Engine - Misfire/Starting Difficulty

05.1-14

DATE
5/96

Sedan Range

MODEL:
1995-96 MY
Sedan (4.0L) Range

VIN:
720001-771156

Engine Misfire/Starting Difficulty -
Harness Connector Modification

ISSUE:

Some 1995-96 MY Sedan Range vehicles within the above VIN range may exhibit engine misfire/starting difficulty due to terminal corrosion caused by the entry of water at connector PI1. The condition has been found on 4.0L Sedan Range vehicles, however, connector PI1 carries the engine management power supply on all engine variants on 1995-96 MY Sedan Range vehicles.

The connector was modified beginning with VIN 771157. The modification can be made on earlier vehicles if corrosion is found.

ACTION:

In case of a customer complaint of engine misfire/starting difficulty on a 1995-96 MY Sedan Range vehicles within the above VIN range, check for the entry of water into the white harness connector (PI1), located rearward of the right side headlamp. If corrosion is found, relocate the connector as described, in addition to any other repairs made.

Note the following:

^ If severe corrosion and pitting or damage to the terminal blades has occurred, replace BOTH the right side forward harness AND the Engine PI1 harness. Note the oxygen sensor connection orientation during disassembly, to avoid reversing the orientation which would cause a misfire condition. Perform the oxygen sensor orientation procedure using the PDU following reassembly.

^ If only water ingress and slight tarnishing of the connector terminals is found, thoroughly dry the connector and grease the terminals. Use only a dry and filtered air supply when using shop air to blow water from the connector. If using a warm air blower, ensure that the connector does not reach excessive temperatures.

In either of the above cases, apply a generous coating of electrical spray grease to the faces of both connectors. Use part no. JLM 20054 (or the previous JLM 11472). Allow 15 seconds for solvents in the spray grease to evaporate before joining the connectors.

After performing the above repairs, modify the connector location as described.

RELOCATING CONNECTOR PI1

1. Do not return connector PI1 to its original location in the bracket below the black connector PI61.





2. Secure the white connector PI1 (Illustration 1) to the fuel injection (PI) harness using a tie-strap so it is adjacent to the black connector PI61. Position the latch outwards as shown in Illustration 1.

PARTS INFORMATION:

DESCRIPTION PART NUMBER QTY

Tie strap ADU 9028 1
Electrical grease JLM 20054 -
Right side forward harness:
up to VIN 739426 LNA 3110AF 1
VIN 739427 - 746280 LNA 3110CC 1
from VIN 746281
& from VIN 746814 LNA 3110CE 1

4.0L NA fuel injection harness:
up to VIN 739426 LNA 3340CG 1
VIN 749427 - 746412 LNA 33040HB 1
from VIN 746413 to EIN 8E.12207 LNA 3340HD
from EIN 8E.12208 LNA 3340KA 1

4.0L SC fuel injection harness:
up to VIN 739426 LNA 3340DG 1
VIN 739427 - 746412 LNA 3340JA 1
from VIN 746413 to EIN 8E.12207 LNA 3340JC 1
from EIN 8E.12208 LNA 3340LA 1






WARRANTY INFORMATION