Service Manual 5008740_200-300 HP 90 ° V Electrical And Ignition [Connector Servicing]

IMPORTANT: Electrical Grease is recommended. Incorrect grease application can cause electrical or warning system problems.

To disconnect the connector, press the latch and pull the connectors apart.

To connect the connector, confirm that the seal is in place . Cle an off any old grease and dirt from connectors. Apply a light coat of Electrical Grease to seal only. Push connectors together until latched.

42079A

1. Latch
2. Seal

Terminal Removal

Use hook-end of Connector Service Tool, P/N 342667, to pull out wedge from receptacle, or use other end of tool to pry out wedge from plug. Use need le-nose pliers to remove wedge from 3-pin receptacle.

42327

1. Wedge

Release terminal latch and gently pull on wire.

423293

1. Terminal latch (receptacle)
2. Terminal latch (plug)

Terminal Installation

Push terminal through seal until it locks into place. Fill connector with Electrical Grease to 1/32 in. (0.8 mm) below ledge or end of plug.

42330

1. Ledge of plug
2. End of plug

Push wedge in until latched. W edge in 2-pin receptacle is not symmetrical; position latch shoulders next to terminals.

Crimping Terminals

Strip insulation back 3/16 in. (5 mm). Place terminal in 18-gauge notch of Crimping Pliers, P/N 322696. Position end of wire strands in terminal past wire crimp area, and position end of insulation past insulation crimp area. Capture all wire strands in crimp; leave no loose strands. Crimp wire securely. Do not s older. Crimp insulation in 14/16-gauge notch of crimping pliers.

1. End of wire strands

2. Insulation crimp area

3. End of insulation

4. Wire crimp area

IMPORTANT: Always use the appropriate meter test probe s and adapters when testing components fitted with these terminals. Electrical grease is NOT used on AMP connectors.

SUPERSEAL 1.5

Disconnect

Lift latch. Pull connectors apart.

Connect

Confirm the seal is in place. Push connectors together until latched.

002448

1. Latch
2. Seal

Terminal Removal

Use Secondary Lock Tool, P/N 777078, to release anti-backout device of connector housing. Next, use Primary Lock Tool, P/N 77 7077, to release locking tab of connector housing. Release locking tab a nd pull on wire to remove from connector housing.

002449
002450

1. Anti backout device, plug
2. Anti backout device, receptacle

002447

1. Locking tab, plug
2. Locking tab, receptacle

Terminal Installation

Align terminal with connector housing. Push connector and seal into housing until seated.

002451

1. Terminal and seal

Align anti-backout device with connector housing and terminals. Use Secondary Lock In staller, P/N 777079, to seat device in connector.

Crimping Terminals

Crimping Superseal 1.5 terminals requires AMP Crimp Tool with dies, P/N 777281.

002452

1. Terminal
2. Seal

SUPER SEAL

The J1-A and J1-B connectors of the EMM are AMP Super Seal connectors.

Disconnect

Depress BOTH latches and pull connector from plug.

Connect

Push connector into plug until latches engage.

002118

1. Latch

Terminal Removal

Open lock mechanism and remove terminal from connector housing.

002453

1. Latch
2. Lock mechanism

Terminal Installation

Push terminal through seal until it is seated in connector housing. Close lock mechanism.

002454

1. Terminal

POWER TIMER SERIES

The J2 connector of the EMM is a AMP Power Timer Series connector.

Disconnect

Use a screw driver to open latch. Pull connector from plug.

Connect

Push connector until seated in plug. Close latch completely.

002448

1. J2 connector
2. Latch (closed)

Terminal Removal

Use Terminal Release Tool, P/N 351413, to release BOTH locking mechanisms of connector. Pull terminal from housing.

002455

1. Locking mechanism(s)

002313

1. Terminal release tool

Terminal Installation

Align terminal with connector housing and push terminal with se al in to connector housing until seated.

002456

1. Latch
2. Terminal with seal

IMPORTANT: Always use the appropriate meter test probes and adapters when testing components fitted with these terminals.

Disconnect

Lift latch(s). Remove connector.

Connect

Confirm the seal is in place. Push connector onto housing until latched.

dsc02124

Terminal Removal

A tab on the back side of the terminal engages a shoulder in the connector housing to hold the terminal in place. The terminal is removed by releasing the tab and then pushing the terminal and wire through connector housing.

Insert a thin tool into the connector above the terminal to release tab.

DRC5940a

1. Tab

Terminal Installation

Install wire gasket on wires and feed wires through the correct terminal position of the connector housing. Terminal is crimped onto wire and then pulled back into connector housing until locking tab engages and terminal is seated.

Crimping Terminals

Strip insulation back 3/16 in. (5 mm). Position end of wire strands in terminal past the wire crimp area and the end o f insulation in the insulation crimp area of the terminal.

Capture all wire strands in crimp ; leave no loose strands. Crimp wire and insulation securely using crimping pliers.