Engine - Intermittent No Start
Article No.97-24-10
11/24/97
NO START - INTERMITTENT - LOSS OF
CRANKSHAFT POSITION (CKP) SENSOR SIGNAL -
4.6L 4-VALVE VEHICLES
LINCOLN-MERCURY:
1995-97 CONTINENTAL
This TSB article is being republished in its entirety to include a phone number for non-U.S. dealers.
ISSUE:
There may be an intermittent no start on some vehicles. This may be caused by a poor connection at the female terminals at the Crankshaft Position (CKP) sensor connector terminals. This may result in a loss of CKP signal which will result in a no spark and no fuel condition.
ACTION:
Install new terminal ends. The new terminal ends should reduce the possibility of corrupting the CKP signal. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Disconnect the 2-way connector from the CKP sensor and pull back any convoluted tubing, tape and/or aluminum foil to expose approximately 63 mm (2.5") of wire. Be careful not to damage the wiring, plastic convolute or aluminum foil since these must be reused. For wire color coding, refer to Figure 1.
2. Pry up the yellow terminal lock wedge (Figure 2) inside the connector and remove but do not discard.
3. Disconnect only one terminal at a time to avoid reversing leads. Splice on a new pigtail/terminal and reconnect the terminal before disconnecting the other terminal. The terminal is removed by lifting the plastic finger lock (Figure 3) located inside the connector, away from the terminal and then pulling on the wire.
4. Unwind the twisted wire and splice on the new terminal lead from the Ford Terminal Repair Kit, matching the length of the existing take out. Use Ford approved solder splice procedures.
NOTE:
TERMINALS MAY BE ORDERED FROM THOMAS AND BETTS AT (800) 466-1986 (810-493-1220 OUTSIDE THE U.S.), DRAWER D # 44 FROM BOX # 3. CUT OFF APPROXIMATELY 63 mm (2.5") OF EXISTING HARNESS WIRES LEAVING ENOUGH LENGTH TO COMPENSATE FOR THE SPLICE AND EQUAL TO THE ORIGINAL LENGTH OF WIRE REMOVED FROM THE CONNECTOR.
NOTE:
THE NEW TERMINAL WIRES MAY BE A LARGER GAUGE THAN THE ONES REMOVED FROM THE EXISTING HARNESS AND MAY NOT BE COLOR CODED. PLEASE INSTALL NEW TERMINALS WITH PIGTAILS INDIVIDUALLY AS INSTRUCTED ABOVE.
5. Reinsert terminal into the connector, orienting properly for the plastic finger to hold the terminal in the connector and verifying the leads match Figure 1. Refer to Figure 4.
6. Repeat Steps 3 through 5 for the other terminal lead.
7. Reinsert the terminal lock wedge from Step 2. Reassemble the harness by twisting the wires, reapplying the aluminum foil, returning the convolute to its original position and retaping the end of the convolute to the harness. Be sure to tie wrap or tape the harness pigtail away from the fuel line protection clip to eliminate the possibility of chafing.
8. Reconnect the connector to the CKP sensor and verify the repair.
CAUTION:
APPLYING DIELECTRIC GREASE TO THE TERMINALS AS OUTLINED IN TSB 97-14-5 WAS AN INTERIM REPAIR PROCEDURE AND SHOULD NOT BE PERFORMED WHEN THESE REPLACEMENT TERMINALS ARE INSTALLED.
OTHER APPLICABLE ARTICLES: 97-24-14
SUPERSEDES: 97-19-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
972410A Replace Crankshaft 0.5 Hr.
Position (CKP) Terminal
Ends
DEALER CODING
CONDITION
BASIC PART NO. CODE
12ASR1 X4
OASIS CODES: 602300, 603300