Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 019-208   Deutsch HDP20 and HD30 Connector Series

Pin Replacement

TOC

Remove the two clamp capscrews (1) from the rear of the connector.

Turn the retainer of the connector counterclockwise until the two pieces are separated.

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Use the Deutsch extraction tool, listed in the table below, to remove a pin from the connector.

Tool Part Number Wire Size
3824815 20 gauge
3822760 16 gauge
3824816 12 gauge

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

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.

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Push the tool into the connector about 25 mm [1 in] until it bottoms on the terminal flange.

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Hold the tool on the terminal flange and pull the wire and the connecting pin out of the connector. Note and record the hole from which the pin is removed.

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NOTE: The repair wire is 127 mm [5 in] long.

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

Refer to the appropriate wiring repair kit 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.

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

Use the wire crimping tool 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 the wire crimping tool to crimp the repair wire onto the bare wire.

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Use heat gun, Part Number 3822860, or an open flame to heat shrink the tubing around the wire. The tubing will shrink and make the connector waterproof.

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Insert the pin into the correct hole of the connector.

The pin must click into place and hold the wire in the connector.

Pull the wire gently to make sure it is seated in the connector.

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Install the retainer. Tighten the two clamp capscrews.

Torque Value:  1  n.m  [9 in-lb]

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Connector Replacement

TOC

Remove the two clamp capscrews (1) from the rear of the connector.

Turn the retainer of the connector counterclockwise until the two pieces are separated.

SMALL | MEDIUM | LARGE
   


Use the Deutsch extraction tool, listed in the table below, to remove a pin from the connector.

Tool Part Number Wire Size
3824815 20 gauge
3822760 16 gauge
3824816 12 gauge

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

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

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

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

SMALL | MEDIUM | LARGE
   


Push the tool into the connector about 25 mm [1 in] until it bottoms on the terminal flange.

SMALL | MEDIUM | LARGE
   


Hold the tool on the terminal flange and pull the wire and connecting pin out of the connector. Note and record the hole from which the pin is removed.

SMALL | MEDIUM | LARGE
   


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
   


Insert the pins into the correct holes of the connector.

The pin must click into place and hold the wire in the connector.

Pull the wire gently to make sure it is seated in the connector.

SMALL | MEDIUM | LARGE
   


Install the retainer. Tighten the two clamp capscrews

Torque Value:  1  n.m  [9 in-lb]

SMALL | MEDIUM | LARGE
Last Modified:  09-Jun-2004