Battery Positive Cable - Retaining Clip Damage
414-05DATE 7/99
MODEL
1999 MY XK8 Range
VIN
038540
038732
Battery Positive Cable - Modify Retention - Service Action S830
Issue:
On some 1999 MY XK8 vehicles within the above VIN range, the possibility exists that the retaining clip for the battery positive extension-cable, above the right over-axle exhaust pipe, may have been damaged during production installation. This may result in the battery cable becoming detached from the clip.
Action:
On all 1999 MY XK8 vehicles within the above VIN range, check the clip for damage and replace if necessary. The clip is located furthest toward the rear, where the battery cable is exposed between the rear edge of the heat shield and the grommet where the cable enters the trunk compartment (Illustration 1).
If the battery cable has been damaged, replace the cable as described below at Battery Positive Extension-Cable, Replace.
WORKSHOP PROCEDURES RETAINING CLIP - CHECK
1. Raise the vehicle on a four-post lift.
Warning:
Ensure the exhaust is cool.
2. Steadily pull on the battery cable in area of the clip (Illustration 1).
3. If the cable remains secure no action is required. If not, proceed to the "Retaining Clip, Replace" procedure.
4. Lower the vehicle.
RETAINING CLIP. REPLACE
1. Raise the vehicle on a four-post lift.
Warning:
Ensure the exhaust is cool.
2. Disconnect the clip from the battery cable (Illustration 1).
3. Unscrew the remaining part of the clip from the body stud.
4. Install new clip to the body stud - gently tap the clip until it is fully seated on the stud.
5. Secure the battery cable into the clip.
6. Lower the vehicle.
BATTERY POSITIVE EXTENSION-CABLE. REPLACE
Remove
1. Position vehicle on a four-post lift.
2. Open hood and install fender covers.
3. Open the trunk and install fender covers.
4. Disconnect battery. (Refer to JTIS operation 86.15.19 for further information about window drop system).
5. Remove the trunk floor carpet. Remove the front liner from the trunk, using care when pulling the ends from behind the side liners.
6. Remove the right side intermediate muffler assembly. Refer to JTIS operation 30.10.16.
7. From the left-hand false bulkhead inside the engine-compartment, remove the cover from the battery lead body stud.
8. Remove the nut from the body stud.
9. Remove the starter motor cable from the body stud.
10. Remove the battery cable from the body stud.
11. Release the battery cable from all retaining clips.
12. Release the battery cable from behind the engine heat shield.
13. Pull the battery cable through the transmission tunnel towards the rear of the vehicle.
14. Remove 3 nuts securing the right side of the rear heat shield to the body.
l5. Gently pull the heat shield down to allow the battery cable to be released from behind the heat shield.
16. From inside the trunk remove the cover from the high-power protection module.
17. Remove the nut securing the battery cable and release the cable from the stud.
18. Feed the battery cable through the trunk grommet.
Installation
1. Feed the battery cable through the trunk grommet.
2. Install the battery cable on the stud in the high-power protection module.
3. Install the nut and tighten to 8-10 Nm.
4. Install the cover on the high-powered protection module.
5. Route the battery cable over rear the heat shield and through the transmission tunnel.
6. Install and tighten the rear heat shield nuts.
7. Route the battery cable under engine heat shield and through to the false-bulkhead body stud.
8. Secure the battery cable into all the retaining clips.
9. Install the battery cable and the starter motor cable to the body stud.
10. Install the nut on the body stud and tighten to 9-11 Nm.
11. Install the cover on the body stud.
12. Install the right side intermediate muffler assembly. Refer to JTIS operation 30.10.16.
13. Install the front liner in the trunk. Refer to JTIS operation 76.19.31.
14. Connect the battery. (Important: refer to JTIS operation 86.15.15 for further information).
15. Remove the protection covers from the vehicle.
Parts Information:
DESCRIPTION PART NUMBER
Battery Positive Extension Cable UC 3692AA
Retaining Clip KZC 100006
Warranty Information:
NOTE:
Always perform a DCS claim search first to determine whether this service action has been performed on this vehicle. The warranty selection under the vehicle inquiry will give a listing of all claims against the vehicle. If S830 appears in the fault code field, do not perform this service action.
CLAIM SUBMISSION PROCEDURE:
Warranty summary codes have been assigned to this service action in order to simplify claim submission. The dealership will be reimbursed the parts and labor time allowance as indicated.
DCS DEALERS
Submit claims using the appropriate summary code for the vehicle model and work performed. Follow standard campaign submission procedures.
NON-DCS DEALERS
Submit claims on the Recall Campaign Summary form W-25. Enter the appropriate summary code for the vehicle model and work performed in the Repair Code column. Do not use the W-l warranty claim form.