Engine Controls - Correct Oxygen Sensor Harness Routing
No.: LM303-006Issue: 1
Date: June 12, 2006
SECTION: 303-08
Oxygen Sensor Harness Routing
AFFECTED VEHICLE RANGE:
New Range Rover (LM) (M62 V8 Engine Only) VIN: 3A101029 to 5A198056
CONDITION SUMMARY:
CORRECT OXYGEN SENSOR HARNESS ROUTING FOR M62 V8 ENGINE
Situation:
This bulletin applies to the M62 V8 gasoline engine only. This bulletin has been issued to provide service procedures for correctly routing and securing the RH and LH downstream oxygen sensor wire harnesses. Incorrect harness routing can lead to wire damage (following oxygen sensor replacement or exhaust system installation).
Action:
When installing a downstream oxygen sensor on an M62 V8 engine, refer to the appropriate Repair Procedure detailed in this bulletin to correctly route the wire harness.
PARTS:
No parts required. Information purposes only.
WARRANTY:
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
CORRECTLY ROUTE THE LEFT-HAND DOWNSTREAM OXYGEN SENSOR WIRE HARNESS
NOTE:
The black harness insulation must be positioned against the end of the sensor body.
1. Place the sensor on a flat surface.
2. Straighten the sensor harness. (Figure 1)
3. Measure 80 mm (3-1/8 inches) from the end of sensor body and mark the harness at that distance. (Figure 1)
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/LM - New Range Rover/2003 > Workshop Manuals > Service Procedures > Bookmark "17-2 - EMISSION CONTROL - V8" Link "19.22.71 Sensor - heated oxygen (H02S) - post catalyst"
4. Refer to GTR section 17-2 - Emission Control operation 19.22.71 and install the LH downstream oxygen sensor into the exhaust.
5. Tighten the sensor to 50 Nm (37 lbf-ft).
CAUTION:
Correct routing and securing of the sensor harness is crucial to proper operation.
^ The harness must not have any sharp bends, twists or tight sections.
^ New retaining clips should be used if the harness is not properly secured when using the existing clips.
6. Position the 80 mm mark in the center of the retaining clip mounted in the middle of heat-shield and secure the harness to the clip. (Figure 2)
7. Work backwards along the vehicle to secure the harness into the remaining retaining clips. (Figure 3)
8. Connect the sensor connector to the transmission harness.
9. Securely clip the two flat sides of the sensor connector housing into the housing clip mounted to the top area of the Transfer Box housing.
10. Verify that there are no sharp bends, twists or tight sections in the installed harness.
CORRECTLY ROUTE THE RIGHT-HAND DOWNSTREAM OXYGEN SENSOR WIRE HARNESS
NOTE:
The black harness insulation must be positioned against the end of the sensor body. (Arrowed in Figure 4)
1. Place the sensor on a flat surface.
2. Straighten the sensor harness. (Figure 4)
3. Measure 200 mm (7-7/8 inches) from the end of sensor body and mark the harness at that distance. (Figure 4)
4. Measure 230 mm (9 inches) from the end of the electrical connector and mark the harness at that distance. (Figure 5)
5. Refer to GTR section 17-2 - Emission Control operation 19.22.71 and install the RH downstream oxygen sensor into the exhaust.
6. Tighten the sensor to 50 Nm (37 lbf-ft).
CAUTION:
Correct routing and securing of the sensor harness is crucial to proper operation.
^ The harness must not have any sharp bends, twists or tight sections.
^ New retaining clips should be used if the harness is not secure when using the existing clips.
^ The two edge clips mounted forward of the 02 sensor must not be used. (Figure 6)
7. Position the 200 mm mark in the center of the first retaining clip and secure the harness to the clip. (Arrowed in Figure 6)
8. Position the 230 mm mark in the center of the second retaining clip and secure the harness to the clip. (Arrowed in Figure 7)
9. Secure the end of the harness closest to the connector into a retaining clip as shown. (Arrowed in Figure 8)
10. Securely clip the two flat sides of the sensor connector housing into the housing clip mounted to the Transfer Box housing where shown. (Figure 8)
11. Verify that there are no sharp bends, twists or tight sections in the installed harness.
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