505 V6-2849cc 2.8L ZN3J (1987)
screwdriver
C.
Insert the screwdriver between rolled side of terminal and side of the socket; pull down on wire to release it from socket
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Remove wire # 46 from pin 3 of the existing starter relay and insert it into the bypass relay connector at pin 3 (Bosch relay pin 30)
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Cut a 12-inch length of 16 gauge wire. Using proner pliers, crimp terminals P/N 6542.32 to both ends. Install one end into existing starter
relay pin 5 and new bypass relay connector pin 2 (Bosch relay pin 85)
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Cut a 6-foot length of 16 gauge wire. To one end crimp terminal
P/N 6542.32 and to the other end crimp terminal P/N 6540.27. Insert terminal P/N 6542.32 into pin 3 of the original starter relay. Route the
wire along existing wire harness and attach terminal P/N 6540.27 to ground block MM2 (next to left side headlight)
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Cut a 52-inch length of 12 gauge wire. To one end crimp terminal P/N 6542.30 and install it into bypass relay connector pin 5 (Bosch relay
pin 87). On the end crimp terminal P/N 6540.38 and insulate with heat shrinkable tubing. Plug terminal into open pin of battery junction
block located on positive battery cable
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Secure new wires to existing wiring harness with nylon wire ties
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Reinstall original starter relay into its connector
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Install Bosch relay into new bypass relay connector. The relay connector can be secured to an existing hole in the relay support bracket using
relay clip P/N 0065.47
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Reinstall protective covering and relay bracket to firewall.
Reconnect battery and test starting
WARRANTY INFORMATION:
Damage Code:
654194
Operation Number:
990111
Time Allowance:
0075 hours