Navajo 4WD V6-4.0L OHV (1991)
Ignition Switch: All Technical Service Bulletins
Ignition Switch - Hard Start
Bulletin No.
011/92
Issued
7/10/92
Revised
Category
T
Applicable Model/s
1991 Navajo
Subject
HARD START/NO START
DESCRIPTION
The engine may not start without cycling the key to the off position and back to start. A modified ignition switch with a synthetic lubricant has been
developed to remedy this situation.
INSPECTION AND REPAIR PROCEDURE
Vehicles experiencing the above problem should have the modified ignition switch installed. Also, the mating harness connector must also be changed to
a new material that is compatible with the synthetic lubricant in the new switch. The following is the removal and installation procedure for the new
switch and harness connector.
REMOVAL
1.
Disconnect the negative battery cable.
2.
Remove the upper and lower shroud as shown on page N-04-17 of the Workshop Manual.
3.
Turn the lock cylinder to the RUN position.
4.
Remove the two nuts on the ignition switch.
5.
Separate the connector (ZZL5 67 741) from the ignition switch by gently prying on the ears of the connector and pulling it apart firmly.
6.
Disengage the terminals from the existing connector and discard the connector.
7.
Insert the terminals into the proper locations in the replacement connector (ZZL5 67 741). See Figure 1 for wiring details.
INSTALLATION
1.
Remove the spring clip from the new switch (ZZL1 66 123). This clip keeps the switch in position during shipment.
2.
Press the connector (ZZL5 67 741) onto the terminals of the ignition switch. Insure that the tabs lock securely.
3.
Seat the switch on the weld studs on the steering column. The end of the actuator rod must fit in the hole on the slider.
4.
Install the nuts on the weld studs and torque them to 4.45 - 7.74 N-m.
5.
Reconnect the negative battery cable.
6.
Check the operation of the ignition switch. Adjust according to the ignition switch adjustment procedure on page N-04-11 of the Workshop