EDI DIAGNOSIS SERVICE MANUAL NUMBER 22
Page 5E-100 90-860074--1 FEBRUARY 2002
WIRE REPAIR
1. Locate damaged wire.
2. Remove insulation as required.
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3. Splice two wires together using a splice clip. Solder with rosin core solder.
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4. Cover splice with heat shrink sleeve to insulate from other wires.
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CONNECTOR SERVICE
Most connectors in the engine compartment are protected against moisture and dirt which
could create oxidation and deposits on the terminals. This protection is important because
of the very low voltage and current levels found in the electronic system. The connectors
have a lock which secures the male and female terminals together. A secondary lock holds
the seal and terminal into the connector.
When diagnosing, open circuits are often difficult to locate by sight because oxidation or
terminal misalignment are hidden by the connectors. Merely wiggling a connector on a
sensor or in the wiring harness may locate 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. Some connectors look
similar but are serviced differently. Replacement connectors and terminals are listed in the
Parts Catalog.
NOTE: Replacement connectors for Mercury MerCruiser EDI engines may come with the
wires already attached to the connector.
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