Service Procedure
1. Open the trunk and ensure the negative battery cable is disconnected from the battery.2. Open the hood, then remove and save the engine plastic cover.
3. Remove and save the Totally Integrated Power Module (TIPM) B+ terminal nut (Figure 1).
4. Disconnect the Electro-Hydraulic Power Steering (EHPS) connector (Figures 1 and 2).
5. Disengage the TIPM/EHPS wire routing clips along the passenger shock tower (Figure 2).
6. Using a high speed cut-off wheel, cut off the TIPM/EHPS wire harness where it meets the main engine wire harness (Figure 2).
7. Apply electrical tape to the abandoned wire stub on the engine harness.
8. Remove and save the Powertrain POWERTRAIN Control Module (PCM) plastic CONTROL MODULE access cover.
9. Remove and save the PCM mounting bolt.
10. Pull the PCM up and out of the cowl and set aside (Figure 3).
CAUTION:
Do not disconnect the PCM connectors.
11. Disconnect the alternator B+ connector eyelet and alternator
field connector at the alternator.
12. Lift the vehicle on an appropriate hoist.
13. Remove and save the plastic underbody splash shield.
14. Disconnect the engine oil pump solenoid electrical connector.
15. Disconnect the crankshaft position sensor electrical connector.
16. Remove and save the starter solenoid heat shield.
17. Remove and save the starter B+ terminal nut and disconnect the
starter solenoid wire (Figure 4).
18. Partially lower the vehicle.
19. Remove and save the right front wheel and tire assembly.
20. Remove and save the right front wheel opening plastic liner.
21. Disconnect the engine B+ wire body that is located in the right wheel opening (Figure 5).
22. Pull the engine B+ wire and grommet down to expose the wire above the grommet (Figure 6).
23. Measure up from the grommet approximately 6 inches (152 mm)
6" (152 MM) and place a mark on the engine B+ wire (Figure 6).
24. Using a high speed cut-off wheel, cut the B+ wire at the mark made in Step 23 (Figure 7).
25. Apply electrical tape to the abandoned wire stub on the engine harness.
26. Lower the vehicle from the hoist.
27. Using a high speed cut-off wheel, cut off the alternator B+ wire
approximately 8 inches from the wire eyelet at the end of the alternator B+ wire (Figure 8).
CAUTION:
Use extreme caution not to nick other underhood components when cutting the alternator B+ wire.
28. Apply electrical tape to the abandoned alternator B+ wire stub on the engine harness.
29. Raise the vehicle on the hoist.
30. Place a mark on the starter B+ wire approximately 2 inches from the end of the wire (Figure 9).
31. Using a high speed cut-off wheel, cut the starter B+ wire at the mark made in Step 30 (Figure 9).
CAUTION:
Use extreme caution not to nick other components when cutting the starter B+ wire.
32. Apply electrical tape to the abandoned wire stub on the engine harness.
33. Lower the vehicle from the hoist.
34. At this point in the repair the components in Figure 10 have been cut from the original engine wire harness.
NOTE:
The new overlay wire harness has grey tape bands to indicate the
tie strap locations. Tie straps are to be placed at these locations to properly secure the overlay harness to the original engine wire harness.
35. Starting at the rear of the right valve cover, carefully route the new engine battery positive overlay wire harness starter B+ wire along the existing engine wiring harness.
CAUTION:
Be sure to route the starter B+ wire behind the grey 24 way connector wire harness at the rear of the left cylinder head
36. Raise the vehicle on the hoist.
37. Connect the new engine battery positive overlay wire harness starter B+ terminal to the starter. Tighten the starter B+ terminal nut to 97 in.lbs. (11 Nm).
NOTE:
Inspect all wire harness push pin tie strap retainers and replace as
required.
38. Connect the starter solenoid wire from the original engine wiring harness to the starter solenoid.
39. Using one of the provided plastic tie straps, secure the new engine battery positive overlay wire harness to the original engine wire harness (Figure 11).
CAUTION:
Make sure the starter B+ wire cannot come in contact with
the exhaust pipe. Use tie straps as required to secure the starter B+ wire.
40. Install the starter solenoid heat shield.
41. Lower the vehicle from the hoist.
42. Route the engine battery positive overlay wire harness B+ cable into position and through the body routing hole (Figure 12).
CAUTION:
Be sure to seat the B+ wire grommet securely into the body
routing hole.
43. Remove and save the throttle body air inlet tube.
44. Route the Totally Integrated Power Module (TIPM) B+ terminal, the
Electro-Hydraulic Power Steering (EHPS) connector and related wiring into
position and engage routing clips.
45. Install the engine battery positive overlay wire harness TIPM B+
overlay terminal nut. Tighten the nut to 106 in. lbs. (12 Nm) (Figure 13).
46. Connect the engine battery positive overlay wire harness
EHPS connector to the EHPS body connector (Figure 13).
47. Route the engine battery positive overlay wire harness for the alternator into position and connect the alternator B+
connector eyelet. Tighten the retaining nut to 97 in.lbs. (11 Nm).
48. Using plastic tie straps, secure the alternator overlay harness to the original engine wiring harness at the grey tape bands.
49. Install the PCM into position and install the mounting bolt.
50. Install the PCM plastic access cover.
51. Lift the vehicle on the hoist.
52. Connect the crankshaft position sensor electrical connector to the sensor.
53. Connect the engine oil pump solenoid electrical connector to the solenoid.
NOTE:
Replace the push pin tie straps if required.
54. Connect the alternator field connector to the alternator.
55. Install the plastic underbody splash shield.
56. Partially lower the vehicle.
57. Route the engine battery positive overlay wire harness red B+ wire to the B+ stud on the body. Engage the retaining tab into the body and then tighten the B+ terminal nut to 97 in.lbs. (11 Nm).
CAUTION:
Adjust the B+ wire routing as required to prevent
chaffing.
58. Install the right front wheel opening plastic liner.
59. Install the right front tire and wheel assembly. Tighten the lug nuts to 110 ft. lbs. (150 Nm) in the sequence shown in Figure 14.
60. Lower the vehicle from the hoist.
61. Install tie straps to secure the overlay harness to the engine wiring harness at the grey tape band locations.
62. Inspect the new overlay wiring harness routing and ensure that the harness is properly secured to the original engine wire harness. Make any adjustments as required.
63. Install the throttle body air inlet tube.
64. Install the engine plastic cover.
65. Connect the negative battery cable to the battery post.
66. Connect the wiTECH scan tool to the vehicle and clear any Diagnostic Trouble Codes (DTCs).
67. Remove the wiTECH scan tool from the vehicle.
68. Close the hood.