Electrical - MIL ON/Multiple DTC's Set/Systems Inop.

No: 86/05/00/NAS
Ref:
Issue: 1
Date: 10/27/00

Engine Harness Routing

AFFECTED VEHICLE RANGE:

Discovery Series II (LT) Up to YA275031

SITUATION:

POTENTIAL FOR HARNESS DAMAGE

Correct routing of the engine harness is critical to avoiding contact with the engine. Some vehicles may have clips incorrectly positioned on the cowl lip leading to the possibility of harness damage.

NOTE:
If the engine harness is not correctly routed, over time the customer may experience blown fuses and the check engine light may illuminate or flash. Upon investigation, an array of engine management and sensor faults will be found. These symptoms may result from damaged wiring from contact between the engine harness and the engine.

RESOLUTION:

RE-ROUTE ENGINE HARNESS

Install the clips at the new locations on the harness to ensure proper clearance between intake manifold and other engine components.

PARTS INFORMATION:

No parts required

WARRANTY CLAIMS:

86.70.89/61 Time 0.20 hrs.
Position clips and adjust harness routing.

FAULT CODE: K

Damaged harnesses should be claimed following normal warranty procedures

Normal warranty policy and procedures apply

REPAIR PROCEDURE

POSITIONING CLIPS CORRECTLY

1. Remove the rubber seal from the edge of the cowl.





2. Refer to Figure 1. If clips are all located in the firewall notches, the right clip must be relocated as described below:

^ Unclip the harness from the three securing clips.

CAUTION:
The right clip must not be located in the notch to the right of the brake pipe clip.

NOTE:
There is no notch in the new right side clip location





^ Relocate the clip on the passenger (right) side of the vehicle to a location directly above the brake pipe clip. (Figure 2)

^ Verify that the remaining two clips are located in the cowl notches to the drivers side (left) of the brake pipe clip.

NOTE:
If necessary, slacken the harness retaining tie-wrap on right side of cowl to gain slack in engine harness for the next step.





3. Place the plastic "Y" protector into the center clip. (Figure 3)

CAUTION:
It is important that the harness be routed to avoid slack or drooping between the clips. Excess harness, if any, should be located on the driver's side of the vehicle beyond the driver's side clip.

4. Install the harness in the remaining two clips.

5. Ensure that excess harness is routed toward the left (driver's) side and is also pushed back toward the bulkhead.

6. If loosened, tighten the cable tie-wrap on right side of the cowl.

7. Install the rubber seal on the cowl.