Engine Electrical Devices: Wiring Suzuki XL7 I

Heated Oxygen Sensor Wiring Repairs

Special Tool

J-38125 Terminal Repair Kit

If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance.

The following guidelines should be used when servicing the heated oxygen sensor

1. Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems.
2. Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire.
3. Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance.
4. To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector.

The engine harness may be repaired using the J-38125.

Scheme 23

Scheme 24

1. Remove the instrument panel left lower closeout panel. Refer to «INSTRUMENT PANEL INSULATOR PANEL REPLACEMENT - LEFT SIDE»(ref-268421-S19714458352007102300000) .
2. Remove the driver knee bolster. Refer to «KNEE BOLSTER REPLACEMENT»(ref-268421-S32682757152007102300000) .
3. Remove the connector position assurance (CPA) from the accelerator pedal position (APP) sensor connector.
4. Disconnect the APP sensor harness connector. NOTE: Due to clearance issues, the upper attachment bolt cannot be removed from the accelerator pedal assembly. Loose then bolt completely and leave the bolt in the component until the assembly is removed from the vehicle.
5. Remove the APP assembly attachment bolts.
6. Remove the APP assembly from the vehicle.

Scheme 25

Scheme 26

1. Install the upper attachment bolt into the APP assembly.
2. Install the APP assembly into the vehicle. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
3. Install the remaining attachment bolts into the APP assembly. Tightening torque Tighten the bolts to 25 N.m (18 lb ft) .
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt, then pull back to confirm engagement.
5. Install the CPA to the APP sensor harness connector.
6. Install the driver knee bolster. Refer to «KNEE BOLSTER REPLACEMENT»(ref-268421-S32682757152007102300000) .
7. Install the instrument panel left lower closeout panel. Refer to «INSTRUMENT PANEL INSULATOR PANEL REPLACEMENT - LEFT SIDE»(ref-268421-S19714458352007102300000) .

Scheme 27

Scheme 28

1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
2. If equipped with all wheel drive (AWD), remove the transfer case. Refer to «REMOVAL PROCEDURE»(ref-268442-S08514136582007102300000) .
3. Disconnect the engine wiring harness electrical connector (2) from the crankshaft position (CKP) sensor.
4. Remove the crankshaft sensor bolt.
5. Remove the crankshaft sensor.

Scheme 29

Scheme 30

1. Install the crankshaft position sensor. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the crankshaft position sensor bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
3. Connect the engine wiring harness electrical connector to the CKP sensor.
4. If equipped with all AWD, install the transfer case. Refer to «INSTALLATION PROCEDURE»(ref-268442-S20235993322007102300000) .
5. Lower the vehicle.

Scheme 31

Scheme 32

1. Remove the air cleaner assembly. Refer to «REMOVAL PROCEDURE»(ref-268436-S12581550432007102300000) .
2. Disconnect the engine wiring harness electrical connector (1) from the bank 1 exhaust camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

Scheme 33

Scheme 34

1. Install the CMP sensor. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the CMP sensor bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
3. Connect the engine wiring harness electrical connector (1) to the bank 1 exhaust CMP sensor.
4. Install the air cleaner assembly. Refer to «INSTALLATION PROCEDURE»(ref-268436-S15496293442007102300000) .

Scheme 35

Scheme 36

1. Remove the air cleaner assembly. Refer to «REMOVAL PROCEDURE»(ref-268436-S12581550432007102300000) .
2. Disconnect the engine wiring harness electrical connector (2) from the bank 1 intake camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

Scheme 37

1. Install the CMP sensor. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the CMP sensor bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
3. Connect the engine wiring harness electrical connector (2) to the bank 1 intake CMP sensor.
4. Install the air cleaner assembly. Refer to «INSTALLATION PROCEDURE»(ref-268436-S15496293442007102300000) .

Scheme 38

Scheme 39

1. Remove the air cleaner assembly. Refer to «REMOVAL PROCEDURE»(ref-268436-S12581550432007102300000) .
2. Disconnect the engine wiring harness electrical connector (6) from the bank 2 exhaust camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

Scheme 40

Scheme 41

1. Install the CMP sensor. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the CMP sensor bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
3. Connect the engine wiring harness electrical connector (6) to the bank 2 exhaust CMP sensor.
4. Install the air cleaner assembly. Refer to «INSTALLATION PROCEDURE»(ref-268436-S15496293442007102300000) .

Scheme 42

Scheme 43

1. Remove the air cleaner assembly. Refer to «REMOVAL PROCEDURE»(ref-268436-S12581550432007102300000) .
2. Disconnect the engine wiring harness electrical connector (8) from the bank 2 intake camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

Scheme 44

Scheme 45

1. Install the CMP sensor. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the CMP sensor bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
3. Connect the engine wiring harness electrical connector (8) to the bank 2 intake CMP sensor.
4. Install the air cleaner assembly. Refer to «INSTALLATION PROCEDURE»(ref-268436-S15496293442007102300000) .

Scheme 46

Scheme 47

1. Remove the air cleaner assembly. Refer to «REMOVAL PROCEDURE»(ref-268436-S12581550432007102300000) .
2. Disconnect the engine wiring harness electrical connector (3) from the bank 1 intake camshaft position (CMP) actuator solenoid valve.
3. Remove the CMP actuator solenoid valve bolt.
4. Remove the CMP actuator solenoid valve.
5. Inspect the CMP actuator solenoid valve seal and replace as necessary.

Scheme 48

Scheme 49

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
3. Install the CMP actuator solenoid valve bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
4. Connect the engine wiring harness electrical connector (3) to the bank 1 intake CMP actuator solenoid valve.
5. Install the air cleaner assembly. Refer to «INSTALLATION PROCEDURE»(ref-268436-S15496293442007102300000) .

Scheme 50

Scheme 51

1. Remove the air cleaner assembly. Refer to «REMOVAL PROCEDURE»(ref-268436-S12581550432007102300000) .
2. Disconnect the engine wiring harness electrical connector (5) from the bank 1 exhaust camshaft position (CMP) actuator solenoid valve.
3. Remove the CMP actuator solenoid valve bolt.
4. Remove the CMP actuator solenoid valve.
5. Inspect the CMP actuator solenoid valve seal and replace as necessary.

Scheme 52

Scheme 53

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
3. Install the CMP actuator solenoid valve bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
4. Connect the engine wiring harness electrical connector (5) to the bank 1 exhaust CMP actuator solenoid valve.
5. Install the air cleaner assembly. Refer to «INSTALLATION PROCEDURE»(ref-268436-S15496293442007102300000) .

Scheme 54

Scheme 55

1. Remove the engine mount strut bracket. Refer to «ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT SIDE»(ref-268436-S02218912532007102300000) .
2. Disconnect the engine wiring harness electrical connector (2) from the bank 2 intake camshaft position (CMP) actuator solenoid valve.
3. Remove the CMP actuator solenoid valve bolt.
4. Remove the CMP actuator solenoid valve.
5. Inspect the CMP actuator solenoid valve seal for damage and replace as necessary.

Scheme 56

Scheme 57

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
3. Install the CMP actuator solenoid valve bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
4. Connect the engine wiring harness electrical connector (2) to the bank 2 intake CMP actuator solenoid valve.
5. Install the engine mount strut bracket. Refer to «INSTALLATION PROCEDURE»(ref-268436-S27174710502007102300000) .

Scheme 58

Scheme 59

1. Remove the engine mount strut bracket. Refer to «ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT SIDE»(ref-268436-S02218912532007102300000) .
2. Disconnect the engine wiring harness electrical connector (7) from the bank 2 exhaust camshaft position (CMP) actuator solenoid valve.
3. Remove the CMP actuator solenoid valve bolt.
4. Remove the CMP actuator solenoid valve.
5. Inspect the CMP actuator solenoid valve seal for damage and replace as necessary.

Scheme 60

Scheme 61

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
3. Install the CMP actuator solenoid valve bolt. Tightening torque Tighten the bolt to 10 N.m (89 lb in) .
4. Connect the engine wiring harness electrical connector (7) to the bank 2 exhaust CMP actuator solenoid valve.
5. Install the engine mount strut bracket. Refer to «INSTALLATION PROCEDURE»(ref-268436-S27174710502007102300000) .

Scheme 62

Scheme 63

Scheme 64

1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
2. Remove the rear exhaust manifold heat shield bolts and shield.
3. Remove the right catalytic converter. Refer to «REMOVAL PROCEDURE»(ref-268435-S33781526622007102300000) .
4. Disconnect the engine wiring harness electrical connector (2) from the bank 1 knock sensor.
5. Loosen the knock sensor bolt and remove the knock sensor.

Scheme 65

Scheme 66

Scheme 67

1. Position the knock sensor and tighten the knock sensor bolt. Tightening torque Tighten the bolt to 23 N.m (17 lb ft) .
2. Connect the engine wiring harness electrical connector (2) to the bank 1 knock sensor.
3. Position the rear exhaust manifold heat shield to the engine and install the bolts. Tightening torque Tighten the bolts to 50 N.m (37 lb ft) .
4. Install the right catalytic converter. Refer to «INSTALLATION PROCEDURE»(ref-268435-S37942799152007102300000) .
5. Lower the vehicle.

Scheme 68

Scheme 69

1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
2. Disconnect the engine wiring harness electrical connector (2) from the bank 2 knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.

Scheme 70

Scheme 71

1. Position the knock sensor and tighten the knock sensor bolt. Tightening torque Tighten the bolt to 23 N.m (17 lb ft) .
2. Connect the engine wiring harness electrical connector (2) to the bank 2 knock sensor.
3. Lower the vehicle.