Repair Procedure
NOTE:WHEN VARIATIONS EXIST BETWEEN 1981-1982 MODELS AND 1983-1984 MODELS, THESE DIFFERENCES WILL BE NOTED ON GRAPHICS AND PROCEDURE WITH AN ASTERISK (*).
ON FRONT WHEEL DRIVE MINI VAN APPLICATION (HK) THIS AFTER-RUN FAN SYSTEM IS FOR THE RADIATOR FAN MOTOR, NOT THE CONDENSER FAN MOTOR.
1. After-run harness assembly has two fuse links, one of which will not be used.
*1981-1982 - Snap brown one-way insulator supplied in package to gold fuse link terminal of after-run wiring assembly and tape back to harness.
*1983-1984 - Snap black one-way insulator supplied in package to silver fuse link terminal of after-run wiring assembly and tape back to harness.
2. Disconnect battery and wiring at carburetor choke housing, radiator fan motor, and large connector at starter relay (1981-1982 four-way connector, 1983-1984 five-way connector). When equipped with underhood lamp, extract orange fuse link terminal from connector and reset tang (Figure 6).
3. Remove wing nuts and set air cleaner aside.
4. M and Z Models
Using new after-run radiator fan relay as a guide, drill a 3/16" (5 mm) hole into overhang flange (left top shock tower) and fasten relay with 1/4" self-tapping screw (Figure 1).
P-D-C-V-L-J-E-T-H-K Models
Remove fender-to-side shield screw just forward of left shock tower, insert relay between fender and side shield, centering relay bracket hole on screw hole in fender flange. Reinstall screw (Figure 2). For cars equipped with EVA (Electronic Voice Alert), it may be necessary to bend relay bracket upward to position relay so EVA (Electronic Voice Alert) vacuum switch hose runs below center of relay.
5. Install ambient sensor to fan shroud.
*1981 (All) - 1982 (A/C Only) - Use 10 x 16 x 1/2" screw (Figure 3).
*1982 (W/0 A/C) - 1983-1984 (All) - Use tie straps to hold in place (Figure 3). Ambient sensor bracket should be bent to fit as necessary.
6. Add ground eyelet of after-run wiring assembly to lower outer air pump bracket bolt (at cylinder head) and retorque to 40 foot pounds/54 N-m (Figure 4).
CAUTION:
BE SURE ALL PRODUCTION GROUND EYELETS ARE REINSTALLED.
7. Connect after-run wiring assembly to ambient sensor and radiator fan motor wiring. Connect bullet on after-run wiring to two-way connector of existing harness (previously disconnected from motor Figure 3).
CAUTION:
BE SURE CONNECTIONS ARE AS DESCRIBED IN ILLUSTRATIONS TO AVOID THE POSSIBILITY OF A SHORT CIRCUIT.
8. Route after-run harness along engine wiring toward carburetor and connect production choke wire to harness. Connect remaining wire of new harness to carburetor choke (Figure 5).
9. Route remaining after-run harness to after-run relay. Connect black and white three-way insulators to relay (Figure 1 or 2).
10. Underhood lamp (when so equipped)
Remove loose insulator from taped back single connector on after-run wiring and snap in terminal of orange fuse link for underhood lamp feed of existing harness. Connect feed to the taped back single connector on the after-run fan wiring (Figure 2).
11. Snap bare terminal of after-run harness (crimped to fuse link) into starter relay connector (cavity next to 12 GA red wire - Figure 6). Reconnect starter relay insulator to starter relay.
12. Tie strap new harness to production wiring. Tape back all excess wire to assure no interference with radiator fan.
13. Reinstall air cleaner and wing nuts. Reconnect battery.
NOTE:
FOR OVERALL SYSTEM WIRING SCHEMATIC SEE FIGURE 9.
STEPS 14 THROUGH 23 APPLY TO TC3/024/TURISMO CHARGER/SCAMP/RAMPAGE MODELS ONLY
14. Remove the frontmost horn assembly on dual horn systems for clear access to the canister.
15. Remove the three (3) mounting nuts from the canister and disconnect all hoses from the canister.
16. Lower the canister from the vehicle.
17. Remove and discard the cap from the center lowest port of the canister (canister vent) Figure 7.
18. Install molded vacuum hose end nearest the 90~ elbow to the center lowest port of the canister and clamp with PN 6030541. Orient the canister vent hose to the front. Install the Ribbed Cap, PN 4041910, to the open end of the vent hose.
19. Reinstall the canister to the vehicle with the three (3) mounting nuts.
20. Route the newly installed canister vent hose through the:
^ Alternator adjustment opening of the front fascia on passenger car models (Figure 8).
^ Headlamp wiring opening of the front fascia on truck models (Figure 8).
21. a. Passenger Car Only
Locate vacuum line-to-canister vacuum control valve and remove a 3-1/2" section from the canister purge control (signal) vacuum hose at a point approximately 5" up from the 90~ rubber elbow fitting to the control valve.
b. For Vehicles With Nylon Purge Control (Signal) Vacuum Hoses Only
Cut off two 1-1/2" pieces of bulk 3/16" I.D. Rubber Vacuum Hose, Bulk Roll PN 4105167, and secure them on the open ends of the two remaining nylon line sections.
c. Install the Delay Valve, PN 4201385, between the two sections, making certain that the white side is toward the vacuum source.
d. If the car is a California package, install Hose Routing Label, PN 4307522, over the old label.
22. Reconnect all vacuum lines and start engine. Check for leaks.
23. Reinstall horn assembly if removed.
24. To Verify After-Run Fan System Operation:
^ A/C Passenger Cars Only - Start engine with A/C switch in A/C mode. Fan should operate with A/C clutch at room temperature prior to warm up.
CAUTION:
SHUT DOWN ENGINE IMMEDIATELY IF A/C CLUTCH OPERATES WITHOUT FAN AND DETERMINE CAUSE.
^ All Vehicles - Turn A/C (heater) switch to "Off" position (fan should shut off with cold engine). Start engine and run at 2000 rpm until radiator fan motor comes on.
CAUTION:
SHUT DOWN ENGINE IMMEDIATELY IF ENGINE LIGHT COMES ON OR TEMPERATURE GAUGE MOVES TO HOT BEFORE FAN MOTOR OPERATES AND DETERMINE CAUSE.
^ Bring engine to idle and turn off. Fan should continue to operate approximately 10 minutes (fan will not after-run in extremely cold temperatures).
25. Type the Authorized Modification Label, PN 4275086.
If vehicle still exhibits a fuel foaming condition, refer to Procedure No. 2 to install a fuel reservoir package.
POLICY:
Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No. 14-48-84-90.......0.5 Hrs.
FAILURE CODE:
AM - Authorized Modification