Service Procedure

NOTE:
Verify that the vehicle is affected by the campaign by identifying the vehicle identification number and vehicle production date.





1. Turn the radio on and record the customer's pre-set radio stations on a copy of the table.





2. Disconnect the battery negative (-) terminal.





3. Pry off the MAF connector locking clip. Disconnect the MAF sensor connector from the MAF sensor.








4. Remove the plastic protective tube from the MAF sensor connector wiring harness and set aside for later use. Cut the MAF sensor connector wiring at approximately 1" (25 mm) from the end of the connector. Discard the removed connector.





5. Strip the wires back about 1/2" (13 mm).

6. Slide the heat shrink tubes, supplied with the repair kit, on the end of each of the four wires on the new MAF sensor connector pigtail.





7. Splice the ends of the four wires from the new MAF sensor connector pigtail to the four exposed wires. Interlace the wire strands together, one color at a time, and twist them together. Make sure the wire colors and sizes match before splicing the wire together.





8. Using the included crimp clips, crimp the wires together, using an electrical crimping tool. Make sure to use one of the "Large" crimp clips on the red wire.

NOTE:
The crimp clips do not provide a reliable joint by themselves. They are only intended to hold the wires together during the soldering operation. Each joint must be soldered after using the crimp clips.

9. Plug in the soldering iron and allow the tip to come up to operating temperature (typically 3 to 5 minutes). Coat the soldering iron tip with a thin film of solder by melting a small amount of flux core solder on the tip (to protect the tip from oxidation).

NOTE:
The ideal tip temperature is 700 to 800 degrees F. The soldering iron used should be able to reach and maintain the appropriate temperature.

10. Touch the wire strands/wire crimp to be soldered with the soldering iron tip and allow the wires to heat up. Angle the tip of the soldering iron so that the contact surface to the wires/crimp is maximized.

11. Make sure that the wires do not get too hot. When the wires become overheated, the insulation will begin to deform & become damaged.

12. While the wires are heating up, periodically touch the end of the rosin-core solder to the wire strands next to the soldering iron tip. When the wire strands are heated to the proper temperature, the solder will melt and flow very quickly away from the solder tip.





13. The recommended solder wire is 0.032 in diameter 60/40 (tin/lead) Rosin-Core Solder. (available at electronic supply stores, including Radio Shack)





14. Quickly feed enough rosin-core solder wire to achieve an even, moderate thickness coat of solder over the joint. Once the solder begins to flow, the soldering process will be completed in a few seconds.

NOTE:
A good solder joint will have an even, smooth & shiny appearance. A poor solder joint (also called a cold solder joint) will have a dull appearance & an uneven surface.





15. Slide the heat shrink tubes over the solder joints.





16. Using a heat gun with a heat deflector attachment, heat up the shrink wrap tubing until the tubing shrinks tightly and the sealant starts to flow out of the end of the tubing.





17. Replace the protective tube removed in step 4 over the MAF sensor connector wiring harness. Then tape the MAF sensor connector wiring harness from the end of the protective tube to the end of the vinyl tube with electrical tape.





18. Connect the MAF sensor connector and reinstall the MAF connector locking clip which was removed in Step 3 of this procedure.

19. Reconnect the negative cable on the battery and check engine for proper starting.

20. Set the radio station buttons to the customer's pre-set stations and verify reception in all bands (AM, FM1, FM2). Reset the clock to the correct time.