Attachment III
ACCESSORY POWER CIRCUIT WIRING MODIFICATIONAFFECTED VEHICLES:
1992-1997 MODEL YEAR AEROSTAR
SERVICE PROCEDURES
Use the following Service Procedure to install a relay wiring harness into the ignition switch electrical connector. See Figure 1.
1.
NOTE:
The following test will be a baseline for the verification test at the end of this Service Procedure (Step 33). Note whether or not the following components are operational. Upon completion of the repair, operation (or non-operation) of the components should be unchanged. This test at the conclusion of the service procedure will ensure the relay harness is installed properly.
Test the following components:
^ Turn blower motor to HIGH
^ Turn radio on
^ Check brake shift interlock system by trying to shift from Park to any other gear without depressing brake pedal
2. Record radio stations, then disconnect battery negative cable.
3. Remove knee bolster.
4. Remove instrument panel reinforcing panel. See Figure 2.
5. Completely loosen ignition switch electrical connector retaining screw, then disconnect ignition switch electrical connector. See Figure 3.
6. Remove ignition switch electrical connector wiring shield and terminal locking plate. See Figure 4.
7. Remove black/light green wire, circuit 297, from terminal A1 of ignition switch electrical connector. See Figure 5.
8. Install black/light green wire of "Jumper A" into terminal A1 of ignition switch electrical connector. See Figure 6.
9. Install black/light green wire, circuit 297, into open slot of "Jumper A" connector. See Figure 7.
10. Remove yellow wire, circuit 37, from terminal B2 of ignition switch electrical connector. See Figure 8.
11. Install yellow wire, circuit 37, into loose 2-way connector in slot opposite the key way. See Figure 9.
12. Remove gray/yellow wire, circuit 287, from terminal A2 of ignition switch electrical connector. See Figure 10.
13. Install gray/yellow wire, circuit 287, into loose 2-way connector in slot next to the key way. See Figure 11.
14. Install ignition switch electrical connector wiring shield and terminal locking plate.
15. Disconnect brake shift lock solenoid electrical connector. See Figure 12.
16. Remove locking wedge from brake shift lock solenoid electrical connector.
17. Remove black wire, circuit 57, from center terminal of brake shift lock solenoid electrical connector. See Figure 13.
18. Install Black wire of "Jumper B" into center terminal of brake shift lock solenoid electrical connector. See Figure 14.
19. Install locking wedge into brake shift look solenoid electrical connector.
20. Remove locking wedge from "Jumper B" electrical connector.
21. Install black wire, circuit 57 (removed from brake shift lock solenoid electrical connector) into either open slot of "Jumper B." See Figure 15.
22. Install locking wedge into "Jumper B" electrical connector.
23. Connect brake shift lock solenoid electrical connector.
24. Install ignition switch electrical connector. Tighten retaining screw securely.
25. Connect relay harness to the three (3) open electrical connectors.Connector halves will only mate with their correct opposite halves. See Figure 16.
26. Using foam tape, wrap both gray electrical connectors together. Refer to Figure 17.
27. Using foam tape, wrap black electrical connector. See Figure 17.
28. Using tie straps on relay harness, secure relay harness as shown in Figure 18. Make sure relay is accessible for service. See Figure 18.
29. Trim tie straps.
30. Install instrument panel reinforcing panel. Tighten retainers to 10-14 Nm (7-10 lb-ft).
31. Install knee bolster.
32. Connect battery negative cable.
33. Start engine and verify modification as follows:
^ Turn blower motor to HIGH
^ Turn radio on
^ Check brake shift interlock system by trying to shift from Park to any other gear without depressing brake pedal
^ If any of the above components were operational before the modification and is not operational now, repeat the Service Procedure
34. Program radio stations