Service Upgrade 117 (SB37-0020-0703)

SERVICE UPGRADE 117

TECHNICAL SERVICE BULLETIN

BACKGROUND

Water intrusion into the ground lead cables may cause improper function of certain engine components. The corrective action consists of inspecting, and where necessary modifying and replacing certain components.

Improved sealing of engine ground points has been introduced into production. The following method describes how to upgrade vehicles produced prior to the production change.

MATERIAL

CABLES

Cable harness, repair 

1. Location of the ground terminals

   The relevant ground terminals are on the passenger side and driver side front wing liners. See Fig 1 .

   Fig 1: Location Of Ground Terminals

   
2. Checking the ground leads

   Check that all the ring cable terminals are correctly installed. The copper terminals must be upwards and visible. See Fig 2 .

   Fig 2: Checking Ground Leads

   
   NOTE: If a ring cable terminal is incorrectly installed, with the opening pointing downwards, all the affected connectors at the other end of the cable must be checked thoroughly to ensure that there is no water in them.

   See step 4 to identify the connectors.

   NOTE:

   If water has got into any of these connectors, the entire cable harness in the engine compartment must be replaced. Before installing a new cable harness, any oxidation and moisture must be removed from the connected connectors.

   If there is water in the connector for the Brake Control Module (BCM), the Brake Control Module (BCM) must also be replaced according to the method in VADIS.

   If no water has got into the connectors, disconnect the ring cable terminal and reinstall it the correct way (with the copper terminals upward).

   Replace the existing screw with a new one.

   See step 4 to identify the ground leads.

3. Sealing the cables

   If there is no water in the connectors and all the ring cable terminals are verified to be correctly positioned, all the cable ends at the front wing liners must be sealed using the cavity protection.

   Spray cavity protection into the can lid. Then apply 2-3 drops to each copper cable using a brush. Do not spray directly on to the terminals. See Fig 3 .

   If the cable harness is replaced, all the cable ends must be sealed using cavity protection.

   Fig 3: Sealing Cables

   
4. Identifying ground leads

   Identification is only necessary if one of the ground terminals was turned the wrong way.

   Note that the positioning of the ground leads may be reversed.

   Ground leads, driver side (31/93, 31/95):

   1. Ground lead 1 consists of 2 black/brown cables (4 mm² ) leading to the Brake Control Module (BCM). See step 5.
   2. Ground lead 2 consists of 1 heavy duty black cable (10 mm² ) leading to the electrical cooling fan. See step 6.
   3. Ground lead 3 consists of three black wires which go to the accessory connector for the auxiliary heater and the automatic gearbox. See step 7.

   Ground leads, Passenger side (31/94, 31/96):

   1. Ground lead 1 consists of 1 black cable (4 mm² ) leading to the engine control module (ECM). This cable does not need to be checked.
   2. Ground lead 2 consists of 2 black cables leading to the headlamp washers. See step 8.
   3. Ground lead 3 consists of 2 black cables leading to the headlamp on the passenger side. This cable does not need to be checked.
5. Ground lead 1, Driver side

   The connector is on the Brake Control Module (BCM).

   See the method in VADIS to disconnect the connector:

   Repair and installation

   Function group 59

   Brake Control Module (BCM), replacing.

   Fig 4: Ground Lead 1, Driver Side

   
6. Ground lead 2, Driver side

   The connector is to the right of the electrical cooling fan.

   Fig 5: Ground Lead 2, Driver Side

   
7. Ground lead 3, Driver side

   The connector for:

   1. the accessory connector for the auxiliary heater is located by the driver side wing (connector 54/9). Disconnect left-hand headlight for easier access.
   2. the automatic gearbox is located in front of the air cleaner, (connector 54/58), the small 8-terminal connector third from the left.
   Fig 6: Ground Lead 3, Driver Side

   
8. Ground lead 2, Passenger side

   The connectors to the headlamp washers are in front of the passenger side wing liner (1), the relevant connectors (2 and 3) are shown in Fig 7 .

   Fig 7: Ground Lead 2, Passenger Side

   
9. Sealing the copper cables when replacing the cable harness

   If the cable harness is replaced, all the cable ends must be sealed using the cavity protection. See step 3.

10. Function test

    Test the function for referred to ground lead.

    Erase any diagnostic trouble codes (DTC's).