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ON-VEHICLE SERVICE
WIRE HARNESS REPAIR
The ECM harness electrically connects the
ECM to a various components in both the en-
gine 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. Al-
ways 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 diag-
nosis. 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.
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 indi-
cated. 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 Com-
pact Three connectors look similar, but are
serviced differently.
REPAIRING TWISTED/SHIELDED CABLE
1. Remove outer jacket
2. Unwrap aluminum/Mylar tape. Do not re-
move Mylar.
3. Untwist conductors, strip insulation as ne-
cessary.
4. Splice wire using splice clips and rosin
core solder. Wrap each splice to insulate.
5. Wrap with Mylar and drain wire (uninsu-
lated) wire.
6. Tape over entire juncture and secure.
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