Engine Controls - EGI Harness Chafing Damage

SOURCE: Kia Technician Times

TITLE: EGI Harness Chafing Damage

APPLIES TO: 98 Sephia

SERVICE TIP:

CONDITION

Repeat occurrences of DTCs involving misfire (P0300-P0304) and/or injectors (P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271)

CAUSE

This condition is frequently caused by the EGI harness being damaged/chafed against protruding objects and sharp edges where it is routed through the vehicle. The EGI harness is routed down from the fuel injectors, along the rear of the cylinder head, across the top of the transaxle and from there through the bulkhead to the interior of the vehicle.

The damage to the EGI harness typically occurs along the rear of the cylinder head and across the top of the transaxle case.






There are two hose clamps that potentially interfere with the EGI harness. The first is the hose clamp securing the coolant return line which is routed from the throttle body to the T-connection, then to the coolant return hose coming from the heater core.






The second hose clamp is the one that holds the coolant feed pipe to the heater core coolant supply hose.

A bendable metal harness clamp attached to the rear upper side of the transaxle case is used to hold the EGI harness in position. There is a protective rubber grommet on the clamp where it contacts the EGI harness.






With the normal engine rocking motion experienced during dynamic operation, the rubber grommet protecting the EGI harness sometimes slips out of the clamp causing the metal to contact the EGI harness. When this happens, the unprotected portions of the EGI harness can rub against the rear edge and corner of the clamp resulting in damage to the EGI harness.

CORRECTIVE ACTION

1. The EGI harness, where it is routed by the hose clamps identified in Figures 1 and 2, should be inspected and, if necessary, repositioned so that the sharp protruding ends of the clamps in no way interfere and aren't facing the EGI harness.
2. If necessary, re-position the rubber grommet shown in Figure 3 back into the bendable metal clamp and add a tie-wrap to the clamp to prevent the grommet from becoming mispositioned again.