bulletin: Appropriate year Electronic Service Manual (ESM) Trouble Diagnosis for the DTC displayed DTC Circuit charts on pages 5 through Perform Continuity Checks A and B on pages 3 through 4. If the open or short is confirmed, replace the entire harness (see the PARTS INFORMATION section for additional information). If you cannot confirm an open or short in the specified wire(s) as they pass through the indicated harness bend with the continuity checks, this bulletin does not apply. Diagnosis Procedure Non-DTC Symptom Use this procedure if the vehicle symptom is listed on the Symptom Chart on page Verify that the symptom is listed in Symptom Chart. 2. Refer to the system wiring diagram in the appropriate year ESM together with the Symptom Chart (page 7) to determine the pin location for the circuit in question. 3. Perform continuity checks A and B (on pages 3 through 4) on the wire(s) for the malfunctioning circuit to isolate the short or open to the incident wire(s). 2/8

3 4. Check for intermittent open or short circuits by aggressively wiggling the EGI harness side to side and up and down at the specified harness bend (see Figure 1, on page 1) and performing the indicated continuity check(s). If ohmmeter values changes significantly when you shake the harness, then wire damage has been confirmed. Replace the harness (see the PARTS INFORMATION section for additional information). If the value does not change significantly, then you cannot confirm an open or short in the specified wire(s) as they pass through the indicated harness bend with the continuity checks. This bulletin does not apply. Continuity Check A (open circuit check) see Figure 2, below 1. Record the radio presets for later reprogramming. 2. Turn Ignition Key Off and disconnect the vehicle s negative battery cable. 3. Disconnect the ECM and the engine component connectors. 4. Connect a jumper wire to the harness side of the appropriate pin of the ECM connector. IMPORTANT: Be very careful not to spread or otherwise damage the connector pin. 5. Route the jumper wire to the engine compartment. 6. Connect an ohmmeter between the jumper wire and the harness side of the appropriate pin of the component connector. 7. Aggressively wiggle the EGI harness side to side and up and down while you monitor the ohmmeter reading. Resistance value should be close to zero ohms. If resistance value is high/over range, or fluctuates, an open circuit exists. NOTE: If resistance is high or over range, be sure it is not caused by poor ohmmeter probe or jumper wire connections. DISCONNECT Bulkhead DISCONNECT H.S. H.S. To pin for incident wire Harness bend (shake here) Component connector ECM CONNECTOR Jumper wire Check A Pin for incident wire OFF Check B (connect to engine ground) TC Figure 2 Continuity Check B (short to ground check shielded wires only) 1. After completing Continuity Check A, move the ohmmeter lead from the component connector to an engine ground. 3/8

4 2. Again aggressively wiggle the EGI harness side to side and up and down while you monitor the ohmmeter reading. The resistance value should indicate an open circuit with infinite resistance (over range). If other than infinite resistance is indicated, the wire s outer shield is shorted to the inner signal wire and you must replace the harness (see the PARTS INFORMATION section for additional information). NOTE: If the resistance value indicates an open circuit, be sure it is not caused by poor ohmmeter probe or jumper wire connections. 3. Re-connect the vehicle s negative battery cable. 4. Re-set the vehicle radio presets. 4/8

5 Engine DTC Chart #1 DTC Circuit P0100 Air Flow Meter to ECM ; QA- " " Air Flow Meter to ECM ; QA+ " " Air Flow Meter to ECM ; VB " " Air Flow Meter to ECM ; AVCC P0105 Absolute Pressure Sensor to ECM ; PRES " " Absolute Pressure Sensor to ECM ; AVCC " " Absolute Pressure Sensor to ECM ; GND-A P0110 Intake Air Temp. Sensor to ECM ; GND-A " " Intake Air Temp. Sensor to ECM ; TA P0115 Coolant Temp. Sensor to ECM ; GND-A " " Coolant Temp. Sensor to ECM ; TW P0120 Throttle Position Sensor ECM ; AVCC " " Throttle Position Sensor ECM ; GND-A " " Throttle Position Sensor ECM ; TVO1 P0125 Coolant Temp. Sensor to ECM ; GND-A " " Coolant Temp. Sensor to ECM ; TW P0130 O2 Sensor Front-Bank 1 to ECM ; O2SFR P0131 O2 Sensor Front-Bank 1 to ECM ; O2SFR P0134 O2 Sensor Front-Bank 1 to ECM ; O2SFR P0135 O2 Sensor Front-Bank 1 to ECM ; O2HFR " " O2 Sensor Front-Bank 1 to IGN Fuse P0137 O2 Sensor Rear-Bank 1 to ECM ; O2SRR " " O2 Sensor Rear-Bank 1 to Engine Ground F42 P0138 O2 Sensor Rear-Bank 1 to ECM ; O2SRR " " O2 Sensor Rear-Bank 1 to Engine Ground F42 P0139 O2 Sensor Rear-Bank 1 to ECM ; O2SRR " " O2 Sensor Rear-Bank 1 to Engine Ground F42 P0140 O2 Sensor Rear-Bank 1 to ECM ; O2SRR " " O2 Sensor Rear-Bank 1 to Engine Ground F42 P0141 O2 Sensor Rear-Bank 1 to ECM ; O2HRR " " O2 Sensor Rear-Bank 1 to IGN Fuse P0150 O2 Sensor Front-Bank 2 to ECM ; O2SFL P0151 O2 Sensor Front-Bank 2 to ECM ; O2SFL P0154 O2 Sensor Front-Bank 2 to ECM ; O2SFL P0155 O2 Sensor Front-Bank 2 to ECM ; O2HFL " " O2 Sensor Front-Bank 2 to IGN Fuse P0157 O2 Sensor Rear-Bank 2 to ECM ; O2SRL " " O2 Sensor Rear-Bank 2 to Engine Ground F42 P0158 O2 Sensor Rear-Bank 2 to ECM ; O2SRL " " O2 Sensor Rear-Bank 2 to Engine Ground F42 P0159 O2 Sensor Rear-Bank 2 to ECM ; O2SRL " " O2 Sensor Rear-Bank 2 to Engine Ground F42 P0160 O2 Sensor Rear-Bank 2 to ECM ; O2SRL " " O2 Sensor Rear-Bank 2 to Engine Ground F42 5/8

6 Engine DTC Chart #2 P0161 O2 Sensor Rear-Bank 2 to ECM ; O2HRL " " O2 Sensor Rear-Bank 2 to IGN Fuse P0300 Multiple Injectors to ECM; INJ #s - 1 through 6 P0301 Injector No.1 to ECM ; INJ#1 P0302 Injector No.2 to ECM ; INJ#2 P0303 Injector No.3 to ECM ; INJ#3 P0304 Injector No.4 to ECM ; INJ#4 P0305 Injector No.5 to ECM ; INJ#5 P0306 Injector No.6 to ECM ; INJ#6 P0325 Knock Sensor to ECM ; KNK P0335 Crank Position Sensor to ECM ; POS " " Crank Position Sensor to ECM ; VB " " Crank Position Sensor to Engine Ground F42 P0340 Camshaft Position Sensor (Phase) to ECM ; PHASE " " Camshaft Position Sensor (Phase) to Engine Ground F42 * P0403 EGR Volume Control Valve to ECM ; EGR#1 * " " EGR Volume Control Valve to ECM ; EGR#2 * " " EGR Volume Control Valve to ECM ; EGR#3 * " " EGR Volume Control Valve to ECM ; EGR#4 * " " EGR Volume Control Valve to Fuse P0443 Purge Volume Control Solenoid Valve to ECM ; EVAP " " Purge Volume Control Solenoid Valve to Fuse P0505 IACV-AAC Valve to ECM ; ISC#1 " " IACV-AAC Valve to ECM ; ISC#2 " " IACV-AAC Valve to ECM ; ISC#3 " " IACV-AAC Valve to ECM ; ISC#4 P0510 Closed Throttle Position Switch to ECM ; IDLE " " Closed Throttle Position Switch to IGN Fuse P1130 Swirl Control Solenoid Valve to ECM ; SCV " " Swirl Control Solenoid Valve to Fuse P1148 O2 Sensor Front-Bank 1 to ECM ; O2SFR P1165 Swirl Control Vacuum Check Switch to ECM ; BSTSW P1168 O2 Sensor Front-Bank 2 to ECM ; O2SFL P1320 IGN Coil No.1 to ECM ; IGN#1 " " IGN Coil No.2 to ECM ; IGN#2 " " IGN Coil No.3 to ECM ; IGN#3 " " IGN Coil No.4 to ECM ; IGN#4 " " IGN Coil No.5 to ECM ; IGN#5 " " IGN Coil No.6 to ECM ; IGN#6 P1335 Crank Position Sensor to ECM ; REF P1336 Crank Position Sensor to ECM ; POS " " Crank Position Sensor to ECM ; VB * P1401 EGR Temp. Sensor to ECM ; EGRTS * " " EGR Temp. Sensor to ECM ; GND-A * DTC codes only apply to '00 Model Year vehicles with VINS up to YT or YT /8

7 Transmission DTC Chart DTC Circuit P0705 Inhibitor Switch to ATCU ; 1 SW " " Inhibitor Switch to ATCU ; 2 SW " " Inhibitor Switch to ATCU ; D SW " " Inhibitor Switch to ATCU ; N SW " " Inhibitor Switch to ATCU ; P SW " " Inhibitor Switch to ATCU ; R SW " " Inhibitor Switch to IGN Fuse P0710 A/T Fluid Temp Sensor to ECM ; GND-A " " A/T Fluid Temp Sensor to ATCU ; OIL TEMP SENS P0720 A/T Revolution Sensor to ECM ; GND-A " " A/T Revolution Sensor to ATCU ; SPEED SEN1 P0740 TCC Solenoid Valve to ATCU ; LU DUTY SOL P0745 Line Pressure Solenoid Valve to ATCU ; PL DUTY SOL(DR) " " Drop Resistor to ATCU ; PL DUTY SOL(DR) P0750 Shift Solenoid Valve to ATCU ; SHIFT SOL A P0755 Shift Solenoid Valve to ATCU ; SHIFT SOL B P1705 Throttle Position Switch to ATCU : WIDE OPEN SW P1760 Overrun Clutch Solenoid Valve to ATCU ; OVR/C SOL Symptom Chart Symptom Starter Motor Inoperative Engine No Start A/C Inoperative A/C On/Off Idle Adjust Inoperative Engine Mount Inoperative Oil Pressure Warning Light Inoperative Circuit Inhibitor Switch to Engine Ground ECCS Relay to ECM ; VB Engine Ground to ECM ; GND-C Fuse B+ to ECM ; VB Ignition Switch to ECM ; IG+ A/C Relay to ECM ; ACRLY A/C Triple-Pressure Switch to ECM ; ARCON IACV-FICD Solenoid to ECM ; PWST IACV-FICD Solenoid to IGN Fuse IACV-FICD Solenoid Valve to Engine Ground (Manual A/C System) Front Engine Mounting to BATT Fuse Front Engine Mounting to ECM ; EMNT1 Front Engine Mounting to ECM ; EMNT2 Oil Pressure Switch to Gauge 7/8

8 PARTS INFORMATION VEHICLE VEHICLE DESCRIPTION PART NAME PART NUMBER APPLICATION DATE 2000 Model Year All EGI Harness Y Model Year All EGI Harness Y901 CLAIMS INFORMATION Submit a Primary Failed Part (PP) line claim using the following claims coding DESCRIPTION PFP OP CODE SYM DIA FRT Repair EGI/EFI Wiring Harness (1) DE38AA (2) 61 or 62 (3) (1) Use the P/N of the repaired wiring harness. (2) As indicated by customer complaint. (3) Straight-time operation include actual time required for diagnosis and repair. Do NOT include any other Op Code on this claim. 8/8