OWNER NOTIFICATION PROGRAM
99M03
 
Certain 1995-1997 Contour and Mystique vehicles - Under Hood Wire Harness - Additional Coverage.

 

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October, 1999

To:
All Ford and Lincoln-Mercury Dealers

Subject:
Owner Notification Program 99M03 - Certain 1995-1997 Contour and Mystique vehicles - Under Hood Wire Harness - Additional Coverage.

OASIS:

Yes

OWNER LIST:

Yes

PARTS RETURN:

No

PROGRAM TERMS:

This program provides extended coverage on certain under hood wire harnesses through 10 years or 100,000 miles which ever occurs first, from the original warranty start date.

AFFECTED VEHICLES

Certain 1995 - 1997 Contour and Mystique vehicles built from Job #1 1995 through Model Year End 1997.

REASON FOR RECALL

Under ambient factors of high temperature and high humidity, certain 1995 - 1997 Contour and Mystique vehicles may be susceptible to the wiring insulation becoming brittle and cracking on certain engine compartment wiring harnesses.

These harnesses deliver electrical power to the engine and its cooling and control systems, the climate control, and other power distribution systems. If wire harness insulation cracking is found during the additional warranty period, the under hood wire harnesses are to be replaced at no charge to the customer.

SERVICE ACTION

 

Additional Warranty Coverage

Effective immediately, Ford is providing additional coverage for the replacement of the under hood wire harnesses on these vehicles for a period of 10 years or 100,000 miles, which ever occurs first, from the original warranty start date. This coverage exceeds the provisions of the original component warranty coverage on the affected vehicles and is automatically transferred to subsequent owners at no charge. This additional coverage does not include normal service diagnostic or repair charges unrelated to wire harness brittleness and cracking. After this additional coverage has expired, wire harness replacements will be at the expense of the vehicle owner.

QUESTIONS?

Claims Information 1-800-423-8851

Other Recall Questions 1-800-325-5621

Attachments

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ATTACHMENT I
Owner Notification Program 99M03


Certain 1995-1997 Contour and Mystique vehicles Under Hood Wire Harness Replacement

OASIS

You must use OASIS to determine if a vehicle is eligible for this recall.

CLAIMS PREPARATION AND SUBMISSION

 

OWNER REFUNDS

Ford Motor will only refund for owner-paid repairs on wire harness replacement due to insulation cracking made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer).

Refer to ACESII Manual for Refund information. Enter claims using DWE:

 

 

   
Program Code: 99M03
Misc. Expense: REFUND
Misc. Espense: ADMIN
Misc. Expense: 0.2 Hr.

RENTAL CARS

If there is damage to the wire harnesses, Ford will pay for a loaner or rental vehicle except for fuel which will be at the owner's expense. Rentals should be provided only while the vehicle is at the dealership overnight for wire harness repairs, not to exceed 2 days . Follow Extended Service Plan (ESP) guidelines. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim.


 

ATTACHMENT II
Owner Notification Program 99M03


Certain 1995-1997 Contour and Mystique vehicles Under Hood Wire Harness Replacement.

LABOR ALLOWANCES

Operation Description Labor Allowances Labor Operation
Visual Inspection 0.2 Hours 99M03A
Electronic Inspection 0.6 Hours 99M03K

 

 

Harness Replacement - Excludes Inspection
 

Operation Description Labor Allowances Labor Operation
Replace 4 harnesses - 2.5L Auto Trans., with ABS 7.7 Hours 99M03B
Replace 4 harnesses - 2.5L Man. Trans., with ABS 6.9 Hours 99M03C
Replace 3 harnesses and overlay harness - 2.5L Auto. Trans., no ABS 4.1 Hours 99M03D
Replace 3 harnesses and overlay harness - 2.5L Man. Trans., no ABS 3.5 Hours 99M03F
Replace 3 harnesses - 2.0L, with ABS 5.7 Hours 99M03G
Replace 2 harnesses and overlay harness - 2.0L, no ABS 1.9 Hours 99M03H

PARTS REQUIREMENTS

Parts Ordering Information

Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as noted below:

 

 

     
All Orders Types First 60 days after launch Call 1-800-325-5621
All Order Types After 61 days Normal order process

 

 

Part Number (Kit) Description Quantity
F5RZ-14K289-S4TB 95 2.0L Manual or Auto With ABS 1
F5RZ-14K289-S4TA 95 2.0L Manual or Auto no ABS 1
F5RZ-14K289-S6MB 95 2.5L Manual Trans With ABS 1
F5RZ-14K289-S6MA 95 2.5L Manual Trans no ABS 1
F5RZ-14K289-S6AB 95 2.5L Auto Trans With ABS 1
F5RZ-14K289-S6AA 95 2.5L Auto Trans no ABS 1
F6RZ-14K289-S4TC 96-97 2.0L Manual or Auto With MECA II with ABS 1
F6RZ-14K289-S4TD 96-97 2.0L Manual or Auto With MECA III with ABS 1
F6RZ-14K289-S4TA 96-97 2.0L Manual or Auto no ABS 1
F6RZ-14K289-S6MC 96-97 2.5L Manual Trans With MECA II with ABS 1
F6RZ-14K289-S6MD 96-97 2.5L Manual Trans With MECA III with ABS 1
F6RZ-14K289-S6MA 96-97 2.5L Manual Trans no ABS 1
F6RZ-14K289-S6AC 96-97 2.5L Auto Trans With MECA II with ABS 1
F6RZ-14K289-S6AD 96-97 2.5L Auto Trans With MECA III with ABS 1
F6RZ-14K289-S6AA 96-97 2.5L Auto Trans no ABS 1

DEALER PRICE

For latest prices, check or call your:

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.


 

ATTACHMENT III
Owner Notification Program 99M03


ENGINE COMPARTMENT WIRING HARNESS REPLACEMENT

AFFECTED VEHICLES:

1995-1997 CONTOUR AND MYSTIQUE

OVERVIEW

Purpose: The purpose of this program is to extend the warranty on 1995 through 1997 Contour and Mystique vehicle for concerns related specifically to under hood wire harness degradation.

If it is found through diagnosis that driveability concerns are caused by wire harness degradation, or visible signs of wire harness degradation exist, under hood wiring harnesses replacement is required.

ENGINE COMPARTMENT WIRING HARNESS REPAIR PROCESS FLOW CHART

 


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WIRING HARNESS EVALUATION

VISUAL INSPECTION

The purpose of this inspection is to visually identify degrading in the wiring insulation of certain vehicle components.

  1. To visually identify wiring degradation See Figure 1, noting the following characteristics:


    ir99m03a.gif
    FIGURE 1

     

  2. To visually identify a vehicle with wiring degradation, check component wires at locations designated by circles in Figures 2 through 4. Also check battery positive cable (not illustrated).


    ir99m03b.gif
    FIGURE 2

     


    ir99m03c.gif
    FIGURE 3

     


    ir99m03d.gif
    FIGURE 4

     

    ELECTRONIC INSPECTION

    The purpose of this inspection is to electronically identify wiring issues that can not be seen visually due to convolute or wrap around wiring harness looms.

    This inspection procedure will use the New Generation STAR (NGS) Tester and the Powertrain Control/ Emissions Diagnosis (PCED) Manual. If electronic inspection is required please call 1-800-325-5621 for further directions.

SERVICE PROCEDURE MATRIC CHART

On the Contour/Mystique vehicle line there are four (4) main engine compartment wiring harnesses. The Service Procedure for individual vehicles will vary depending on the engine application and the type of brake system. Refer to the matrix chart below to determine the required Service Procedure for the vehicle you are servicing.

 

 

  Fan Control Harness Replacement (8C290) Fuel Charge Harness Replacement (9H589) Engine Control Harness Replacement (12A522) Power Distribution Harness Replacement (14K733) Power Distribution Harness - Overlay Installation Only (14K095) (14300)
2.0L non- ABS Yes Yes No No Yes
2.0L with ABS Yes Yes No Yes* No
2.5L non- ABS Yes Yes Yes No Yes
2.5L with ABS Yes Yes Yes Yes* No

* Cooling module (condenser, fan and radiator) must also be removed.

SERVCE PRODCEDURE

 
The order of harness removal and installation is critical to the repair process. Perform each step of the service procedure as described on the following pages.

 

 

 
Refer to the fold-outs in the back of this instruction manual for most component locations and wiring harness routing illustrations.

FAN CONTROL HARNESS - REMOVAL

REFER TO FOLD-OUT #1, FOR FAN CONTROL HARNESS ILLUSTRATIONS

SINGLE COOLING FAN

 

  1. Record radio stations.
  2. Disconnect and remove the battery.
  3. Raise and support the vehicle.
  4. Remove the lower air deflector.
  5. Completely drain the engine cooling system.
  6. Disconnect and detach the engine cooling fan control resistor connector.
  7. Lower the vehicle.
  8. Remove the ground wire from the radiator support.
  9. Disconnect the air conditioning clutch connector.
  10. Remove the fan control harness from the passenger-side of the fan shroud.
  11. Detach then disconnect the power distribution harness connectors.
  12. Detach the fan control harness from two (2) pushpins and two (2) routing clips on the fan shroud.
  13. Disconnect the engine cooling fan and the air conditioning clutch cycling switch connectors.
  14. Remove the fan control harness from the vehicle.

DUAL COOLING FAN

  1. Record radio stations.
  2. Disconnect and remove the battery.
  3. Raise and support the vehicle.
  4. Remove the lower air deflector.
  5. Remove the passenger-side engine splash shield.
  6. Completely drain the engine cooling system.
  7. Disconnect the air conditioning clutch connector.
  8. Disconnect the passenger-side engine cooling fan connector, then detach the wiring pushpin.
  9. Disconnect the driver-side engine cooling fan connector, then detach the wiring pushpin.
  10. Disconnect the engine cooling fan control resistor connector.
  11. On 1995 models, detach the diode pushpin from the fan shroud.
  12. Lower the vehicle.
  13. Remove the water pump pulley cover from the front of the engine.
  14. Remove the ground wire from the radiator support.
  15. Remove the fan control harness from all routing clips and pushpins on the fan shroud.
  16. Detach then disconnect the power distribution harness connectors.
  17. Disconnect the air conditioning clutch cycling switch connector.
  18. Remove the fan control harness from the vehicle.

FUEL CHARGE HARNESS - REMOVAL

2.0L ENGINE

REFER TO FOLD-OUT #2, FOR 2.0L FUEL CHARGE HARNESS ILLUSTRATIONS

  1. Disconnect the mass air flow sensor and the intake air temperature sensor connectors.
  2. Remove the air cleaner box, air cleaner cover, clean air tube, resonator and throttle body cover as an assembly. The fresh air tube must be disconnected from the back side of the valve cover.
  3. Disconnect the engine coolant temperature sensor connector.
  4. Disconnect the vacuum line from the tap on the intake manifold.
  5. Route the engine coolant temperature sensor wiring back to the main harness casing.
  6. Disconnect the idle air control solenoid, the camshaft position sensor and the throttle position sensor connectors.
  7. Disconnect all fuel injector connectors.
  8. Disconnect the engine control harness connector from the fuel charge harness.
  9. Remove the throttle body retaining bolts, then position the throttle body aside.
  10. Cover the intake manifold port with a shop towel.
  11. Remove the fuel charge harness casing retaining screws, then remove the fuel charge harness.

2.5L ENGINE

 

REFER TO FOLD-OUT #3, FOR 2.5L FUEL CHARGE HARNESS ILLUSTRATIONS

  1. Raise and support vehicle.
  2. Disconnect the oil pressure sensor connector, located on the engine block behind the air conditioning compressor.
  3. Detach then disconnect the crankshaft position sensor connector. The pushpin is anchored to a front cover stud.
  4. Lower the vehicle.
  5. Remove the front fresh air tube from the valve cover.
  6. Detach then disconnect the throttle position sensor connector.
  7. Disconnect the mass air flow sensor connector.
  8. Remove the back two (2) fresh air tubes from the clean air tube.
  9. Disconnect the intake air temperature sensor connector.
  10. Remove the air cleaner box, air cleaner cover, clean air tube and resonator as an assembly.
  11. Disconnect the throttle cables and the return spring from the throttle body.
  12. Remove the throttle cable bracket retainers. Position the bracket and throttle cables aside.
  13. Remove the two (2) vacuum taps and the positive crankcase ventilation hose from the upper intake manifold.
  14. Remove the vacuum line from the exhaust gas recirculation valve.
  15. Disconnect the idle air control solenoid connector.
  16. Disconnect the vacuum regulator solenoid vacuum and electrical connections.
  17. Separate the exhaust gas recirculation valve from the upper intake manifold.
  18. Remove the upper intake manifold retaining bolts in the sequence shown in Figure 5. Remove the upper intake manifold and gaskets. Cover intake ports with clean shop towels.


    ir99m03e.gif
    FIGURE 5

     

  19. Remove the coil pack and the radio suppressor connectors. Remove the coil pack and the ignition wires as an assembly.
  20. Disconnect the engine coolant temperature sensor connector.
  21. On 1995 models, disconnect the intake manifold runner control solenoid connector.
  22. On 1996-1997 models, disconnect intake manifold runner control actuator connector.
  23. Disconnect the front oxygen sensor and the camshaft position sensor connectors.
  24. Remove the retaining bolt securing the power steering line and the ground wire to the motor mount.
  25. Detach the three (3) engine control harness connectors and the coil pack wiring from the valve cover bracket.
  26. Disconnect the engine control harness connectors.
  27. Remove the fuel charge harness from the five (5) studs on the valve covers.
  28. Disconnect all fuel injector connectors.
  29. Remove the fuel charge harness from the vehicle.

ENGINE CONTROL HARNESS - REMOVAL

2.5L ENGINE

 

REFER TO FOLD-OUT #3 AND #4, FOR 2.5L ENGINE CONTROL HARNESS ILLUSTRATIONS

 

  1. On 1995 models, remove the ignition control module bracket retainers, then lift the bracket away from its mounting.
  2. On 1995 models, disconnect the ignition control module and the heated oxygen sensor relay connectors. Remove the ignition control module bracket assembly.
  3. Position the power steering reservoir out of the way.
  4. Remove the ground wire from the fender.
  5. Disconnect the powertrain control module connector.
  6. Remove the engine control harness from the bulkhead clip.
  7. Disconnect the power steering pressure switch connector.
  8. Raise and support the vehicle.
  9. Disconnect all alternator connections.
  10. Disconnect the knock sensor connector.
  11. On 1996-1997 models, detach then disconnect rear catalyst monitor connector.
  12. On vehicles equipped with an automatic transaxle, disconnect turbine shaft speed sensor connector.
  13. On 1996-1997 models, detach then disconnect front catalyst monitor connector.
  14. Lower the vehicle.
  15. Disconnect the rear oxygen sensor connector.
  16. Remove the harness casing from the back of the engine. Position the casing in a more accessible location.
  17. Release the tie straps securing the mega-fuse wires to the harness casing. Separate the mega-fuse from the harness casing.
  18. Disconnect the exhaust gas recirculation transducer connector.
  19. On vehicles equipped with a automatic transaxle, proceed as follows:
  20. Disconnect the vehicle speed sensor connector. The sensor connector is tie-strapped to the wiring harness near the rear engine mount.
  21. On vehicles equipped with a automatic transaxle, disconnect the transaxle range sensor and the transaxle 10-pin connectors.
  22. On vehicles equipped with a manual transaxle, disconnect the backup lamp switch and water temperature indicator sender unit connector.
  23. Disconnect the 42-pin connector, located on the driver-side strut tower.
  24. Remove the metal retaining clip securing the engine control harness to the top of the transaxle.
  25. On vehicles equipped with a automatic transaxle, detach the turbine shaft speed sensor wiring from the routing clips on the transaxle.
  26. Remove engine control harness by pulling the harness out from the passenger-side of the vehicle.

POWER DISTRIBUTION HARNESS PRELIMINARY COMPONENT - REMOVAL

 
Only perform cooling module removal on vehicles that required complete power distribution harness replacement. Vehicles requiring overlay harness installation, proceed to "Power Distribution Harness - Overlay Installation".

COOLING MODULE - REMOVAL

 

SINGLE COOLING FAN

 

CONTOUR

 

  1. Recover refrigerant from the air conditioning system.
  2. On vehicles equipped with a automatic transaxle, disconnect the upper transaxle line from the radiator.
  3. Disconnect the upper radiator hose from the radiator.
  4. On 1995 models, detach the oxygen sensor wiring from the fan shroud.
  5. On 1996-1997 models, detach the oxygen sensor/catalyst monitor wiring from the fan shroud.
  6. Raise and support the vehicle.
  7. Position the power steering cooler away from the condenser/radiator assembly.
  8. On vehicles equipped with a automatic transaxle, disconnect the lower transaxle line from the radiator.
  9. Disconnect the lower radiator hose from the radiator.
  10. Disconnect the air conditioning lines from the condenser. Cap both lines and condenser ports.
  11. On vehicles equipped with a automatic transaxle, disconnect the transaxle lines from the routing clip.
  12. With an assistantís help, remove the cooling module (fan, radiator and condenser).

MYSTIQUE

  1. Recover refrigerant from the air conditioning system.
  2. On vehicles equipped with a automatic transaxle, disconnect the upper transaxle line from the radiator.
  3. Disconnect the upper radiator hose from the radiator.
  4. Separate the engine cooling fan from the radiator.
  5. Release the oxygen sensor wiring from the clips on the fan shroud.
  6. Secure the engine cooling fan to the lifting eye.
  7. Raise and support the vehicle.
  8. Position the power steering cooler away from the condenser/radiator assembly.
  9. On vehicles equipped with a automatic transaxle, disconnect the lower transaxle line from the radiator.
  10. Disconnect the lower radiator hose from the radiator.
  11. Disconnect the air conditioning lines from the condenser. Cap both lines and condenser ports.
  12. On vehicles equipped with a automatic transaxle, disconnect the transaxle lines from the routing clip.
  13. With an assistantís help, remove the cooling module (radiator and condenser).
  14. Cut the wire securing the engine cooling fan to the lifting eye, then remove the engine cooling fan from the vehicle.

DUAL COOLING FAN

 

CONTOUR

  1. Recover refrigerant from the air conditioning system.
  2. Disconnect the coolant over flow tube from the radiator. Position the tube aside.
  3. On vehicles equipped with automatic transaxle, disconnect the upper transaxle line from the radiator.
  4. Disconnect the upper radiator hose from the radiator.
  5. Raise and support the vehicle.
  6. Position the power steering cooler away from the condenser/radiator assembly.
  7. On vehicles equipped with automatic transaxle, disconnect the lower transaxle line from the radiator.
  8. Disconnect the lower radiator hose from the radiator.
  9. Disconnect the air conditioning lines from the condenser. Cap both lines and condenser ports.
  10. On vehicles equipped with automatic transaxle, disconnect the transaxle lines from the routing clip.
  11. With an assistantís help, remove the cooling module (fan, radiator and condenser).

MYSTIQUE

  1. Recover refrigerant from the air conditioning system.
  2. Disconnect the coolant over flow tube from the radiator. Position the tube aside.
  3. On vehicles equipped with automatic transaxle, disconnect the upper transaxle line from the radiator.Disconnect the coolant over flow tube from the radiator. Position the tube aside.
  4. Disconnect the upper radiator hose from the radiator.
  5. Separate the engine cooling fan from the radiator.
  6. Secure engine cooling fan to radiator core support.
  7. Raise and support the vehicle.
  8. Position the power steering cooler away from the condenser/radiator assembly.
  9. On vehicles equipped with automatic transaxle, disconnect the lower transaxle line from the radiator.
  10. Disconnect the lower radiator hose from the radiator.
  11. Disconnect the air conditioning lines from the condenser. Cap both lines and condenser ports.
  12. On vehicles equipped with automatic transaxle, disconnect the transaxle lines from the routing clip.
  13. With an assistantís help, remove the cooling module (radiator and condenser).
  14. Cut the wire securing the engine cooling fan to the core support, then remove the engine cooling fan from the vehicle.

POWER DISTRIBUTION HARNESS - REMOVAL

 
Only use this procedure when the "Service Procedure Matrix Chart requires complete power distribution harness replacement, otherwise proceed to "Clean and Inspect Section"

REFER TO FOLD-OUT #4, FOR POWER DISTRIBUTION HARNESS ILLUSTRATIONS

 

  1. Remove both front inner fender well splash shields.
  2. Detach the passenger-side front antilock brake wheel sensor connector wiring, then disconnect the connector.
  3. Disconnect, remove and plug the windshield washer bottle.
  4. Disconnect the passenger-side horn and fog lamp connectors, then detach the connector wiring.
  5. Position the passenger-side side air deflector away from the tie bar.
  6. Swing aside the clips securing the power distribution harness to the tie bar channel.
  7. Position the driver-side side air deflector away from the tie bar.
  8. Remove the A/C accumulator bracket retainers, if equipped. Position the accumulator assembly away from the power distribution harness elbow casing.
  9. Disconnect the driver-side horn and fog lamp connectors, then detach the connector wiring.
  10. On vehicles equipped with a 2.0L engine, remove the fender well air intake resonator.
  11. Disconnect the driver-side front antilock brake wheel sensor connector wiring, then detach the connector.
  12. Remove the speed control servo mounting bracket retaining nuts.
  13. Lower the vehicle.
  14. On 1995 models, detach then disconnect the evaporative emissions purge solenoid connector.
  15. On 1996-1997 models, disconnect the vapor management valve connector, then detach the connector wiring from bottom of strut tower.
  16. On vehicles equipped with antilock brakes, detach then disconnect connector C124.
  17. Remove the degas bottle retainers, then slightly lift the bottle upward. Disconnect the low coolant sensor connector, then position the degas bottle aside.
  18. Disconnect the air conditioning pressure cutoff switch connector.
  19. Detach then disconnect the two (2) traction control motor connectors.
  20. Detach then disconnect the hood switch connector.
  21. Disconnect the passenger-side front primary airbag crash sensor connector.
  22. Disconnect the two (2) passenger-side headlamp connectors.
  23. Remove and disconnect the passenger-side marker lamp.
  24. Remove the ground wire from driver-side inner fender.
  25. Disconnect the driver-side front primary airbag crash sensor connector.
  26. Disconnect the two (2) driver-side headlamp connectors.
  27. Remove and disconnect the driver-side marker lamp.
  28. Remove one (1) battery pad (insulator) retaining strip, then lift up the battery pad to expose the inner fender.
  29. Disassemble the positive and the negative battery cable assemblies.
  30. Remove the power distribution box retainer. Lift the power distribution box up and away from the wiring harness along the driver-side fender.
  31. Slide the 42-pin connector off of its mounting bracket on the strut tower.
  32. Disconnect the brake fluid level sensor and the two (2) hydraulic control unit connector(s).
  33. Remove both wiper arms and the leaf screen.
  34. Disconnect the speed control servo electrical connector, then position the speed control servo away from the wiring harness.
  35. On 1995 models, remove the antilock brake diagnostic connector from the stud on the left strut tower. The plug retainer may come off with the original harness.
  36. On 1995 models, disconnect the two (2) data link connectors from the cap.
  37. Detach then disconnect the hood lamp connector.
  38. Remove the speed control servo mounting bracket.
  39. Remove and disconnect the wiper motor and transmission assembly.
  40. Separate the power distribution harness assembly from the engine compartment as follows:
  41. On Mystique models, remove knee bolster storage compartment.
  42. Remove the knee bolster.
  43. Separate the fuse box from its bracket.
  44. Disconnect the seven (7) connectors from the fuse box, then position the fuse box aside.
  45. On 1996-1997 models, detach diagnostic link connector from its holder.
  46. Disconnect the five (5) male connectors from the fuse box bracket organizer. See Fold-Out #4 (Part 6 of 6).
  47. Slide the organizer off of the fuse box bracket.
  48. Pull the five (5) female connectors out of the organizer. Position the organizer aside.
  49. Remove the fuse box bracket retaining bolts and wiring harness tie strap, then position the bracket down toward the floor pan.
  50. Detach the following connectors from the fuse box bracket:
  51. Remove fuse box bracket from vehicle.
  52. Cut the brake on/off switch wiring in an accessible location. Remove the cut section of the wiring from the vehicle.
  53. On 1996-1997 models, remove driver-side rocker panel ground wire as follows:
  54. With an assistantís help, route the instrument panel section of the wiring harness into the engine compartment.
  55. Remove the power distribution harness from the vehicle.

CLEAN AND INSPECT

2.0L ENGINE

 

  1. Clean and inspect the throttle body gasket and gasket surface.

2.5L ENGINE

  1. Clean and inspect the upper intake manifold gasket. Replace the gasket, if necessary.
  2. Clean the exhaust gas recirculation valve-to-upper intake manifold gasket surface.
  3. Clean the coolant crossover tube mounting bores. Clean and inspect the crossover tube O-rings. Replace, as necessary.

POWER DISTRIBUTION HARNESS - OVERLAY INSTALLATION

The following service procedure will replace two portions of the power distribution harness.

Two individual sub-harnesses will be used two complete this procedure, they are:

1) Battery positive wiring branch. This sub-harness includes the battery positive cable and battery positive connections going to the power distribution box.

2) Cooling fan wire harness jumper. This sub-harness includes power and ground connections for the fan control harness and connections going to the power distribution box.

  1. Remove one (1) battery pad (insulator) retaining strip, then remove the battery pad.
  2. Remove the power distribution box retainer. Lift the power distribution box up and away from the wiring harness along the driver-side fender.
  3. Turn the power distribution box over to access the bottom of the box, then cut the tie strap retaining the wiring harness to the power distribution box.
  4. Remove the relays from the power distribution box. See Figure 6.


    ir99m03f.gif
    FIGURE 6

     

  5. Remove the bottom cover from the power distribution box. See Figure 7.


    ir99m03g.gif
    FIGURE 7

     

  6. Detach the pushpins and the tie strap retaining the battery positive cable to the battery support.
  7. Cut the tape from the wiring harness under the power distribution box, then unzip the wiring harness wrap. See Figure 8. Expose 5-6 inches of the wiring.


    ir99m03h.gif
    FIGURE 8

     

  8. Detach and remove the relay box from the power distribution box. See Figure 9.
  9. Release the maxi fuse assembly retaining tabs, then slide the maxi fuses out from the bottom of the relay box. See Figure 9.


    ir99m03i.gif
    FIGURE 9

     

  10. Disconnect all electrical connectors from the bottom of the power distribution box.
  11. Mark and remove the Gray/Black wire from the 4-pin white connector. This connector was removed from the bottom of the power distribution box. See Figure 10.


    ir99m03j.gif
    FIGURE 10

     

  12. Disconnect the battery positive busbar from the maxi fuses. Temporarily secure the three (3) eyelet wires back onto the maxi fuses. See Figure 11.


    ir99m03k.gif
    FIGURE 11

     

  13. Remove the battery positive wiring branch from the bottom of the power distribution box.
  14. Disassemble the battery positive cable. Also disconnect the starter motor electrical connector.
  15. Remove the battery positive wiring branch from the vehicle.
  16. Install the new battery positive wiring branch in the vehicle. Route the wiring through the bottom of the power distribution box.
  17. Remove the wires from the maxi fuses, then connect the busbar and the wires to the maxi fuses. Tighten the retainers to securely.
  18. Install the Gray/Black wire of the new battery cable into the marked terminal on the 4-pin white connector.
  19. Mark and remove the relay connector spacers. See Figure 12.


    ir99m03l.gif
    FIGURE 12

     

  20. Route the cooling fan wire harness jumper through the bottom of the power distribution box.
  21. Connect the cooling fan wire harness jumper from the new overlay to the affected terminals in the relay box. See Figure 13. Follow color codes. Leave the original wires hanging at this time.


    ir99m03m.gif
    FIGURE 13

     

  22. Using a Duraseal connector, splice the Purple/Black wire from the cooling fan wiring harness jumper to the Purple/Black wire removed from the relay box. See Figure 14.


    ir99m03n.gif
    FIGURE 14

     

  23. Pull remaining wires of the old fan harness out of the power distribution box.
  24. Install the relay connectors spacers. Make sure the correct spacer is used on the correct relay.
  25. Install the maxi fuses into the relay box.
  26. Install the relay box into the power distribution box.
  27. Connect all electrical connectors to the bottom of the power distribution box.
  28. Cut off the three wires, removed from the relay box. Cut the wire at the base of the exposed wiring harness so the wrap will cover them.
  29. Zip the wiring harness wrap back to the bottom of the power distribution box, then secure the wrap with electrical tape.
  30. Install the bottom cover to the power distribution box.
  31. Disconnect two (2) fan control harness connectors.
  32. Unclip wiring branch for two power distribution box to fan control harness connectors, then cut off the original harness near the headlamp opening.
  33. Route and clip the new cooling fan wiring harness jumper.
  34. Disconnect the air conditioning pressure switch electrical connector.
  35. Remove the Purple wire from the air conditioning pressure switch connector. See Figure 15. Using supplied shrink tubing cover the terminal of the purple wire.


    ir99m03o.gif
    FIGURE 15

     

  36. Insert the terminal from the cooling fan jumper branch into the air conditioning pressure switch electrical connector. See Figure 16.


    ir99m03p.gif
    FIGURE 16

     

  37. Connect the air conditioning pressure switch electrical connector.
  38. Route and secure the jumper branch to the main wiring harness loom.
  39. Position the power distribution box in the installed position. Tighten the retainers securely.
  40. Install the original relays into the power distribution box, then install the power distribution box cover.
  41. Secure the battery positive cable to the battery support using tie strap and pushpins.
  42. Assemble the battery positive cable. Also connect the starter motor electrical connector.
  43. Install the battery pad.

POWER DISTRIBUTION HARNESS - INSTALLATION

  1. Transfer the following components:
  2. Modify brake ON/OFF switch wiring as follows:


    ir99m03q.gif
    FIGURE 17

     

  3. With an assistantís help, route the wiring harness into the passenger compartment. Make sure the grommet is completely seated in the bulkhead.
  4. On 1996-1997 models, install driver-side rocker panel ground wire as follows:
  5. Connect the rear lamp connector.
  6. Attach the following connectors to the fuse box bracket:
  7. Install the fuse box bracket.
  8. Install the five (5) female connectors into the back of the organizer.
  9. Slide the organizer onto the fuse box bracket.
  10. Connect the five (5) male connectors to the correct female connectors.
  11. On 1996-1997 models, attach diagnostic link connector into its holder.
  12. Position the fuse box close to the installed position, then connect the seven (7) connectors to the fuse box.
  13. Install the fuse box to the fuse box bracket.
  14. Connect the brake on/off switch connector. Tie-strap the bundle to the brake pedal support bracket. See Figure 18.


    ir99m03r.gif
    FIGURE 18

     

  15. Install the knee bolster.
  16. On Mystique models, install the knee bolster storage compartment.
  17. Loosely route the power distribution harness around the engine compartment as follows:
  18. Install and connect the wiper motor and transmission assembly. Tighten the retainers to 8 Nm (71 lb-in). Secure the wiring to the transmission with a single tie strap.
  19. Position the speed control servo mounting bracket.
  20. Connect then attach the hood lamp connector.
  21. On 1995 models, connect the two (2) diagnostic link connector connectors to the cap.
  22. On 1995 models, connect the antilock brake diagnostic connector to the left strut tower.
  23. Install and connect the speed control servo. Tighten the retainer to 57 Nm (44-62 lb-in). Remove shorting bar from hardshell before connection.
  24. Install the leaf screen and both wiper arms. Tighten the wiper arm retainers to 25 Nm (18 lb/ft).
  25. Connect the hydraulic control unit and the brake fluid level sensor connector.
  26. Slide the 42-pin connector onto its mounting bracket.
  27. Position the power distribution box close to the installed position.
  28. Route the positive battery cable under the battery support. Attach pushpins and install tie strap.
  29. Install the negative cable ground wire. Tighten the retainer securely.
  30. Final install the power distribution box. Tighten the retainer to 8-12 Nm (6-8 lb-ft).
  31. Install the battery pad and the retaining strip.
  32. Assemble the positive and negative battery cables. Connect the starter connector.
  33. Route the driver-side marker lamp and horn/fog lamp wiring. Secure the wiring harness with pushpins.
  34. Connect and install the driver-side marker lamp.
  35. Connect the driver-side headlamp connectors and the driver-side front primary airbag crash sensor connector.
  36. Install ground wire(s). Tighten retainer securely.
  37. Route the passenger-side marker lamp wiring. Secure the wiring with a pushpin.
  38. Connect and install the passenger-side marker lamp.
  39. Route the passenger-side horn/fog lamp wiring. Attach the protective clip onto the inner fender.
  40. Connect the passenger-side headlamp connectors and the passenger-side front primary airbag crash sensor connector.
  41. Connect the hood switch connector, then attach the connector pushpin.
  42. Connect the traction control motor connectors, then attach the connector pushpin.
  43. Connect the air conditioning pressure cutoff switch connector.
  44. Route the final part of the wiring harness up the passenger-side fender. Secure the wiring harness with pushpins.
  45. Position the degas bottle close to the installed position, then connect the low coolant sensor connector. Remove shorting bar from hardshell before connection.
  46. Install the degas bottle.
  47. Route the passenger-side antilock brake front wheel sensor wiring harness down through the fender grommet.
  48. On vehicles equipped with antilock brakes, connect connector C124, then attach the connector pushpin.
  49. On 1995 models, connect the evaporative emissions purge connector, then attach the connector pushpin.
  50. On 1996-1997 models, attach then connect the vapor management valve connector.
  51. Raise and support the vehicle.
  52. Install the speed control servo bracket mounting nuts.
  53. Connect the driver-side antilock brake front wheel sensor connector, then secure the wiring with pushpins.
  54. On vehicles equipped with a 2.0L engine, install the fender well air intake resonator.
  55. Connect the driver-side horn/fog lamp connectors, then secure the wiring with pushpins.
  56. Position the air conditioning accumulator assembly in installed position. Tighten the retainer to 6-8 Nm (4-6 lb-ft).
  57. Connect the passenger-side horn/fog lamp connectors, then secure the wiring with pushpins.
  58. Install, unplug and connect the windshield washer bottle.
  59. Connect the passenger-side antilock brake front wheel sensor connector, then secure the wiring with pushpins.
  60. Install both inner fender well splash shields.

POWER DISTRIBUTION HARNESS PRELIMINARY COMPONENT - INSTALLATION

COOLING MODULE - INSTALLATION

SINGLE COOLING FAN

CONTOUR

 

  1. With an assistants help, install the cooling module (fan, radiator and condenser). Tighten the retainers to 8-11 Nm (71-97 lb-in).
  2. On vehicles equipped with a automatic transaxle, connect the transaxle lines to the routing clip.
  3. Connect the air conditioning lines to the condenser.
  4. Connect the lower radiator hose to the radiator.
  5. On vehicles equipped with a automatic transaxle, connect the lower transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).
  6. Position the power steering cooler in the installed position. Tighten the retainers to 6 Nm (53 lb-ft).
  7. Lower the vehicle.
  8. On 1995 models, attach the oxygen sensor wiring to the two (2) clips on the fan shroud.
  9. On 1996-1997 models, attach the oxygen sensor/catalyst monitor wiring to the fan shroud.
  10. Connect the upper radiator hose to the radiator.
  11. On vehicles equipped with a automatic transaxle, connect the upper transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).

MYSTIQUE

  1. Lower vehicle.
  2. Place a length of wire through the lifting eye. Drape the ends of the wire down toward the bottom of the engine.
  3. Raise and support the vehicle.
  4. Position the cooling fan into the engine compartment. Secure the cooling fan with the wire.
  5. With an assistantís help, install the cooling module (radiator and condenser). Tighten the retainers to 8-11 Nm (71-97 lb-in).
  6. On vehicles equipped with an automatic transaxle, connect the transaxle lines to the routing clip.
  7. Connect the air conditioning lines to the condenser.
  8. Connect the lower radiator hose to the radiator.
  9. On vehicles equipped with an automatic transaxle, connect the lower transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).
  10. Position the power steering cooler in the installed position. Tighten the retainers to 6 Nm (53 lb-in).
  11. Lower the vehicle.
  12. Cut the wire securing the cooling fan to the lifting eye.
  13. Attach the cooling fan to the radiator. Make sure the fan is seated in the lower retaining clips, then tighten the side retainers to 3-5 Nm (24-48 lb-in).
  14. Secure the oxygen sensor wiring to the clips on the fan shroud.
  15. Connect the upper radiator hose to the radiator.
  16. On vehicles equipped with an automatic transaxle, connect the upper transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).

DUAL COOLING FAN

CONTOUR

 

  1. With an assistants help, install the cooling module (fan, radiator, condenser). Tighten the retainers to 8-11 Nm (71-97 lb-in).
  2. On vehicles equipped with automatic transaxle, connect the transaxle lines to the routing clip.
  3. Connect the air conditioning lines to the condenser.
  4. Connect the lower radiator hose to the radiator.
  5. On vehicles equipped with automatic transaxle, connect the lower transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).
  6. Position the power steering cooler in installed position. Tighten the retainers to 6 Nm (53 lb-in).
  7. Lower the vehicle.
  8. Connect the upper radiator hose to the radiator.
  9. On vehicles equipped with automatic transaxle, connect the upper transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).
  10. Connect the coolant over flow tube to the radiator.

MYSTIQUE

  1. Lower the vehicle.
  2. Place a length of wire through the radiator core support. Drape the ends of the wire down toward the bottom of the engine.
  3. Raise and support the vehicle.
  4. Position the cooling fan into the engine compartment. Secure the cooling fan with the wire.
  5. With an assistantís help, install the cooling module (radiator and condenser). Tighten the retainers to 8-11 Nm (71-97 lb-in).
  6. On vehicles equipped with an automatic transaxle, connect the transaxle lines to the routing clip.
  7. Connect the air conditioning lines to the condenser.
  8. Connect the lower radiator hose to the radiator.
  9. On vehicles equipped with an automatic transaxle, connect the lower transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).
  10. Position the power steering cooler in the installed position. Tighten the retainers to 6 Nm (53 lb-in).
  11. Lower the vehicle.
  12. Cut the wire securing the cooling fan to the radiator core support.
  13. Attach the cooling fan to the radiator. Make sure the fan is seated in the lower retaining clips, then tighten the side retainers to 3-5 Nm (24-48 lb-in).
  14. Connect the upper radiator hose to the radiator.
  15. On vehicles equipped with an automatic transaxle, connect the upper transaxle line to the radiator. Tighten the line to 24-31 Nm (18-23 lb-in).
  16. Connect the coolant overflow tube to the radiator.

ENGINE CONTROL HARNESS - INSTALLATION

2.5L ENGINE

 

  1. With an assistantís help, loosely route the engine control harness. Install the harness from the passenger-side of vehicle.
  2. On vehicles equipped with a manual transaxle, connect the backup lamp switch and water temperature indicator sender unit connectors.
  3. On vehicles equipped with a automatic transaxle, connect the transaxle range sensor and the transaxle 10-pin connectors.
  4. Install the metal retaining clip securing the wiring harness to the top of the transaxle.
  5. On vehicles equipped with a automatic transaxle, attach the turbine shaft speed sensor wiring into clips on the transaxle.
  6. Connect the 42-pin connector and the vehicle speed sensor connector.
  7. On vehicle equipped with a automatic transaxle, proceed as follows:
  8. Connect the exhaust gas recirculation transducer connector.
  9. Install the harness casing to the back of the engine. Tighten the retainers securely.
  10. Clip the mega-fuse to the harness casing. Using tie straps, secure the mega-fuse wiring to the casing.
  11. Connect the rear oxygen sensor connector.
  12. Install the wiring harness into the bulkhead clip.
  13. On 1995 models, connect the ignition control module and the heated oxygen sensor relay connectors. Install the ignition control module bracket assembly.
  14. Connect the power steering pressure switch.
  15. Connect the powertrain control module connector. Tighten the retainer to 4 Nm (32 lb/in).
  16. Connect the ground wire to fender.
  17. Secure the power steering reservoir in installed position.
  18. Raise and support the vehicle.
  19. On 1996-1997 models, attach then connect front catalyst monitor connector.
  20. On vehicles equipped with an automatic transaxle, connect turbine shaft speed sensor connector.
  21. On 1996-1997 models, attach then connect rear catalyst monitor connector.
  22. Connect the knock sensor connector.
  23. Connect all alternator connections. Tighten the retainer to 9-11 Nm (80-97 lb/in).
  24. Lower the vehicle.

FUEL CHARGE HARNESS - INSTALLATION

2.0L ENGINE

 

  1. Install the fuel charge harness onto the intake manifold. Tighten the retainers securely.
  2. Remove the shop towel from the throttle body port.
  3. Install the throttle body. Tighten the retainers to 8-12 Nm (71-106 lb-in).
  4. Connect the fuel charge harness connector to the engine control harness connector.
  5. Connect all fuel injector connectors.
  6. Connect the throttle position sensor, the camshaft position sensor and the idle air control solenoid connectors.
  7. Route the wiring to the engine coolant temperature sensor, then connect the sensor connector.
  8. Connect the vacuum line to the tap on the intake manifold.
  9. Install the air cleaner box, air cleaner cover, clean air tube, resonator and the throttle body cover as an assembly. The fresh air tube must be connected to the back side of the valve cover. Tighten the throttle body cover retainers to 4-6 Nm (38-56 lb-in).
  10. Connect the intake air temperature sensor and the mass air flow sensor connectors.

2.5L ENGINE

  1. Loosely route the fuel charge harness across the engine.
  2. Connect all fuel injector connectors.
  3. Install the fuel charge harness to the five (5) studs on the valve cover.
  4. Connect the three (3) fuel charge harness connectors to the corresponding engine control harness connectors.
  5. Secure the above connectors and the coil pack wiring to the valve cover bracket as follows:
  6. Install the power steering line bracket and the ground wire to the motor mount. Tighten the retainer to 6 Nm (53 lb-in).
  7. Connect the camshaft position sensor and the front oxygen sensor connectors.
  8. On 1995 models, connect the intake manifold runner control transducer connector.
  9. On 1996-1997 models, connect intake manifold runner control actuator connector.
  10. Connect the engine coolant temperature sensor connector.
  11. Install the coil pack. Make sure the ground wire and the radio suppressor are secured by the coil pack retainers. Tighten the retainers to 5-7 Nm (40-61 lb-in).
  12. Connect the coil pack and the radio suppressor connectors.
  13. Connect the ignition wires to the spark plugs.
  14. Install the intake manifold. Tighten the retainers in sequence shown in Figure 19 to 8-12 Nm (71-106 lb-in).


    ir99m03s.gif
    FIGURE 19

     

  15. Install the gas recirculation valve. Tighten the retainers to 20-30 Nm (15-22 lb-ft).
  16. Connect the vacuum regulator solenoid vacuum and electrical connections.
  17. Connect the idle air control solenoid connector.
  18. Connect the vacuum line to the EGR valve and the PCV hose to the upper intake manifold.
  19. Connect the two (2) vacuum taps to the top of the upper intake manifold.
  20. Install the throttle cable bracket assembly. Tighten the retainers to 8-12 Nm (71-106 lb-in).
  21. Connect the throttle cables and the return spring to the throttle body.
  22. Install the air cleaner box, air cleaner cover, clean air tube and the resonator as an assembly.
  23. Connect the intake air temperature sensor connector.
  24. Install the back two (2) fresh air tubes to the clean air tube.
  25. Connect the mass air flow sensor connector.
  26. Connect the throttle position sensor connector, then attach the routing clip.
  27. Install the front fresh air tube to the valve cover.
  28. Raise and support the vehicle.
  29. Connect the crankshaft position sensor connector, then secure the wiring with a pushpin.
  30. Connect the oil pressure sensor connector.
  31. Lower vehicle.

FAN CONTROL HARNESS - INSTALLATION

SINGLE COOLING FAN

 

  1. Loosely position the fan control harness around the fan assembly.
  2. Connect the air conditioning clutch cycling switch and the engine cooling fan connectors.
  3. Secure the fan control harness to the fan shroud with two (2) pushpins and two (2) routing clips.
  4. Connect then attach the power distribution harness connectors.
  5. Secure the fan control harness to the passenger-side of the fan shroud.
  6. Connect the air conditioning clutch connector.
  7. Install the ground wire to the radiator support. Tighten the bolt securely.Connect the air conditioning clutch connector.
  8. Raise and support the vehicle.
  9. Attach and connect the engine cooling fan control resistor connector.
  10. Install the lower air deflector.
  11. Lower the vehicle.
  12. Install and connect the battery.
  13. Fill the engine cooling system.
  14. Recharge the air conditioning system, if necessary.
  15. Reprogram radio stations.
  16. Make sure of proper operation of vehicle by performing test drive.

DUAL COOLING FAN

  1. Loosely position the fan control harness around the fan assembly.
  2. Connect the air conditioning clutch cycling switch connector.
  3. Install the fan control harness to all accessible routing clips and pushpins on the fan shroud.
  4. Connect then attach the power distribution harness connectors.
  5. Install the ground wire to the radiator support.
  6. Install the water pump pulley cover onto the front of the engine.
  7. Raise and support the vehicle.
  8. On 1995 models, attach the diode pushpin to the fan shroud.
  9. Connect the engine cooling fan control resistor connector.
  10. Attach the driver-side engine cooling fan wiring pushpin, then connect the cooling fan connector.
  11. Attach the passenger-side engine cooling fan wiring pushpin, then connect the cooling fan connector.
  12. Connect the air conditioning clutch connector.
  13. Install the passenger-side engine splash shield.
  14. Install the lower air deflector.
  15. Lower the vehicle.
  16. Install and connect the battery.
  17. Fill the engine cooling system.
  18. Recharge the air conditioning system, if necessary.
  19. Reprogram radio stations.
  20. Make sure of proper operation of vehicle by performing test drive.

 

ATTACHMENT III (CONT.)
Owner Notification Program 99M03



99m03f01.gif

 

FOLD-OUT 1

 

SINGLE COOLING FAN

 

  1. ENGINE COOLING FAN CONTROL RESISTOR CONNECTOR
  2. GROUND WIRE ON RADIATOR SUPPORT
  3. A/C CLUTCH CONNECTOR
  4. POWER DISTRIBUTION HARNESS CONNECTORS
  5. ENGINE COOLING FAN AND A/C CLUTCH CYCLING SWITCH CONNECTORS

DUAL COOLING FAN

 

  1. A/C CLUTCH CONNECTOR
  2. PASSENGER-SIDE ENGINE COOLING FAN CONNECTOR
  3. DRIVER-SIDE ENGINE COOLING FAN CONNECTOR
  4. ENGINE COOLING FAN CONTROL RESISTOR CONNECTOR
  5. GROUND WIRE ON RADIATOR SUPPORT
  6. POWER DISTRIBUTION HARNESS CONNECTORS
  7. A/C CLUTCH CYCLING SWITCH CONNECTOR
  8. COOLING FAN DIODE


99m03f02.gif

 

FOLD-OUT 2 (1OF 3)

 

LEGEND

 

1. MASS AIR FLOW SENSOR AND INTAKE AIR TEMPERATURE SENSOR CONNECTORS

2. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

8. TURBINE SHAFT SPEED SENSOR CONNECTOR (AUTOMATIC TRANSAXLE)

9. OXYGEN SENSOR/CATALYST MONITOR SENSOR CONNECTOR

10. CRANKSHAFT POSITION SENSOR AND ENGINE COOLANT TEMPERATURE SENDER CONNECTORS

13. COIL PACK CONNECTOR

14. RADIO SUPPRESSOR AND VEHICLE SPEED SENSOR CONNECTORS

15. TRANSAXLE RANGE SENSOR AND TRANSAXLE 10-PIN CONNECTORS (AUTOMATIC TRANSAXLE)

17. 42-PIN CONNECTOR


99m03f03.gif

 

FOLD-OUT 2 (2 OF 3)

 

LEGEND

 

1. MASS AIR FLOW SENSOR AND INTAKE AIR TEMPERATURE SENSOR CONNECTORS

2. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

9. OXYGEN SENSOR/CATALYST MONITOR SENSOR CONNECTOR

10. CRANKSHAFT POSITION SENSOR AND ENGINE COOLANT TEMPERATURE SENDER CONNECTORS

13. COIL PACK CONNECTOR

14. RADIO SUPPRESSOR AND VEHICLE SPEED SENSOR CONNECTORS

16. BACKUP LAMP SWITCH CONNECTOR (MANUAL TRANSAXLE)

17. 42-PIN CONNECTOR


99m03f04.gif

 

FOLD-OUT (3 OF 3)

 

LEGEND

 

2. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

3. IDLE AIR CONTROL, CAMSHAFT POSITION SENSOR AND THROTTLE POSITION SENSOR CONNECTORS

4. FUEL INJECTOR CONNECTORS

5. ENGINE CONTROL HARNESS CONNECTOR TO FUEL CHARGE HARNESS

6. FUEL CHARGE HARNESS CASING RETAINING SCREWS

7. OIL PRESSURE SENDER AND KNOCK SENSOR CONNECTORS

11. HARNESS CASING FROM BACK OF ENGINE

12. MEGA-FUSE FROM HARNESS CASING


99m03f05.gif

 

FOLD-OUT 3 (1 OF 3)

 

LEGEND

 

3. THROTTLE POSITION SENSOR CONNECTOR

4. MASS AIR FLOW SENSOR CONNECTOR

5. INTAKE AIR TEMPERATURE SENSOR

6. IDLE AIR CONTROL CONNECTOR

7. VACUUM REGULATOR SOLENOID CONNECTIONS

8. COIL PACK AND RADIO SUPPRESSOR CONNECTORS

9. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

10. INTAKE MANIFOLD RUNNER CONTROL TRANSDUCER CONNECTOR

13. FUEL INJECTOR CONNECTORS

14. KNOCK SENSOR CONNECTOR

15. TURBINE SHAFT SPEED SENSOR CONNECTOR (AUTOMATIC TRANSAXLE)

16. REAR OXYGEN SENSOR CONNECTOR

17. HARNESS CASING FROM BACK OF ENGINE

18. MEGA-FUSE

19. EXHAUST GAS RECIRCULATION TRANSDUCER CONNECTOR

20. WATER TEMPERATURE INDICATOR SENDER UNIT CONNECTOR

21. VEHICLE SPEED SENSOR CONNECTOR

22. TRANSAXLE RANGE SENSOR AND TRANSAXLE 10-PIN CONNECTORS (AUTOMATIC TRANSAXLE)

24. 42-PIN CONNECTOR

25. INTAKE MANIFOLD RUNNER CONTROL SOLENOID CONNECTOR.


99m03f06.gif

 

FOLD-OUT 3 (2 OF 3)

 

LEGEND

 

3. THROTTLE POSITION SENSOR CONNECTOR

4. MASS AIR FLOW SENSOR CONNECTOR

5. INTAKE AIR TEMPERATURE SENSOR

6. IDLE AIR CONTROL CONNECTOR

7. VACUUM REGULATOR SOLENOID CONNECTIONS

8. COIL PACK AND RADIO SUPPRESSOR CONNECTORS

9. ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

10. INTAKE MANIFOLD RUNNER CONTROL TRANSDUCER CONNECTOR

13.FUEL INJECTOR CONNECTORS

14. KNOCK SENSOR CONNECTOR

16. REAR OXYGEN SENSOR CONNECTOR

17. HARNESS CASING FROM BACK OF ENGINE

18. MEGA-FUSE

19. EXHAUST GAS RECIRCULATION TRANSDUCER CONNECTOR

20. WATER TEMPERATURE INDICATOR SENDER UNIT CONNECTOR

21. VEHICLE SPEED SENSOR CONNECTOR

23. BACKUP LAMP SWITCH CONNECTOR (MANUAL TRANSAXLE)

24. 42-PIN CONNECTOR

25 .INTAKE MANIFOLD RUNNER CONTROL SOLENOID CONNECTOR


99m03f07.gif

 

FOLD-OUT 3 (3 OF 3)

 

LEGEND

 

1. OIL PRESSURE SENSOR CONNECTOR

2. CRANKSHAFT POSITION SENSOR CONNECTOR

11. FRONT OXYGEN SENSOR AND CAMSHAFT POSITION SENSOR CONNECTORS

12. ENGINE CONTROL HARNESS CONNECTORS

26. IGNITION CONTROL MODULE CONNECTOR

27. HEATED OXYGEN SENSOR RELAY CONNECTOR


99m03f08.gif

 

FOLD-OUT 4 (1 OF 6)

 

PASSENGER-SIDE HALF OF ENGINE COMPARTMENT

 

1. GROUND WIRE FROM FENDER

2. PCM CONNECTOR

3. POWER STEERING PRESSURE SWITCH

4. EXHAUST GAS RECIRCULATION TRANSDUCER CONNECTOR

5. VACUUM REGULATOR SOLENOID CONNECTOR

6. IGNITION CONTROL MODULE CONNECTOR

7. PASSENGER-SIDE FRONT ANTI-LOCK BRAKE WHEEL SENSOR CONNECTOR

8. WINDSHIELD WASHER BOTTLE

9. PASSENGER-SIDE HORN AND FOG LAMP CONNECTORS

10. CLIPS SECURING POWER DISTRIBUTION HARNESS TO TIE BAR CHANNEL

12. EVAPORATIVE EMISSIONS PURGE SOLENOID CONNECTOR (1995 MODELS)

13. VAPOR MANAGEMENT VALVE CONNECTOR (1996-1997 MODELS)

14. CONNECTOR C124 (WITH ANTI-LOCK BRAKES)

16. AIR CONDITIONING PRESSURE CUTOFF SWITCH CONNECTOR

17. TRACTION CONTROL MOTOR CONNECTORS

18. HOOD SWITCH CONNECTOR

20. PASSENGER-SIDE HEADLAMP CONNECTOR

21.PASSENGER-SIDE MARKER LAMP CONNECTOR

SEPARATING POWER DISTRIBUTION HARNESS FROM ENGINE COMPARTMENT

 

AA. PASSENGER-SIDE FRONT ANTI-LOCK BRAKE WHEEL SENSOR WIRING

BB. FOUR (4) HARNESS PUSHPINS ALONG PASSENGER-SIDE FENDER

CC. PASSENGER-SIDE HORN/FOG LAMP WIRING

DD. PASSENGER-SIDE MARKER LAMP WIRING HARNESS

EE. POWER DISTRIBUTION HARNESS ELBOWS


99m03f09.gif

 

FOLD-OUT 4 (2 OF 6)

 

PASSENGER-SIDE HALF OF ENGINE COMPARTMENT

 

10. CLIPS SECURING POWER DISTRIBUTION HARNESS TO TIE BAR CHANNEL

15. LOW COOLANT SENSOR CONNECTOR

16. AIR CONDITIONING PRESSURE CUTOFF SWITCH CONNECTOR

17. TRACTION CONTROL MOTOR CONNECTORS

18. HOOD SWITCH CONNECTOR

19. PASSENGER-SIDE FRONT PRIMARY AIRBAG CRASH SENSOR CONNECTOR

20. PASSENGER-SIDE HEADLAMP CONNECTOR

21. PASSENGER-SIDE MARKER LAMP CONNECTOR

SEPARATING POWER DISTRIBUTION HARNESS FROM ENGINE COMPARTMENT

 

BB. FOUR (4) HARNESS PUSHPINS ALONG PASSENGER-SIDE FENDER

DD. PASSENGER-SIDE MARKER LAMP WIRING HARNESS

EE. POWER DISTRIBUTION HARNESS ELBOWS


99m03f10.gif

 

FOLD-OUT 4 (3 OF 6)

 

DRIVER-SIDE HALF OF ENGINE COMPARTMENT

 

10. CLIPS SECURING POWER DISTRIBUTION HARNESS TO TIE BAR CHANNEL

22. GROUND WIRE FROM INNER FENDER

23. DRIVER-SIDE FRONT PRIMARY AIRBAG CRASH SENSOR CONNECTOR

24. DRIVER-SIDE HEADLAMP CONNECTORS

25. DRIVER-SIDE MARKER LAMP CONNECTOR

26. POSITIVE AND NEGATIVE BATTERY CABLE ASSEMBLIES

27. LIFT POWER DISTRIBUTION BOX UP AND AWAY

SEPARATING POWER DISTRIBUTION HARNESS FROM ENGINE COMPARTMENT

 

EE. POWER DISTRIBUTION HARNESS ELBOWS

FF. DRIVER-SIDE MARKER, HORN/FOG LAMP WIRING

GG. PUSHPINS FOR BATTERY POSITIVE CABLE


99m03f11.gif

 

FOLD-OUT 4 (4 OF 6)

 

DRIVER-SIDE HALF OF ENGINE COMPARTMENT

 

10. CLIPS SECURING POWER DISTRIBUTION HARNESS TO TIE BAR CHANNEL

11. DRIVER-SIDE HORN, FOG LAMP AND FRONT ANTI-LOCK BRAKE WHEEL SENSOR CONNECTORS

24. DRIVER-SIDE HEADLAMP CONNECTORS

25. DRIVER-SIDE MARKER LAMP CONNECTOR

26. POSITIVE AND NEGATIVE BATTERY CABLE ASSEMBLIES

28. 42-PIN CONNECTOR

29. BRAKE FLUID LEVEL SENSOR AND HYDRAULIC CONTROL UNIT CONNECTORS

30. SPEED CONTROL SERVO ELECTRICAL CONNECTOR

32. DATA LINK CONNECTOR (1995 MODELS)

33. HOOD LAMP CONNECTOR

SEPARATING POWER DISTRIBUTION HARNESS FROM ENGINE COMPARTMENT

 

EE. POWER DISTRIBUTION HARNESS ELBOWS

FF. DRIVER-SIDE MARKER, HORN/FOG LAMP WIRING

HH. DRIVER-SIDE FRONT ANTI-LOCK BRAKE WHEEL SENSOR WIRING

II. HYDRAULIC CONTROL UNIT CONNECTOR WIRING

JJ. WIPER MOTOR WIRING (INCLUDING GROMMET)


99m03f12.gif

 

FOLD-OUT 4 (5 OF 6)

 

DRIVER-SIDE HALF OF ENGINE COMPARTMENT

 

29. BRAKE FLUID LEVEL SENSOR AND HYDRAULIC CONTROL UNIT CONNECTORS

30. SPEED CONTROL SERVO ELECTRICAL CONNECTOR

31. ANTI-LOCK BRAKE DIAGNOSTIC CONNECTOR (1995 MODELS)

32. DATA LINK CONNECTORS (1995 MODELS)

SEPARATING POWER DISTRIBUTION HARNESS FROM ENGINE COMPARTMENT

 

II. HYDRAULIC CONTROL UNIT CONNECTOR WIRING


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FOLD-OUT 4 (OF 6)

 

SEPARATING POWER DISTRIBUTION HARNESS FROM PASSENGER COMPARTMENT

 

KK. CONNECTORS FROM THE FUSE BOX

LL. MALE CONNECTORS FROM THE FUSE BOX BRACKET ORGANIZER

MM. BLUE SPEED CONTROL CUT-OUT RELAY

NN. REAR LAMP CONNECTOR

OO. DEAD PLUG


 

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October, 1999

Serial Number: 12345678901234567 99M03

Mr. John Sample
123 Main Street
Anywhere, USA 12345
 

Ford Motor Company is providing a no-charge Service Program, Number 99M03, to owners of Certain 1995 - 1997 Contour and Mystique vehicles for under hood wire harness - additional coverage.

REASON FOR THIS PROGRAM

Under ambient factors of high temperature and high humidity, your vehicle may be susceptible to under hood wiring harness cracking on certain engine wiring harnesses. These harnesses deliver electrical power to the engine and its cooling and control systems, the climate control, and other power distribution systems.

WHAT WE WILL DO

Ford is voluntarily providing additional coverage.

ADDITIONAL WARRANTY COVERAGE

Effective immediately, Ford is providing additional coverage for the replacement of the under hood wire harnesses on your vehicle for a period of 10 years or 100,000 miles , which ever occurs first, from the original warranty start date. This coverage exceeds the provisions of the original component warranty coverage on your vehicle as reflected by the New Vehicle Limited Warranty, and is automatically transferred to subsequent owners at no charge. This additional coverage does not include normal service diagnostic or repair charges unrelated to wire harness brittleness and cracking.

WHAT YOU SHOULD DO

Please keep this letter as a reminder. If your vehicle should exhibit wiring insulation brittleness and cracking the conditions listed above during the extended coverage period provided by this program, contact your dealer. The dealer will do the repair at no charge to you. If you should lose this letter, the dealer will still honor the provisions of this coverage.

REFUNDS

If you paid to have your wire harnesses replaced due to insulation cracking before the date of this letter, Ford is offering to fully refund to you any amounts you paid. For the refund, please give your paid original receipt to your Ford or Lincoln Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.

CHANGED ADDRESS OR SOLD THE VEHICLE?

Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle.

We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford-built vehicle.

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OWNER NOTIFICATION PROGRAM
99M03

 

 


CPR © 1999 FORD MOTOR COMPANY
Published By: Recall/Service Programs Department
Ford Customer Service Division