MIL ON Intermittently/Hard Start/No Start
NO: 08-31-95GROUP: Electrical
DATE: Aug. 4, 1995
SUBJECT:
Intermittent Check Engine Light,
No Start, Hard Start, or
Inoperative Condenser Fan
MODELS:
1995 (FJ) Avenger/Sebring/Talon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES WITH A 2.0 LITER (420A) ENGINE BUILT PRIOR TO MAY 24, 1995 (MDH 05-24-XX).
SYMPTOM/CONDITION:
Corrosion of the front end wiring harness connector or two wire splice joints may cause varying conditions such as check engine light on, no start, hard start, and or radiator/condenser fan inoperative. The symptoms may be intermittent and Diagnostic Trouble Codes (DTC's) may or may not be present.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding with this bulletin.
For vehicles with no (DTC's) present, perform the Repair Procedure.
PARTS REQUIRED:
AR 4778570 Heat Shrink Tubing
AR NPN Rosin Core Solder
AR NPN Electrical Tape
AR 06149 3M Electrical Moisture Sealant Patch (Box) or P/N 06147 Tape (Roll)
REPAIR PROCEDURE:
This bulletin involves hard wiring the connector location and repairing two splice joints.
1. Record all radio presets, disconnect and isolate the negative battery terminal.
2. Raise the vehicle on a hoist and remove the left front wheel and splash shield.
3. Locate the A-32 connector for Talon models or A-37 connector for Avenger/Sebring models (Figure 1). The connector is a 12 way with a black insulator.
4. Disconnect the connector and carefully inspect the male and female terminals for any corrosion.
5. If corrosion is found, cut the connector from the harness and splice the wires together as listed in step number 6. If no corrosion is found, proceed to the splice repair in step number 7.
6. Remove one inch of insulation from each wire end and place a piece of heat shrink tubing, P/N 4778570, over each wire. Twist the same color wires together and solder each splice with rosin core solder. Center the heat shrink tubing over the repaired area, and heat until the tubing is tightly sealed and sealant flows from each end.
7. Remove the two bolts that hold the left corner of the upper fascia to the body. Move the fascia outward to provide better access to the splices.
8. If the vehicle is ABS equipped, remove the shield from bottom of the control unit.
9. Locate the two splice joints (Figures 1 & 2). It will be necessary to remove the wiring from the protective convolute and any electrical tape to gain access to the splices.
10. Inspect both splice joints for any corrosion. If corrosion is found, remove the corroded portion and re-splice the same colored wires together. Use the procedures outlined in step number 6 to properly repair the splices.
11. If no corrosion is found at the splices, re-solder them using rosin core solder and seal each section with 3M Electrical Moisture Sealant Patch, P/N 06149, or Tape, P/N 06147.
12. After the repair, place the wires back into the convolute. Wrap electrical tape around the convolute to prevent the wires from protruding.
13. Install the ABS control unit shield (if equipped), fascia, splash shield and wheel. Lower the vehicle.
14. Connect the negative battery cable and set the radio presets recorded in step number 1. Set the clock to the appropriate time.
15. Verify proper operation of the vehicle before returning it to the customer.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: Inspect Wiring Harness Connector and Splices for Corrosion
08-94-CA-90 1.1 Hrs.
Remove Connector and Hard Wire
08-94-CA-91 0.3 Hrs.
Repair Splice Corrosion
08-94-CA-92 0.2 Hrs.
FAILURE CODE: 3T - Terminal(s) Corroded