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ON-VEHICLE SERVICE
WIRE HARNESS REPAIR
REPAIRING TWISTED/SHIELDED CABLE
The ECM harness electrically connects the
ECM to a various components in both the engine and passenger compartments.
Wire harnesses should be replaced with proper part number harnesses. When wires are
spliced into a harness, use wire with high temperature insulation only.
Low current and voltage levels are used in the
system, so it is important that the best possible
bond at all wire splices be made by soldering
the splices.
CONNECTORS AND TERMINALS
Use care when probing a connector or replacing terminals in them to prevent shorting
opposite terminals and damage certain components. Always use jumper wires between
connectors, for circuit checking. Do not probe
through the Weather-Pack seals with oversized
wire probes. Use tachometer adapter J 35812
(or equivalent) which provides an easy hook up
of the tach lead. The connector test adapter kit
J 35616 (or equivalent), contains an assortment of flexible connectors used to probe
terminals during diagnosis. Fuse remover and
test tool BT 8616, or equivalent, is used for removing a fuse and to adapt fuse holder, with a
meter, for diagnosis. Do not solder oxygen
sensor wire terminals as these wire ends are
used for the sensors oxygen reference.
1. Remove outer jacket
2. Unwrap aluminum/Mylar tape. Do not remove Mylar.
3. Untwist conductors, strip insulation as necessary.
4. Splice wire using splice clips and rosin
core solder. Wrap each splice to insulate.
5. Wrap with Mylar and drain wire (uninsulated) wire.
6.
Open circuits are often difficult to locate by
sight due to dirt, oxidation, or terminal misalignment. Merely wiggling a connector on a
sensor, or in the wiring harness, may correct
the open circuit condition. This should always
be considered, when an open circuit, or failed
sensor is indicated. Intermittent problems may
also be caused by oxidized or loose connections.
Before making a connector repair, be certain of
the type of connector. Weather-Pack and
Compact Three connectors look similar, but are
serviced differently.
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Tape over entire juncture and secure.