Repair Procedure

The repair procedure outlined below can be used to correct two different conditions. It incorporates the use of a time delay relay to correct an intermittent ignition switch J-2 drop out.

NOTE: IF VEHICLE HAS BEEN SERVICED PER TECHNICAL SERVICE BULLETIN #18-02-85 OR 18-02-85 REV A (FOR SYMPTOM I OF THIS BULLETIN), REMOVE THE WIRING AND RELAY ASSEMBLY, PN 4331865, AND DISCARD BEFORE PROCEEDING.

1. Disconnect the battery.

2. Remove bolt holding starter and radiator fan relays and move relays aside.

FIGURE 1:

3. Drill two 1/8" holes into the left fender side shield as shown in Figure 1.

FIGURE 2:

4. Attach ground eyelet on the new ignition switch drop-out wiring harness assembly, PN 4368729, to fender side shield as shown with the smaller screw, PN 6032114 (Figure 2).
5. Mount provided relay, PN 5227542, to fender side with the larger screw, PN 6032473.

6. Vehicles With A/C

Disconnect single connector from A/C cut-out relay and the 5-way insulator from the starter relay.
Vehicles With Heater Only

Locate and untape the unused A/C cut-out relay single connector from the main engine compartment wiring harness and retape the A/C cut-out relay 3-way insulator to the harness. Disconnect the 5-way insulator from starter relay.

FIGURE 2:

FIGURE 4:

7. Connect the single male blade connector with double crimped 14DB lead on the new ignition switch drop-out wiring assembly, PN 4368729, to the connector disconnected from the A/C cut-out relay or untaped from the main harness. Fold back and tape connection securely (Figures 2 and 4).

a. A/C equipped cars:

Connect the remaining 1-way female connector on the dark blue J-2 wire of the new PN 4368729 harness to the A/C cut-out relay.

b. Heater-only cars:

Loop and tape the remaining 1-way female connector on the dark blue J-2 wire of the new PN 4368729 harness to the opposite shorter blue wire on the same harness after first taping over end of insulator.

FIGURE 3 - STARTER RELAY CONNECTIONS:

FIGURE 4:

8. Underhood Lamp In Starter Relay Insulator

Extract orange (or grey) fuse link terminal from insulator and reset tang (Figures 3 and 4). Insert into the loose insulator mated with taped back gray hypalon wire (on new ignition drop-out wiring assembly, PN 4368729) after removal; then reconnect to 18 GY wire on new harness, PN 4368729.

9. Insert the exposed terminal double crimped to a pair of 18GY hypalon wires on the new PN 4368729 harness into the vacant 5-way cavity next to the A1-12RD wire for the starter relay (some cavity as vocated in Step 8, where applicable) (Figures 3 and 4).

10. Extract S2-18 gauge yellow wire terminal from 5-way starter relay insulator. Reset terminal tang and insert into the remaining loose black female 1-way insulator (on wiring assembly, PN 4368729) after removal; then reconnect to 18 YL/BK* wire on new harness, PN 4368729. Insert exposed terminal with 18YL wire on the new harness assembly into newly vacated 5-way cavity for starter relay (Figures 3 and 4).
11. Connect starter relay insulator to starter relay. Connect the 3-way connector and the single connector (18BK) on the new harness, PN 4368729, to the newly installed relay, PN 5227542.

12. Reattach starter and radiator fan relays to iso-strut tower.

13. Tape wires of new PN 4368729 harness along main wiring assembly to relays and spot tape as appropriate.

14. Reconnect battery.

FIGURE 2:

15. Final assembly should be as shown in Figure 2.
16. To verify proper operations:

a. With ignition coil secondary disconnected and grounded, connect a voltmeter from double crimped S2-18YL (the lead away from the fender) in the 3-way insulator on the new relay to ground. With the ignition switch in the start position (transmission in neutral or park), the voltmeter should read within one volt of battery voltage with the engine cranking.

b. With transmission in neutral or park and the ignition switch off, briefly connect a fused jumper (20 amp fuse or smaller) from the same double crimped S2-18YL on the new relay to the battery positive terminal. The starter will operate under this condition. Verify that, with the ignition switch still off, the cluster voltmeter (if so equipped) indicates ignition voltage, or that a voltmeter reads within one volt of battery voltage anywhere on the J2 circuit (such as at the A/C cut-out relay connector or the diagnostic connector at the right iso-strut tower).

CAUTION: DO NOT ALLOW STARTER MOTOR TO RUN FOR MORE THAN 15 SECONDS.

c. Remove fused jumper and voltmeter. Remove ground jumper wire and reconnect coil secondary.

d. A/C vehicles only:

Start the engine with A/C button and blower switch on. The A/C should engage in about 11 seconds.

e. Automatic transmission vehicles only:

With gear selector in drive, connect a 12 volt test lamp between the positive post of the battery and the S2, terminal of the starter relay. The test lamp should not light.

FIGURE 4:

17. Refer to Figure 4 for ignition switch drop-out wiring schematic.

FIGURE 5:

18. Type Authorized Modification Label, PN 4275086, as shown in Figure 5 and attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No. 08-80-45-91 0.4 Hrs.

FAILURE CODE: 18 - Circuit Open