No Start After Hot Soak

Fig. 2 Starter System Wiring Circuit:

After driving for extended periods of time, especially in warm weather, the engine will not restart after a 30 to 40 minute hot soak. The cause of this is excessive voltage drop in the starter wiring circuit when underhood temperatures are high. When this occurs, voltage is reduced to a level where the starter will not activate.

To correct this condition install an additional starter circuit bypass relay as follows:

1. Disconnect battery ground cable.
2. Remove relay bracket and protector bag from firewall above fuse box.
3. Locate starter relay electrical connector (wire Nos. 32, 45, 45A, 46 and M), then disconnect plug, Fig. 2.
4. Remove wire 45 from pin 5 of existing starter relay and install in bypass relay connector pin 1 (Bosch relay pin No. 86).
5. Release double lock terminal from connector socket as follows:
a. Push wire and terminal into socket.
b. Insert a small standard screwdriver in center of terminal and pull wire down; hold wire in this position and remove screwdriver.
c. Insert screwdriver between rolled side of terminal and side of socket; pull wire down to release from socket.
6. Remove wire No. 46 from pin 3 of existing starter relay and insert into bypass relay connector at pin 3 (Bosch relay pin 30).
7. Cut a 12 inch length of 16 gauge wire, then crimp terminals part No. 6542.32 to both ends.
8. Install one end into existing starter relay pin 5 and new bypass relay connector pin 2 (Bosch relay pin 85).
9. Cut a 6 ft. length of 16 gauge wire, then crimp terminal part No. 6542.32 to one end and terminal No. 6540.27 to the other end.
10. Insert terminal No. 6542.32 into pin 3 of the original starter relay, then route wire along existing harness and attach terminal No. 6540.27 to ground block MM2 (next to left side headlight).
11. Cut a 52 inch length of 12 gauge wire, then crimp terminal No. 6542.30 to one end and install into bypass relay connector pin 5 (Bosch relay pin 87).
12. Crimp terminal No. 6540.38 to other end of 12 gauge wire, insulate with shrinkable tubing, then plug terminal into open pin of battery junction block located on positive battery cable.
13. Secure new wires to existing harness, then reinstall original starter relay into connector.
14. Install Bosch relay into bypass relay connector, then secure relay connector to existing hole in the relay support bracket using clip No. 0065.47.
15. Install protective covering and relay bracket to firewall.
16. Connect battery ground cable and test start.