Cooling Fans - Run Continuously
86-163Amended
1/96
Cooling Fans - Run Continuously - Switch Harness Repair
MODEL: Sedan Range 1993 - 94 MY
DATE: 10/95
VIN 667579 - 708757
Remove and destroy Bulletin 86-163, Date 10/95.
Replace with this Bulletin.
Revisions are marked with a bar and in bold text.
ISSUE:
Some XJ6 and XJ12 vehicles in the above VIN range may experience continuous running of the cooling fans caused by corrosion in the harness connector of the fan switch.
A replacement link harness is available to repair a corroded connector without replacing the side harness.
ACTION:
If corrosion of the fan switch harness connector is determined to be the cause of continuous cooling fan operation, proceed as follows:
FAN SWITCH HARNESS REPAIR
1. Obtain the radio code from dealer records or the customer.
2. Disconnect the vehicle battery after positioning the vehicle on a hoist.
3. Disconnect the harness from the fan switch located on the left radiator tank above the coolant outlet.
4. Raise the vehicle on the hoist.
5. Remove the left side front fog lamp harness from the mounting bracket.
6. Remove the left side front turn signal lamp from the bumper aperture.
7. Remove the fan switch harness (illustration 1) and the front fog lamp harness through the turn signal lamp opening.
8. Carefully unwrap the harness tape (inset, Illustration 1) to expose the fan switch wiring and the fog lamp wiring.
9. Compare the length of the replacement link harness to the existing fan switch harness to mark the point where the existing harness should be cut. Unwrap the tape beyond the mark and then cut the harness at the mark to ensure that the length of the harness will remain the same after the repair.
NOTE:
Use care to cut the black wire for the fan switch and not the black wire for the fog lamp harness.
10. Cut the insulation back 9/32 in. (7 mm) on the cut ends of the fan switch wiring. The insulation on the replacement link harness is already cut back (Illustration 2).
11. Crimp the "Duraseal" connectors onto the bare wire ends of the replacement harness.
12. Crimp the connectors on the bare wire ends of the vehicle harness to connect the replacement link harness to the vehicle harness.
13. Use a suitable heat gun to shrink the insulating sleeves on the connectors.
14. Apply electrical insulation tape to the harness to cover the connectors and wrap the harness together. Wrap the harness only up to point where the fog lamp and fan switch wiring branched previously.
15. Reinstall the fog lamp harness connector on the mounting bracket.
16. Reconnect the fog lamp.
17. Reconnect the fan switch harness to the fan switch located on the radiator.
18. Reinstall the turn signal lamp into the bumper opening.
19. Lower the vehicle hoist.
20. Reconnect the vehicle battery.
21. Enter the radio code and reset the clock.
PARTS INFORMATION:
DESCRIPTION PART NUMBER QTY
Radiator fan switch kit (XJ6) JLM 12040 1
Radiator fan switch kit (XJ12) JLM 12041 1
WARRANTY INFORMATION: