Repair Instructions
FIGURE 1:
Behind Instrument Cluster
1. Remove the left hand speaker grille, the radio and the radio basket.
2. Using the speaker grille opening for access, determine if a protection strip is installed on the dash cross member at Location 8 (Figure 1). If there is no strip, install a 75 mm strip so that it is centered over the hole in the cross member.
3. Again using the access provided through the speaker grille opening, remove the speedometer cable from the speedometer. Install a 75 mm protection strip at Location A (Figure 1).
4. The wiring harness that is connected to the right side of the instrument cluster should be routed over the speedometer cable. Note the following additional precautions:
A) On 1987 8-valve cars, make sure that the wiring harness is also routed over the cable for the 30,000- mile emissions service counter.
B) On turbo's the harness should be routed under the hose for the turbo boost gauge.
C) On cars with cruise control, the harness should be positioned above the wires for the speed sensor.
5. Fasten the harness to the top shelf of the instrument cluster with fabric tape (Figure 1).
6. Install a tie strap through the hole in the cross member at Location B so that the strap fastens the wiring harness over the protection strip just installed (Figure 1). Secure the tie strap, but do not overtighten.
7. Reconnect the speedometer cable to the speedometer.
8. Do not replace the speaker grille at this time.
FIGURE 2:
Heater Fan Resistor Mounting
1. Inspect the mounting position of the heater fan resistor block. The block must be oriented so that the cooling tube is towards the rear of the car (Figure 2).
2. If the block is positioned incorrectly, turn it to the correct position.
FIGURE 3:
Central Dash Wiring
1. Using access provided through the radio opening, determine if the wiring harness is tie strapped to the vacuum servo (Figure 3). If a tie strap is present, cut and remove it.
FIGURE 4:
2. Install the 200 mm long section of corrugated tubing over the wiring harness (Figure 4). Installing the. tube will be made easier by spreading one end at the slit so that the tube can be started over the wiring harness. Once the opened end is over the harness, the rest of the tube can be fed onto the wires. Orient the slit so that the tubing can slide over the branch wires for the heater fan resistor.
FIGURE 5:
3. Feed the tube over the harness until it is at least 1/2 in. past both ribs of the heater core housing mounting bracket. If difficulty is encountered sliding the tube past the edge of the bracket, slide a folded piece of card stock down over the sharp edge of the bracket. The card stock will allow the tube to easily slide past the bracket (Figure 5).
NOTE
The tube must protect the wiring harness from both edges of the heater core housing mounting bracket. It is important that you verify the correct position of this tube before proceeding.
FIGURE 6:
Right-Side Dash Wiring
1. Remove the right speaker grille.
2. Install the 320 mm long corrugated tube over the wiring harness as shown in Figure 6. Orient the slit in the tube so that the tube will slide over the wiring harness branch which supplies the heater fan motor.
3. The slit in the tubing should be positioned so that it protects the harness from chafing against the fan motor and the right-hand dash cross member seam.
FIGURE 7:
4. Install a new tie strap around the wiring harness and the upper servo unit (Figure 7). The tie strap should be positioned around the half of the servo unit which faces the rear of the car. Do not over tighten.
5. Replace the speaker grille.
FIGURE 8:
Radio Wiring (1988 models only)
1. Bend in the ground spade lug on the back of the radio box so that it lays parallel to the side of the box (Figure 8). Using the short tie wrap, secure the radio wiring harness to the antenna and DIN cables as shown in Figure 8.
FIGURE 9:
Wiring Harness for Vacuum Microswitch
1. Disconnect the small diameter grey wire (599 A, 0.75 mm) from the lower of the three terminals on the upper microswitch (Figure 9). Secure it to the wiring harness with tape.
2. Disconnect the connector from the fan motor switch and remove the upper lamp for the dash illumination (Figure 9).
3. Route the wiring harness for the vacuum micro switch under the lamp and the fan motor switch as shown in Figure 9.
4. Reconnect the fan motor switch and replace the dash illumination lamp. Check that the wires running to the micro switch do not project upwards towards the radio opening. This will ensure they do not chafe against the radio box.
FIGURE 10:
4. Replace the radio box. Use the access provided through the speaker grille opening to pull the radio wiring harness forward while inserting the box into the dash opening (Figure 10). This will prevent. the radio harness from being pinched during installation.
5. Replace the left speaker grille.
FIGURE 11:
Rear Seat Bracket
Note
The following step DOES NOT apply to convertible models. Add this protection strip ONLY on 900 sedans and hatchbacks.
1. Fold the rear seat bottom forward. Install protection strip 89 30 349 on the left seat bracket as shown in Figure 11. (This strip may already be installed on some late-1988 models.)
FIGURE 12:
Carpet Bracket at the Floor Tunnel
This repair is applicable only to the following 1988 models without passive seat belts:
VIN J3000000-J3019621 VIN J7000000-J7031781
1. Remove the driver's seat and the sill plate (including the rear sill plate on 4-door cars).
2. Lift the carpet to gain access to the carpet bracket behind the handbrake lever (Figure 12).
3. Cut and remove the tie strap holding the wiring harness to the bracket.
4. Install the protective sleeve as shown in Figure 12. Align the hole in the sleeve with the hole in the bracket.
5. Run a tie strap through the hole and around the wiring harness. Do not overtighten the strap.
6. Replace the carpet over the bracket and reinstall the sill plate(s) and the driver's seat.
Campaign Modification Plate
Stamp box A4 of the campaign plate with the numeral "8" after all recall work has been completed.