Repair Procedure
1. Disconnect battery.2. Remove plastic duct on right side of radiator for access to alternator.
3. Disconnect wiring at radiator fan motor and large (five-way) connector at starter relay. On vehicles equipped with underhood lamp, remove orange fuse link wire terminal from connector and reset terminal tang (Figure 17).
4. Remove fender to side shield screw just forward of left shock tower. Insert relay bracket between fender and side shield, centering relay bracket hole with screw hole on fender flange. Reinstall screw (Figure 13). (For cars equipped with EVA (Electronic Voice Alert), if may be necessary to bend relay bracket upward to position relay so EVA vacuum switch hose runs below center of relay.)
5. Install ambient sensor to fan shroud using 10 x 16 x 1/2" screw (Figure 14).
6. Add ground eyelet of after-run wiring assembly to engine wiring ground bolt and retorque to 45 foot pounds (61 N-m) (Figure 15).
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 of after-run wiring to two-way connector of production wiring for motor (Figure 14).
CAUTION:
BE SURE WIRING IS CONNECTED AS DESCRIBED AND ILLUSTRATED TO AVOID A SHORT CIRCUIT REQUIRING FUSE LINK REPLACEMENT.
8. Route after-run harness along engine wiring to after-run relay. Connect black and white three-way insulators to relay. On vehicles equipped with underhood lamp, 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 13).
9. Route remaining wiring along left side of battery into radiator yoke trough past the radiator and down rear face of yoke forward of the alternator. Snap locator clip into hole in yoke trough over the right half of the radiator. Seat push-on clip over horn mounting bolt on rear face of yoke (Figure 16).
NOTE:
SCRIBE AND LOOSEN HOOD LATCH TO ALLOW PUSH-ON CLIP IN WIRING TO PASS UNDER LATCH. TIGHTEN HOOD LATCH IN ORIGINAL POSITION.
10. Remove the two-way connector from the alternator rectifier end shield. Snap terminal into the alternator two-way and reinstall connector (Figure 16).
NOTE:
VEHICLES EQUIPPED WITH AIR CONDITIONING, ROUTE WIRE BELOW A/C LINES AT CONDENSER SEALING PLATE.
11. Dress yoke wiring toward the left side of car and tie wrap along hood release cable. Continue to dress rearward along wiring at left side of battery to added fan relay (Figure 16).
12. Snap bare terminal of after-run harness (crimped to fuse link) into starter relay insulator (cavity next to 12 GA red wire) (Figure 17). Reconnect starter relay connector to starter relay.
13. Tie strap remaining new harness to production wiring. Tape back all excess wire to assure no interference with radiator fan.
14. Reinstall plastic duct under after-run wiring to right side of radiator.
NOTE:
FOR OVERALL SYSTEM WIRING SCHEMATIC SEE FIGURE 18.
15. Reconnect battery.
16. To verify system operation:
^ A/C Passenger Cars Only - Turn ignition switch to "On" position (engine off) with A/C switch in A/C mode. Fan should operate with A/C clutch at room temperature.
^ 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 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).
17. Type an Authorized Modification Label, PN 4274086.
If vehicle still exhibits a fuel foaming condition, refer to Procedure No. 4 to install a fuel. reservoir package.
POLICY:
Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No. 14-48-84-92.........0.5 Hrs.
FAILURE CODE:
AM - Authorized Modification