Technical Procedure

INSTALLATION OF "LAMP CIRCUIT KIT" (ALL VEHICLES INVOLVED) AND "PUMP CIRCUIT" KIT (CERTAIN INVOLVED VEHICLES).

1. Open vehicle hood and cover fenders.

2. Disconnect negative cable from battery.

FIGURE 1 - I. P. HARNESS TO ENGINE HARNESS CONNECTOR ASSEMBLY:

3. Loosen bolt that retains engine compartment connector assembly to front of dash, and unplug engine harness part of connector from I.P. harness connector. Remove I.P. harness connector from its mounting bracket. Refer to Figure 1.

FIGURE 2 - REMOVING I.P. HARNESS CONNECTOR SECONDARY LOCK:

4. Remove the terminal secondary lock from I.P. connector, as shown in

Figure 2.

FIGURE 3 - MAIN I.P. HARNESS AND MASTER CYLINDER BRANCH:

5. Remove the tape and plastic conduit from the main I.P. harness back to a point where the brake pressure switch connector branch (to master cylinder) leaves the main harness. Refer to Figure 3.

6. Remove the tape and conduit from the pressure switch branch of the wiring.

7. Cut the tan wire with white stripe at a place approximately 7 inches from the end of the pressure switch connector. Refer to Figure 3. Strip both ends of this cut wire.

FIGURE 4 - LAMP CIRCUIT JUMPER WIRE INSTALLATION:

8. Using furnished splice clip, splice the furnished jumper wire lead to the two ends of the cut wire. Use rosin core solder and solder this connection. Refer to Figure 4, View A.

FIGURE 5 - I.P. HARNESS CONNECTOR CAVITY IDENTIFICATION:

FIGURE 6 - INSTALLING LAMP CIRCUIT JUMPER WIRE IN I.P. CONNECTOR:

9. Insulate the soldered connection with electrical tape.

10. Plug the terminal end of the jumper wire into cavity A-1 of the I.P. harness connector. Refer to Figure 5 and Figure 6.

11. Replace the conduit over the pressure switch branch and main I.P. harness, including the new installed jumper wire. Tape all wires exposed by the removal of the tape in steps 5 and 6.
12. Determine if "pump circuit kit" is to be installed in vehicle.. Refer to "Vehicles Involved" and "Parts Information" section of this bulletin.

a. IF "PUMP CIRCUIT" KIT IS NOT TO BE INSTALLED, STEPS 13 THROUGH 16 ARE NOT REQUIRED, PROCEED TO STEP 17.

b. IF PUMP CIRCUIT KIT IS TO BE INSTALLED, PROCEED WITH ALL OF THE FOLLOWING STEPS OF THIS PROCEDURE.

13. Remove the terminal secondary lock from other side of I.P. harness connector. Refer to Figure 2.

FIGURE 7 - UNLOCKING WIRE TERMINAL FROM CONNECTOR:

FIGUHE 8 - INSERTING WIRE TERMINAL REMOVED FROM CAVITY J-6 INTO FURNISHED CONNECTOR:

14. Remove the wire terminal from cavity J6 of connector. Refer to Figure 7. Raise terminal lock tang to original position. Plug the furnished single connector onto this removed terminal and latch the connector lock. Refer to Figure 8. Plug this connector into connector of furnished jumper harness from pump kit.

FIGURE 9 - INSERTING PUMP JUMPER HARNESS WIRES IN I. P. CONNECTOR:

FIGURE 10 - PUMP CIRCUIT HARNESS JUMPER INSTALLED:

15. Plug the larger terminal on jumper harness into cavity J6 and the other terminal to cavity C3 of instrument panel connector. Refer to Figure 9 and 10.

16. Tape the jumper harness connector and wires to the I.P. harness so that they are covered and free from possible pinch.

17. Reinstall connector secondary lock(s).
18. Install the I. P. connector back into its mounting bracket, and plug engine harness and I. P. harness connector together.

19. Install connector assembly on the dash, torquing bolt to 7 N-m (5 lbs. ft.).

20. Connect the negative cable to the battery.
21. Check the vacuum pump low vacuum indicator warning light operation as follows:

a. Remove power brake check valve from booster.

b. With park brake released, turn ignition to "on" or "run" position. Do not start engine.

- Vacuum pump should be running.

- Brake indicator light on instrument panel cluster should come on in 15-45 seconds.

c. After light comes on, reinstall brake booster check valve and start engine and run at idle. Brake light should go "out" in less than ten seconds and vacuum pump should stop operating.

22. If vacuum pump and brake indicator light did not operate as described in step 21, locate and check system problem.

CAMPAIGN IDENTIFICATION LABEL:

23. Install a Campaign Identification Label. Each vehicle modified in accordance with the instruction outlined in this procedure will require a Campaign Identification Label. Each label provides a space to include the campaign number, the five (5) digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. When installing label, clean the surface of the radiator upper mounting support and apply the campaign label where it is readily visible.