Overview and Service Procedure

AFFECTED VEHICLES:
1995-1997 CONTOUR AND MYSTIQUE

OVERVIEW
Purpose: The purpose of this program is to extend the warranty on 1995 through 1997 Contour and Mystique vehicle for concerns related specifically to under hood wire harness degradation.

If it is found through diagnosis that driveability concerns are caused by wire harness degradation, or visible signs of wire harness degradation exist, under hood wiring harnesses replacement is required.

NOTE:
IF IT IS NECESSARY TO REPLACE THE UNDER HOOD WIRING, FOLLOWING THIS PROCEDURE WILL INSURE THAT THE HARNESSES ARE PROPERLY INSTALLED, IN THE LEAST AMOUNT OF TIME.

- As outlined below, the procedure begins with a visual inspection of the under hood wiring harnesses for degradation, and if necessary an electronic inspection is also performed.

- Following the inspection a chart explains which wire harnesses will be replaced, depending on certain vehicle applications (i.e. brake systems, engine application).

- The remaining pages are a detailed procedure (including many 11x17 fold out illustrations of wire harness placement), showing how to replace the under hood wire harnesses on these vehicles.





ENGINE COMPARTMENT WIRING HARNESS REPAIR PROCESS FLOW CHART

WIRING HARNESS EVALUATION

VISUAL INSPECTION
The purpose of this inspection is to visually identify degrading in the wiring insulation of certain vehicle components.





1. To visually identify wiring degradation See Figure 1, noting the following characteristics:

- Wire insulation material is brittle.

- Wire insulation has continuous cracks.

- Cracks in wire insulation are of random orientation.

- Wiring insulation is missing (broken away).











2. To visually identify a vehicle with wiring degradation, check component wires at locations designated by circles in Figures 2 through 4. Also check battery positive cable (not illustrated).

- If any wire of any component shows signs of wiring degradation, proceed to "Service Procedure."

- If there is no visual signs of wiring degradation, proceed to "Electronic Inspection."

ELECTRONIC INSPECTION

The purpose of this inspection is to electronically identify wiring issues that can not be seen visually due to convolute or wrap around wiring harness looms.

This inspection procedure will use the New Generation STAR (NGS) Tester and the Powertrain Control/ Emissions Diagnosis (PCED) Manual. If electronic inspection is required please call 1-800-325-5621 for further directions.

SERVICE PROCEDURE MATRIC CHART





On the Contour/Mystique vehicle line there are four (4) main engine compartment wiring harnesses. The Service Procedure for individual vehicles will vary depending on the engine application and the type of brake system. Refer to the matrix chart to determine the required Service Procedure for the vehicle you are servicing.

SERVICE PROCEDURE

The order of harness removal and installation is critical to the repair process. Perform each step of the service procedure as described on the following pages.

Refer to the fold-outs in the back of this instruction manual for most component locations and wiring harness routing illustrations.