Date of issue 5/96 Bulletin Number 05.1-14 Page 1 of 3
Sedan (4.0L) Range
Some 1995-96 MY Sedan Range vehicles within the above VIN range may exhibit
engine misfire/starting difficulty due to terminal corrosion caused by the entry of
water at connector PI1. The condition has been found on 4.0L Sedan Range
vehicles, however, connector PI1 carries the engine management power supply on
all engine variants on 1995-96 MY Sedan Range vehicles.
The connector was modified beginning with VIN 771157. The modification can be
made on earlier vehicles if corrosion is found.
In case of a customer complaint of engine misfire/starting difficulty on a 1995-96
MY Sedan Range vehicles within the above VIN range, check for the entry of water
into the white harness connector (PI1), located rearward of the right side
headlamp. If corrosion is found, relocate the connector as described on the next
page, in addition to any other repairs made.
Note the following:
• If severe corrosion and pitting or damage to the terminal blades has occurred,
BOTH the right side forward harness
AND the Engine PI harness.
Note the oxygen sensor connection orientation during disassembly, to avoid
reversing the orientation which would cause a misfire condition. Perform the
oxygen sensor orientation procedure using the PDU following reassembly.
• If only water ingress and slight tarnishing of the connector terminals is found,
thoroughly dry the connector and grease the terminals. Use only a dry and
filtered air supply when using shop air to blow water from the connector. If
using a warm air blower, ensure that the connector does not reach excessive
In either of the above cases, apply a generous coating of electrical spray grease to
the faces of both connectors. Use part no. JLM 20054 (or the previous JLM
11472). Allow 15 seconds for solvents in the spray grease to evaporate before
joining the connectors.
After performing the above repairs, modify the connector location as described on
the following page.
Engine Misfire/Starting Difficulty –
Harness Connector Modification