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Service Manual Evinrude E-TEC 40-60 HP Electrical And Ignition [Connector Servicing]

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Service Manual Evinrude E-TEC 40-60 HP Electrical And Ignition [Connector Servicing]
5007209
BRP Marine

Sections:

  1. CONNECTOR SERVICING
  2. AMP Connectors
  3. Packard† Connectors

CONNECTOR SERVICING

DEUTSCH Connectors

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. Clean off any old grease and dirt from connectors. Apply a light coat of Electrical Grease to seal. Push connectors together until latched.

  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 needle-nose pliers to remove wedge from 3-pin receptacle

  1. Wedge

Release terminal latch and gently pull on wire.

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

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.

  1. Ledge of plug
  2. End of plug

Push wedge in until latched. Wedge in 2-pin receptacle is not symmetrical; position latch shoulders next to 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 solder. 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

AMP Connectors

IMPORTANT: Always use the appropriate meter test probes 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

  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 777077, to release locking tab of connector housing. Release locking tab and pull on wire to remove from connector housing

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

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

Terminal Installation

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

  1. Terminal and seal

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

Crimping Terminals

Crimping Super seal 1.5 terminals requires the PRO-CRIMPER II † with a specific crimping die
set. The PRO-CRIMPER II hand tool assembly, P/N 58583-1, comes with die assembly P/N 58583-2.

  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.

  1. J1-A connector
  2. J1-B connector

Terminal Removal

Open lock mechanism and remove terminal from connector housing. Close lock mechanism.

  1. Latch
  2. Lock mechanism

Terminal Installation

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

  1. Terminal

POWER TIMER† SERIES

The J2 connector of the EMM is a AMP PowermTimer Series connector.

Disconnect

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

Connect

Push connector until seated in plug. Close latch completely

  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.

  1. Locking mechanism(s)

  1. Terminal release tool

Terminal Installation

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

  1. Latch
  2. Terminal with seal

Packard† Connectors

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.

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 pushing wire and terminal through connector housing. Insert a thin wire, such as a paper clip, into the connector above the terminal to release tab.

TYPICAL

Terminal Tool

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 of 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.

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