Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 019-205   Deutsch DT Connector Series

Pin Replacement

TOC

The connector can have multiple pin configurations. All type of connectors are repaired in the same manner.

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.

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To replace the pin in the receptacle connector, remove the orange wedge using needle nose pliers or a hook-shaped wire to pull the wedge straight out.

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 CAUTION 

Locking finger can be easily broken. Care must be taken when using this tool. Do not force the tool into place.

To remove the contact out of the connector body, gently pull wire backward, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver.

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 CAUTION 

If more than one wire is being repaired, tag each wire and install it in the original location. Electrical damage can occur if wire is installed in the incorrect location.

Pull the wire and the terminal out of the connector body.

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

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.

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

Use wire crimping tool, Part Number 3822930, to cut 127 mm [5 in] off the wire and pin.

Use wire crimping tool, Part Number 3822930, to remove 6 mm [¼ in] of insulation from the wire.

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Install the correct repair wire on the bare wire.

Make sure the bare wire extends into the splice connector.

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Use wire crimping tool, Part Number 3822930, to crimp the repair wire onto the bare wire.

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Use heat gun, Part Number 3822860, to heat shrink the tubing around the wire.

The tubing will shrink and make the connection waterproof.

 
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 CAUTION 

If more than one wire is repaired or if the connector body is replaced, make sure to insert wires into the same locations as they are in the original connector. If wires are not in the original location electrical damage can occur.

Replace the connector and install the wire and terminal into the connector body. Push the wire and terminal into the seal at the back of the connector. Push the wires straight in until a click is felt. A slight tug will confirm that it is properly locked in place.

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Once the wires are in place, insert the orange wedge with arrow pointing toward the exterior locking mechanism.

Push the orange wedge in until it snaps in place.

Make sure both seals are in place and the back of the connector plug and receptacle. Be sure the rubber seal has been installed on the connector plug.

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Push the connector plug into the connector receptacle until the external locking clip snaps into place.

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Connector Replacement

TOC

The connector can have multiple pin configurations. All types of connectors are repaired in the same manner.

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

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
   


To replace the pin in the plug connector, grasp the orange wedge and pull the wedge straight out.

SMALL | MEDIUM | LARGE
   


 CAUTION 

Locking finger can be easily broken. Care must be taken when using this tool. Do not force the tool into place.

To remove the contact out of the connector body, gently pull wire backward, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver.

SMALL | MEDIUM | LARGE
   


 CAUTION 

If more than one wire is repaired or if the connector body is replaced, be sure to insert the wires into the same location as they were in the original connector. If wires are not in the original location electrical damage can occur.

Replace the connector and install the wire and terminal into the seal at the back of the connector. Push the wires straight in until a click is felt. A slight tug will confirm that it is properly locked in place.

SMALL | MEDIUM | LARGE
   


Once the wires are in place, insert the orange wedge with arrow pointing toward the exterior locking mechanism. Push the orange wedge in until it snaps in place.

Make sure both seals are in place at the back of the connector plug and receptacle. Make sure the rubber seal has been installed on the connector plug.

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Push the connector plug into the connector receptacle until the external locking clip snaps into place.

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Last Modified:  09-Oct-2003