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TSB 18-04-92 Rev. A

No Start/Poor Engine Performance

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Date: Jul. 27, 1992

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-04-92

Models: 1992 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger

1992 (AB) Ram Van/Wagon
         (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger
         (AN) Dakota/Dakota Sport/Cab & Chassis
1993 (ZJ) Grand Cherokee

Symptom/Condition:

Poor engine performance/no start can be caused by an intermittent electrical connection at the 3-way crank position sensor wiring harness connector.

Diagnosis:

Verify that the 3-way crank position sensor wiring harness connector does not have any terminals that are pushed out of place. Reinsert backed out terminals fully into the insulator and ensure that they are locked in place.

Inspect the connector for damage, such as broken locking fingers or terminals. Inspect each female terminal for spreading by inserting a male pin terminal gauge (PN 4400110) into the female terminals. The gauge should mate snugly with the female terminals. If the gauge is loose or the locking fingers or terminals have been broken, replace the 3-way crank position sensor wiring harness connector.

NOTE: DO NOT ATTEMPT TO CLOSE DOWN THE FEMALE TERMINALS.

Parts Required:

1    Wiring Assembly Package (Automatic Transmission AB, AD, AN, ZJ) 4723783

Parts package contents:
       1      Assembly 4723814
     10     1/4" Heat Shrink Tubing 4419644
       1     Male Pin Terminal (to be used as a gauge) 4400110

1    Wiring Assembly Package (Manual Transmission - AB, AD, AN) 4723784

Parts package contents:
       1      Assembly 4723815
     10     1/4" Heat Shrink Tubing 4419644
       1     Male Pin Terminal (to be used as a gauge) 4400110

Repair Procedure:

This bulletin involves replacing the 3-way crank position sensor wiring harness connector.

1.   With the ignition key in the OFF position disconnect the battery negative cable.

2.   Cut the wires of the damaged 3-way connector at staggered lengths and place a piece of heat shrink tubing (PN 4419644) on each wire.

3.   Cut the matching wires on the new 3-way to staggered lengths (allowing extra length for the solder connections) so that the length of the new wiring is the same as the original. (on ZT, match the white with a black tracer wire on the vehicle harness to the orange wire from the repair kit. The other wire colors will match.)

4.   Strip one half inch of insulation from each wire and twist each pair of matching wires together. Solder each connection using a ROSIN CORE solder. Center the heat shrink tubing over the joint. Using a heat gun, heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tube.

5.   Install the wiring in its original routing and connect the wiring to the crank position sensor.

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No. 08-15-79-91 . . . . . . . . . . . 0.5 Hrs.

FAILURE CODE: 83 - Connection Loose