Many of the troubleshooting procedures direct you to a specific electrical connector. Use the following test steps to help determine whether the connector is the cause of the problem. If a problem is found in a connector, repair the connector and verify that the problem is corrected.
Intermittent electrical problems are often caused by poor connections. Always check for an active diagnostic code before you open any connection. Immediately after you reconnect the connector, check for codes again. Sometimes, simply disconnecting a connector and then reconnecting the connector can solve a problem. If this occurs, the following conditions are likely causes:
- Loose terminals
- Bent terminals
- Improperly crimped terminals
- Improperly mated connectors
- Moisture
- Corrosion
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| Illustration 1 | g01162078 |
(1) Jack (2) Plug (3) Jack (4) Plug | |
The MS connectors have a metal housing. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected by a chemical potting which prevents access to the solder point.
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| Illustration 2 | g01162080 |
(1) Contact pin (2) Sealing plug (3) Socket contact (4) Jack (5) Connector for the pin (6) Socket connector (7) Plug (8) Jack (9) Connector for the pin (10) Socket connector (11) Plug (12) Receptacle lock wedge (13) Plug lock wedge | |
Deutsch connectors have a 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.
Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem.
Test Step 1. Check the Connectors.
- Always set the engine control to the OFF/RESET mode before you inspect electrical conductors. Remove the electrical power from the engine.
- 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.
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 a Pull Test on Each Wire Connection.
- Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
- The DT connectors use an orange wedge to lock the terminals in place. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors.
Note: Terminals should ALWAYS be crimped onto the wires with a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool .
Expected Result:
Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body.
Results:
- OK - Proceed to Test Step 3.
- Not OK -
Repair: Repair the circuit.Verify that the repair eliminates the problem.
STOP
Test Step 3. Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled.
- If there is an active diagnostic code that pertains to the circuit, perform the following steps:
- Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.
- Connect an electronic service tool to the engine.
- Restore the electrical power to the engine. Set the engine control to the STOP mode. Then start the engine. Run the engine under normal operating conditions.
- Monitor the Digital Diagnostic Tool (DDT) while you pull on all harnesses and connectors for the circuit with the active code.
If the harness is being pulled and the diagnostic code disappears, there is a problem in the wiring or the connector.
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There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch wires that are associated with the ignition transformer circuit when the engine is cranking or running. |
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- If there are no diagnostic codes that pertain to the circuit, perform the following test:
- Run the engine under normal operating conditions.
- Monitor the DDT while you pull on all harnesses and connectors for the circuit.
If the harness is being pulled and the reading changes erratically, there is a problem in the wiring or the connector.
- If there are no diagnostic codes and there are complaints about intermittent changes in speed or power cutouts, perform the following test:
- Run the engine under normal operating conditions.
- Listen for speed burps or power cutouts while the wiring and/or the connectors are pulled.
If the harness is being pulled and the engine has a speed burp or a power cutout, there could be a problem in the wiring or the connector.
Expected Result:
The problem appears to be external to the harnesses and connectors. Pulling on the harness and on the connectors does not affect the active diagnostic code, component status, or engine performance.
Results:
- OK - Proceed to Test Step 4.
- Not OK -
Repair: Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine. Repair the circuit.Verify that the repair eliminates the problem.
STOP
Test Step 4. Check Wires for Nicks or Abrasion in the Insulation.
- Set the engine control to the STOP mode. Allow the engine to coast to a stop.
- Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.
- Carefully inspect each wire for signs of abrasion, of nicks, or of cuts.
The following areas are likely locations:
- Places with exposed insulation
- Points with wiring that rubs against the engine
- Places with wiring that rubs against a sharp point
- Places with exposed insulation
- Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also, check all of the hold down clamps in order to verify that the harness is not compressed by the clamps. Pull back the harness sleeves in order to check for flattening of the wires by the clamps.
Expected Result:
The wires do not have abrasion, nicks, or cuts and the harness is properly clamped.
Results:
- OK - Proceed to Test Step 5.
- Not OK -
Repair: Repair the wires or replace the wires, as required.Verify that the repair eliminates the problem.
STOP
Test Step 5. Check the Connectors for Moisture or Corrosion.
- Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector.
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| Illustration 3 | g01162092 |
(1) Sealing plug (2) Seal (3) Sealing plug (4) Seal | |
- Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. This will deform the connector seal and this will create a path for the entrance of moisture.
Thoroughly inspect the Electronic Ignition System connector for the EIS for evidence of moisture entry.
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| Illustration 4 | g00690568 |
If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the repair is not made, the problem will recur. Simply drying the connector will not fix the problem. The following list includes likely paths for the entrance of moisture:
- Missing seals or plugs
- Improperly installed seals or plugs
- Nicks in exposed insulation
- Improperly mated connectors
Moisture can also wick from one connector through the inside of a wire to the connector for the EIS. If moisture is found in the connector for the EIS, thoroughly check all connectors and wires on the harness that connects to the EIS. The EIS is not the source of the moisture. Do not replace the EIS control module if moisture is found in connectors for the EIS.
Note: If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. Do not use any cleaners that contain 1,1,1 trichloro-ethylene because 1,1,1 trichloro-ethylene may damage the connector.
Expected Result:
All of the connectors are completely coupled and all of the seals are completely inserted. The harness and the wiring does not have corrosion, abrasion, or pinch points.
Results:
- OK - Proceed to Test Step 6.
- Not OK -
Repair: Repair the circuit. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem by running the engine for several minutes and by checking again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, it may be necessary to replace the wires that have moisture. These wires may have moisture that is trapped inside the insulation. Verify that the repair eliminates the problem.
STOP
Test Step 6. Inspect the Connector Terminals.
Verify that the terminals are not damaged. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector.
Expected Result:
The terminals are properly aligned and the terminals appear undamaged.
Results:
- OK - Proceed to Test Step 6.
- Not OK -
Repair: Repair the terminals and/or replace the terminals, as required.Verify that the repair eliminates the problem.
STOP
Test Step 7. Check the Individual Retention of the Pins and Sockets.
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| Illustration 5 | g01162094 |
(1) Deutsch contact pin (2) Deutsch contact terminal | |
- One at a time, insert a new pin into each socket. Make sure that the pin is properly gripped by the socket.
Note: This is especially important for intermittent problems.
- One at a time, insert a new socket onto each pin. Make sure that the pin is properly gripped by the socket. Verify that the socket holds the pin when the connector hangs freely.
Expected Result:
Each socket firmly grips each pin.
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.Verify that the repair eliminates the problem.
STOP