Repair Procedure

1. Disconnect the battery negative lead.

2. Remove the air cleaner assembly. On 3.5L models, also remove the air intake from the throttle body.

3. Locate the right oxygen sensor connector and disconnect it.





4. Identify the sensor ground terminal. This terminal is the No. 1, K4 circuit, 20 gauge black with a light blue tracer (Figure 1).

5. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 1 by carefully pulling from the rear while spreading the locking finger(s).

6. Choose the shortest terminal lead from the appropriate repair jumper. Insert the new terminal, and wire lead into the vacant cavity (# 1) of the right oxygen sensor connector. Re-assemble the connector by reversing the connector disassembly procedure.

7. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way.

8. Repeat steps 4 through 7 for the left oxygen sensor K4 circuit, (Figure 1) using the other lead from the Y spliced repair jumper, route the lead from the jumper harness by following the same path as the engine harness.

9. On 3.3L engines, route the remaining lead across the heater hose and towards the right ABS sensor. Follow the path of the head lamp and dash harness across the front of the vehicle. For 3.5L engines, route the lead across the back of the engine. Use tie straps p/n 04856503 to secure the jumper to the main wiring bundle(s).








10. Locate and remove the (C137) 60 way PCM connector on 1995 models (Figure 2) or the (C174) 40 way PCM connector on 1996 models (Figure 3).

11. Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector.

10. Remove the wire dress cover from the rear of the connector. Locate the K4 circuit BK/LB (1995 cavity 4 & 1996 cavity 43).

12. Cut the K4 wire 1-1/2 inches from the PCM connector. Strip both ends of the cut wire and the end of the new lead.

12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the PCM connector. Make sure the shrink tube is long enough to seal the splice after soldering.

13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing.

14. Reinstall the wire dress cover to the rear of the PCM connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover.

15. Reconnect the oxygen sensors and the connector to the powertrain control module.

16. Reconnect the battery negative cable.

17. Verify the wiring repair by watching the oxygen sensor switch on the sensor read screen of the DRB III(R).