Electrical Systems - Inoperative

91ford23

Article No. 91-16-6
08/07/91


^ NO START - ALL ENGINES - WATER AND CORROSION IN WIRING CONNECTOR

^ AIR CONDITIONING - COMPRESSOR AND/OR CONDENSER FAN INOPERATIVE

^ HEATER - BLOWER RELAY INOPERATIVE

^ LAMP - HEADLAMP COVERS INOPERATIVE

^ LAMP - UNDERHOOD - MICRO SWITCH INOPERATIVE OR FUSES BLOWN

^ WIRING - CONNECTOR - ELECTRICAL CONCERNS RELATED TO WATER AND CORROSION - REPAIR PROCEDURE


FORD: 1989-91 PROBE


ISSUE: Water may enter the wiring connectors in the engine compartment and in front of the radiator resulting in shorted and corroded terminals. This may cause various types of electrical concerns such as:

^ Discharged battery and a "NO Start" condition
^ Inoperative underhood lamp/micro switch and/or blown fuses
^ Inoperative headlamps, retractor motors, "Headlamp Out Warning" lamp and inoperative high beam relay
^ Non-functional air conditioner compressor and/or condenser fan
^ Inoperative heater blower motor relay

Figure 1:

The wiring connectors join the body and engine wiring looms. A diagram of the connectors and the circuits routed through them is shown on pages 151-1, 2, 3 and 4 of the 1991 Probe EVTM or Figure 1.

ACTION: Inspect and repair the wiring connectors and wires as required. Refer to the following procedure for service details.


HEADLAMP CONNECTORS

1. If there is water and corrosion in the headlamp connectors, refer to the repair procedure outlined in TSB 89-17-8.


2. If there are damaged or broken wires, install waterproof butt splice connectors. Refer to TSB 86-3-11 for additional general wiring repairs.

CONNECTOR/PIN REPAIR OR RELAY REPLACEMENT

If the vehicle has an electrical concern related to wire short circuiting or corrosion that requires a connector/pin repair or a relay replacement, perform the following procedure.

Figure 2:

1. Inspect the wiring and connector for corrosion damage. Repair the wiring as needed.

a. Use a small brush and/or compressed air to clean and remove corrosion or water from the connector.

b. If required, use an electric contact cleaner. Refer to the 1991 Probe Shop Manual, Page 18-00-3, for connector and wire/terminal removal procedure, Figure 2.

NOTE: PLASTIC ELECTRICAL WIRE CONNECTORS ARE NOT AVAILABLE FROM THE PARTS SYSTEM.

Figure 3:

2. If the wire terminal and/or connector can not be reused, install a butt splice connector as described in TSB 89-17-8. See Figure 3.

3. If the wire terminal or connector can be cleaned and reused, proceed as follows:


a. Coat the wire terminal/connector and the component terminals (relay, solenoid, switch, etc.) with dielectric grease (D7AZ-19A331-A).

b. Reinstall the repaired wire(s) in the correct slot(s) of the connector.

4. Apply electrical tape to the harness or connector if needed.

PART NUMBER PART NAME CLASS

D7AZ-19A331-A Dielectric Grease AM


OTHER APPLICABLE ARTICLES: 86-3-11, 89-17-8
WARRANTY STATUS: Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
911606A Repair Wiring Connectors 1.3 Hr.
DEALER CODING BASIC PART NO. CONDITION CODE
14290 84
OASIS CODES: 201000, 201200, 203200, 208000, 208100,208200,208300,603300