The Timing Control Module (TCM) uses several different types of connectors for the electrical connections of the wiring harnesses to the system components. Performance problems may result if the electrical connectors are not properly maintained.
The MS Connectors have a metal housing. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected. This may prevent access to the solder point.
Deutsch connectors have a gray plastic housing. The pins and the sockets are crimped onto the electrical wires. The connector has a locking mechanism in order to hold the pins and the sockets. These connectors are repairable without cutting the wires. This procedure has specific instructions on replacing these connectors.
The bodies of the Phoenix terminal strips are made of plastic and metal. The screw clamps hold the electrical wires to the terminal. These connectors are mounted to the rails in the terminal boxes.
Proper maintenance will reduce performance problems. Clean all of the electrical connectors with an alcohol based cleaner.
 | |
| Illustration 1 | g00665112 |
 | |
| Illustration 2 | g00665115 |
Test Step 1. Check the Connectors.
- For the MS connectors, make sure that the receptacle is turned fully in the clockwise direction. Check that the threading is properly aligned and securely mated.
- For the Deutsch HD connectors, make sure that the plug and the receptacle are aligned properly with the index markings. Make sure that the receptacle is turned fully in the clockwise direction. Verify that the receptacle is clicked into the locked position. Make sure that the two halves cannot be pulled apart.
- For the Deutsch DT style, make sure that the orange wedge is used in order to lock the pins. Check that the receptacle has clicked into the locked position. Make sure that the two halves cannot be pulled apart.
- For the Phoenix terminal strip, make sure that the screw is tightened and that the wire is secure.
Expected Result:
All connectors are properly mated and free of damage.
Results:
- OK - Proceed to test step 2.
- Not OK -
Repair: Repair the connectors and/or replace the connectors. Reconnect all of the connectors.
Stop.
Test Step 2. Perform the Pull Test.
- Each wire should easily withstand 45 N (10 lb) of pull. Each wire should remain in the connector body. The diagnostic codes should remain constant. The pull test can be performed by firmly grasping the connector body with one hand and giving each wire a firm tug.
Note: Only the MS connector pins and sockets are soldered. Always crimp the Deutsch pins and sockets. Never solder the Deutsch pins and sockets. Use the 1U-5804 Crimp Tool in order to crimp a pin or a socket.
- Check the Phoenix terminal strips with a pull test. The pull test can be performed by firmly grasping the connector body with one hand and giving each wire a firm tug.
Results:
- OK - Proceed to test step 3.
- Not OK -
Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Reconnect all of the connectors.
Stop.
Test Step 3. Inspect the Connectors for Corrosion and/or Damage.
- Disconnect the connectors and carefully examine the connectors. Inspect the connectors for evidence of corrosion and moisture.
- Ensure that all connector seals, retainers, and terminals are properly installed, and free of damage.
Note: Use only isopropyl alcohol to remove corrosion. Solvents with chlorine may damage the connector.
- For the Phoenix terminal strips, examine the wire ends for evidence of corrosion or frayed strands of wire. If corrosion is present remove any large deposits. Clean the contact with a cotton swab and isopropyl alcohol. Remove the frayed wire strands or solder the wire end.
Expected Result:
All connectors are free of corrosion and moisture. Connector seals are properly installed and free of damage.
Results:
- OK - Proceed to test step 5.
- Not OK - The connectors are damaged.
Repair: Repair the connectors and/or wiring. Replace parts, if necessary. Reconnect all of the connectors.
For Deutsch connectors, proceed to test step 5.
Test Step 4. Check the Individual Pins and Sockets for Retention
Note: This test is especially useful for intermittent problems.
- One at a time, insert a new pin into each socket. Make sure that the pin is properly gripped by the socket.
- One at a time, insert a new socket onto each pin. Make sure that the pin is properly gripped by the socket.
Expected Result:
Each socket firmly grips each pin. The pins will not fall out of the socket when the connector hangs freely.
Results:
- OK - The pins and sockets mate properly. Stop.
- Not OK - The pins and sockets do not mate properly.
Repair: Repair any bad pins and sockets. Replace the connectors, if necessary. Replace the wiring, if necessary.
Stop.
Test Step 5. Contact Removal for Deutsch Connectors.
- Remove the orange wedge. Use pliers or a thin screwdriver to pull the orange wedge from the connector.
- Release the locking finger by moving the locking finger away from the contact in order to remove the contacts. Gently pull the wire out of the connector.
Note: Release the locking finger for the wire with a flat screwdriver.
- For Deutsch HD connectors, use the 151-6320 Wire Removal Tool .
- Slide the 151-6320 Wire Removal Tool along the wire. Engage the contact in order to unlock the retaining clip of the contact. Pull the contact and the wire assembly out of the connector.
Expected Result:
The pins and the sockets have been removed.
Results:
- OK - Proceed to test step 6.
- Not OK -
Repair: The wiring or the contact is bad. Replace the wiring or the contact. Reconnect all of the connectors.
Stop.
Test Step 6. Contact Insertion for Deutsch Connectors.
- For Deutsch DT connectors, grasp the wire about 25 mm (1 inch) behind the contact body. Hold the connector so the rear grommet is facing you. Insert the contacts.
- Push the contact straight into the grommet of the connector until you feel a click.
- After all of the sockets are inserted into the connector and locked in place, insert the orange wedge into the front of the connector. Pull on each of the wires in order to make sure that the wires are locked in place.
- For the Deutsch HD connectors, grasp the wire about 25 mm (1 inch) behind the contact body. Hold the connector so the rear grommet is facing you. Insert the contacts.
- Push the contact straight into the grommet of the connector until you feel a positive stop. The retaining fingers in the connector will snap behind the shoulder of the contact. Pull on each of the wires in order to make sure that the wires are locked in place.
Results:
- OK - Stop.
- Not OK -
Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Reconnect all of the connectors.
Stop.