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eptember 16, 19991995-99 MAXIMA EGI HARNESS WIRE BREAKAGEDIAGNOSIS AND REPAIR PROCEDUREAPPLIED VEHICLES: 1995-99 Maxima (A32)This amended version of NTB98-008a updates the Applied Vehicle date range and corrects and addsinformation to the DTC Charts. Please discard all paper copies of NTB98-008a.SERVICE INFORMATIONIf a 1995-99 Maxima has any of the following incidents: MIL ‘on’, Engine no start, or Other system malfunctions such as A/C inop, A/C idle up inop, rough idle, oil pressurelight inop,The cause may be wire breakage in the engine control harness where it bends over theright rear of the engine next to the right strut tower (see Figure 1). See the symptom chartsbeginning on page 5 for possible diagnostic trouble codes (DTCs) or specific symptomsthat can cause one or more of these incidents.Figure 11/14
This repair procedure may apply to your MIL ‘on’ DTC or symptom if it is specifically listedon the charts. Note that for each DTC or symptom listed there can be more than one circuitto check using the following procedure.Only incidents and circuits listed on the attached chart are applicable to this bulletin. All ofthe incident possibilities are circuits contained in wiring that pass through the bend in theengine control harness.A kit (P/N 24299-0L725) containing a harness protector and four clips must be installed toprevent additional wire breakage.SERVICE PROCEDUREDiagnosis Procedure — MIL ‘ON’Use this procedure when the vehicle has come in with the MIL ‘on’ and a DTC stored inSelf-Diagnosis memory.1. Use CONSULT to display Self-Diagnosis Results.2. Compare the DTC displayed by CONSULT to the DTC charts (Chart #s 1, 2, 3 and 4)beginning on page 5.3. CONSULT can be used in Data Monitor mode as a preliminary check. Monitor theoperation of the system indicated by the DTC.4. Check for intermittent open or short circuits by aggressively wiggling the EGI harnessside to side and up and down at the specified harness bend (see Figure 1) whilewatching the results on CONSULT Data Monitor. If the applicable monitored valuechanges or a DTC sets when you shake the harness then wire damage has beenconfirmed (see NOTE 1 below).5. Use the correct year service manual Trouble Diagnosis for the DTC displayed togetherwith the DTC chart to identify the wire color and pin location for the circuit in question. If the wire color code is listed on the DTC chart, perform continuity check A.If the wire is identified as “shielded wire” on the DTC chart, perform continuitychecks A and B.6. Perform the indicated continuity check(s) on the wire(s)for the circuit in question toisolate the short or open to the incident wire(s). It may be necessary to shake theharness as outlined in step 4 to verify intermittent conditions. Ohmmeter values shouldnot change while shaking the harness (see NOTE 1 below). If an open circuit is confirmed in a color-coded wire, perform the repair procedurebeginning on page 8.If the open or short is confirmed in a “shielded wire,” replace the entire harness.NOTE 1: If you cannot confirm an open or short circuit with CONSULT, it isnecessary to perform the continuity check outline in steps 5 and 6 above. If youcannot confirm an open or short in the specified wire(s) as they pass through theindicated harness bend with the continuity check, this bulletin does not apply.2/14
Diagnosis Procedure — Non MIL SymptomUse this procedure if the vehicle symptom is listed on the Vehicle Symptom Chart (Chart 5,page 8).1. Verify the symptom in question is listed in Chart 5.2. Refer to the system wiring diagram in the correct year service manual together withChart 5 to determine the wire colors and pin location for the circuit in question.3. Perform continuity check A on the wire(s)for the circuit in question to isolate the short oropen to the incident wire(s).4. Check for intermittent open or short circuits by aggressively wiggling the EGI harnessside to side and up and down at the specified harness bend and performing theindicated continuity check(s). If ohmmeter values change while shaking the harness thewire damage has been confirmed (see NOTE 2 below). If an open circuit is confirmed in a color-coded wire, perform the repair procedure forcolor-coded wires beginning on page 8.NOTE 2: If you cannot confirm an open or short circuit in the specified wire(s) asthey pass through the indicated harness bend, this bulletin does not apply.Continuity Check A, (open circuit check) Figure 21. Turn Ignition Key Off and disconnect the vehicle battery.2. Disconnect the ECM and the engine component connectors.3. Connect a jumper wire to the harness side of the appropriate pin of the ECM connector.IMPORTANT: Be very careful not to spread or otherwise damage the connector pin.4. Route the jumper wire to the engine compartment.5. Connect an ohmmeter between the jumper wire and the harness side of the appropriatepin of the component connector.6. Aggressively wiggle the EGI harness side to side and up and down while you monitorthe ohmmeter reading.3/14
Resistance value should be close to zero ohms. If resistance value is high/overrange or fluctuates, an open circuit exists.NOTE: If resistance is high or over range, be sure it is not caused by poorohmmeter probe or jumper wire connections.Figure 2Continuity Check B (short to ground check — shielded wires only)1. After completing Continuity Check A, move the ohmmeter lead from the componentconnector to an engine ground.2. Again aggressively wiggle the EGI harness side to side and up and down while youmonitor the ohmmeter reading. The resistance value should indicate an open circuit with infinite resistance (overrange). If other than infinite resistance is indicated, the wire’s shield is shorted to thesignal wire and you must replace the harness.NOTE: If the resistance value indicates an open circuit, be sure it is not caused bypoor ohmmeter probe or jumper wire connections.4/14
ENGINE DTC CHART 0302P0303P0304P0305P0306CircuitAir Flow Meter to ECM;QAAir Flow Meter to ECM;QA Air Flow Meter to ECM;VBAbsolute Pressure Sensor to ECM;ABSOLUTE PRESS SENAbsolute Pressure Sensor to ECM;AVCCAbsolute Pressure Sensor to ECM;GND-AIntake Air Temp. Sensor to ECM;GND-AIntake Air Temp. Sensor to ECM;TAMBCoolant Temp. Sensor to ECM;GND-ACoolant Temp. Sensor to ECM;TWThrottle Position Sensor ECM;AVCCThrottle Position Sensor ECM;GND-AThrottle Position Sensor ECM;TV01Coolant Temp. Sensor to ECM;GND-ACoolant Temp. Sensor to ECM;TW02 Sensor Front-Bank 1 to ECM;02SFR02 Sensor Front-Bank 1 to ECM;02SFR02 Sensor Front-Bank 1 to ECM;02SFR02 Sensor Front-Bank 1 to ECM;02HFR02 Sensor Front-Bank 1 to IGN Fuse(1995-96MY only) Engine Ground to ECM;02H(1997MY only) Engine Ground F18, F19 to F10599CAL 02 Sensor Rear B1 to ECM99CAL 02 Sensor Rear B1 to ECM99CAL 02 Sensor Rear B1 to ECM99CAL Fuse 31 B to 02 Sensor Rear B102 Sensor Front-Bank 2 to ECM;02SFL02 Sensor Front-Bank 2 to ECM;02SFR02 Sensor Front-Bank 2 to ECM;02SFR02 Sensor Front-Bank 2 to ECM;02HFL02 Sensor Front-Bank 2 to IGN Fuse99CAL 02 Sensor Rear B2 to ECM99CAL 02 Sensor Rear B2 to ECM99CAL 02 Sensor Rear B2 to ECM99CAL Fuse 31 B to 02 Sensor Rear B2Injector No. 1 to ECM;INJ#1Injector No. 2 to ECM;INJ#2Injector No. 3 to ECM;INJ#3Injector No. 4 to ECM;INJ#4Injector No. 5 to ECM;INJ#5Injector No. 6 to ECM;INJ#65/14Wire ColorShielded wireShielded wireRShielded wireRB, not shieldedBSBBYRBShielded wireBYShielded wireShielded wireShielded wireL/YR/BBBShielded wireShielded wireRR/BShielded wireShielded wireShielded wireLR/BShielded wireShielded wireRR/BR/BR/GR/YB/ORL/WPU/R
ENGINE DTC CHART 00CircuitKnock Sensor to ECM;KNKCrank Position Sensor to ECM;POSCrank Position Sensor to ECM;VBCrank Position Sensor to Engine GroundCamshaft Position Sensor (Phase) to ECM;PHASECamshaft Position Sensor (Phase) to Engine Ground96-7MY Purge Control Solenoid Valve to ECM96-7MY Fuse B to Purge Control Solenoid Valve98MY Purge Volume Control Valve to ECM;EVP#198MY Purge Volume Control Valve to ECM;EVP#298MY Purge Volume Control Valve to ECM;EVP#398MY Purge Volume Control Valve to ECM;EVP#498MY Purge Volume Control Valve to ECM;EVP#599MY Purge Volume Control Solenoid Valve to ECM99MY Fuse B to Purge Volume Control Solenoid Valve99MY ECCS Relay to ECM VB terminalsSpeed Sensor to Speedometer “““““““““IACV-AAC Valve to ECM;VBIACV-AAC Valve to ECM-ISC#1IACV-AAC Valve to ECM-ISC#2IACV-AAC Valve to ECM-ISC#3IACV-AAC Valve to ECM-ISC#4Closed Throttle Position Switch to ECM;IDLEClosed Throttle Position Switch to IGN FuseMAP/Baro Switch Solenoid Valve to ECM;SOLMAP/Baro Switch Solenoid Valve to IGN Fuse99CAL Swirl Control S/V to ECM99CAL Fuse 17 B to Swirl Control S/V02 Sensor Front B1 to ECM99CAL Swirl Control Vacuum Check Switch to ECM02 Sensor Front B2 to ECMEngine Ground to ECM;GND-1IGN Coil No.1 to ECM;IGN#1IGN Coil No.2 to ECM;IGN#2IGN Coil No.3 to ECM;IGN#3IGN Coil No.4 to ECM;IGN#4IGN Coil No.5 to ECM;IGN#5IGN Coil No.6 to ECM;IGN#66/14Wire ColorShielded wireShielded wireRShielded wireShielded wireShielded wireL/YR/YYGG/BL/RR(2 Shielded wirePUShielded wireBY/RG/RL/RG/YPU/WGY/R
ENGINE DTC CHART CircuitCrank Position Sensor to ECM;REFCrank Position Sensor to ECM:REFCrank Position Sensor to ECM;POSCrank Position Sensor to Engine GroundEGRC Solenoid Valve to IGN FuseEGRC Solenoid Valve to IGN FuseEGR Temp. Sensor to ECM;EGRTSEGR Temp. Sensor to ECM;GND-AEvap Canister Purge Volume Control Valve to ECM;EVP#1Evap Canister Purge Volume Control Valve to ECM;EVP#2Evap Canister Purge Volume Control Valve to ECM;EVP#3Evap Canister Purge Volume Control Valve to ECM;EVP#4Evap Canister Purge Volume Control Valve to ECM;VB (2-wires)98MY Purge Control Solenoid Valve to ECM98MY Fuse B to Purge Control Solenoid ValveRadiator Fan Relay Coil to ECM;RFRHRadiator Fan Relay Coil to ECM;RFRLWire ColorShielded wireShielded wireShielded wireShielded wireR/YL/BL/ORBYGG/BL/RR(2 wires)L/YR/YLG/BLG/RTRANSMISSION DTC CHART 760CircuitInhibitor Switch to ATCU;1 SWInhibitor Switch to ATCU;2 SWInhibitor Switch to ATCU;D SWInhibitor Switch to ATCU;NSWInhibitor Switch to ATCU;PSWInhibitor Switch to ATCU;R SWInhibitor Switch to IGN FuseA/T Fluid Temp Sensor to ECM GND-AA/T Fluid Temp Sensor to ATCU;OIL TEMP SENSA/T Revolution Sensor to ATCU;SPEED SEN1A/T Revolution Sensor to ECM;GND-ATCC Solenoid Valve to ATCU;LU DUTY SOLLine Pressure Solenoid Valve to ATCU;PL DUTY SOL(DR)Drop Resistor to ATCU;PL DUTY SOL(DR)Shift Solenoid Valve to ATCU;SHIFT SOL AShift Solenoid Valve to ATCU;SHIFT SOL BThrottle Position Switch to ATCU;WIDE OPEN SWOverrun Clutch Solenoid Valve to ATCU; OVR/C SOL7/14Wire ColorPU/WP/BY/LR/GR/GG/WGBGShielded wireShielded wireG/BG/RW/BR/YLG/BW/RBR/Y
SYMPTOM CHART #5SymptomStarter Motor InoperativeEngine Stall/No Start““““““A/C InoperativeA/C InoperativeA/C On/Off Idle AdjustInoperativeA/C On/Off Idle AdjustInoperativeA/C On/Off Idle AdjustInoperativeEngine Mount InoperativeEngine Mount InoperativeEngine Mount InoperativeOil Pressure Warning Light Inop.CircuitInhibitor Switch to Engine GroundECCS Relay to ECM;VBEngine Ground to ECM;GND-CFuse B to ECM;VBIgnition Switch to ECM;IG A/C Relay to ECM;ACRLYA/C Triple-Pressure Switch to ECM;ARCONIACV-FICD Solenoid to ECM;PWSTIACV-FICD Solenoid to IGN FuseIACV-FICD Solenoid Valve to Engine Ground (Manual A/C System)Front Engine Mounting to BATT FuseFront Engine Mounting to ECM;EMNT1Front Engine Mounting to ECM;EMNT2Oil Pressure Switch to GaugeWire ColorBRBWRBRG/BGR/YBWW/LW/RBR/YRepair Procedure (color-coded wires only)Order the harness service kit (P/N 24299-0L725) from the Parts Information table on page14.1. Remove and discard all four clips (A through D) from the EGI harness (see Figure 3-1).You can cut clips C and D. Pull, but DO NOT CUT clips A and B from their brackets.8/14
Figure 32. Cut away the tape and remove the star-shaped support braces from the harness (seeFigure 3-2). Discard these braces.3. Remove the bracket for clip A from the strut tower (see Figure 4).Figure 4CAUTION: Be extremely careful not to cut into any wires within the harness.9/14
4. Cut and unwrap the tape from around the corrugated tube surrounding the harness (seeFigure 5). Remove and discard the corrugated tube.Figure 55. If a wire is accidentally cut, you must repair it (perform steps 10-12 on pages 11-12).6. Unwrap the tape from around the harness that was covered by the corrugated tube.10/14
7. Push the zipper tube (near the bulkhead) down at least 2 inches to gain access to thewires (see Figure 6).Figure 68. Remove the tape to expose the hard plastic cover at the harness intersection (seeFigure 5).9. Visually inspect each wire for breakage within the harness bend that is the coloridentified in the Diagnosis Procedure on page 2. Typically it is a wire that is near theoutside which has been stressed against a larger wire. It may be broken inside theinsulation.A. If the broken wire cannot be identified, then wiggle each wire of this color in theharness bend while checking the continuity of the identified incident circuit.10. Cut the broken wire 1-1/2 inches rearward from the hard plastic cover at the intersectionof the harness (see Figure 7).Figure 711/14
11. Cut the broken wire 1-1/2 inches up from the top of the zipper tube (see Figure 8).Figure 812. Replace the broken wire with an equivalent gauge wire. Splice the bulkhead side of thewire first. Then lay the wire along the harness up to the harness intersection todetermine the correct length for the replacement wire (se
SERVICE INFORMATION If a 1995-99 Maxima has any of the following incidents: MIL ‘on’, Engine no start, or Other system malfunctions such as A/C inop, A/C idle up inop, rough idle, oil pressure light inop, The cause may be wire breakage in the engine control harness where it bends over the right rear of the engine next to the right strut tower (see Figure 1). See the symptom .File Size: 248KBPage Count: 14
