Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 019-203   AMP Connector Series

Pin Replacement

TOC

 CAUTION 

Use care in handling the AMP connectors. They are very fragile and easily damaged. Follow the steps outlined in this procedure to avoid damage.

Check to be sure the connector wedge lock is in the open position.

NOTE: The connector assembly is shipped in one piece, with the wedge lock in the open position. It is possible that during adverse shipping conditions that some wedge locks can get bumped into the closed position.

 
SMALL | MEDIUM | LARGE


If the wedge lock is closed, perform the following:

Insert screwdriver blade (flat) between the matting seal and one of the red wedge lock tabs.

Depress the lock tabs (Item 3 in the figure in the previous step).

Pry open the wedge lock to the open position.

NOTE: The wedge lock must not be removed from the housing for insertion or removal of the contacts.

SMALL | MEDIUM | LARGE
   


Remove the damaged contacts, rotate the contact wire back and forth over a half turn (¼ turn in each direction). Gently pull the wire until the contact is removed.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair wire.

NOTE: Replace one contact wire at a time. If more than one wire needs replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

SMALL | MEDIUM | LARGE
   


Before installing the new repair wire, perform a test fit to make sure the wire is the correct size.

Install a new wire and contact.

Insert wire straight into the appropriate circuit cavity.

Insert the wire until the pin bottoms out.

Pull back gently to be sure the retention fingers are holding the contact.

SMALL | MEDIUM | LARGE
   


After all of the required contacts have been replaced, the wedge lock must be closed to its LOCKED position. Release the locking latches by squeezing them inward.

 
SMALL | MEDIUM | LARGE
   


Slide the wedge lock into the housing until it is flush with the housing.

 
SMALL | MEDIUM | LARGE
   

Connector Replacement

TOC

 CAUTION 

Use care in handling the AMP connectors. They are very fragile and easily damaged. Follow the steps outlined in this procedure to avoid damage.

NOTE: The connector assembly is shipped in one piece, with the wedge lock in the open position. It is possible that during adverse shipping conditions that some wedge locks can get bumped into the closed position.

Check to be sure the connector wedge lock is in the open position.

 
SMALL | MEDIUM | LARGE
   


NOTE: The wedge lock must not be removed from the housing for insertion or removal of the contacts.

If the wedge lock is closed, perform the following:

Insert screwdriver blade (flat) between the matting seal and one of the red wedge lock tabs.

Depress the lock tabs (Item 3 in the figure in the previous step).

Pry open the wedge lock to the open position.

SMALL | MEDIUM | LARGE
   


Replace one contact wire at a time. Attach a lettered tag to each wire removed.

Before installing the new connector, perform a test fit to make sure the connector is keyed correctly.

Remove all of the contacts. Rotate the contact wires back and forth over a half turn (¼ turn in each direction). Gently pull the wire until the contact is removed.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair connector.

Refer to the wiring diagram in Section E for pin locations.

SMALL | MEDIUM | LARGE
   


Install a new wire and contact by:

Insert wire straight into the appropriate circuit cavity.

Insert the wire until the pin bottoms out.

Pull back gently to be sure the retention fingers are holding the contact.

SMALL | MEDIUM | LARGE
   


After all of the required contacts have been replaced, the wedge lock must be closed to its LOCKED position. Release the locking latches by squeezing them inward.

 
SMALL | MEDIUM | LARGE
   


Slide the wedge lock into the housing until it is flush with the housing.

 
SMALL | MEDIUM | LARGE
Last Modified:  03-Apr-2003