Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 019-214   Bosch™ Actuator and Sensor Connector Series

Pin Replacement

TOC

The connector is
not repairable. If any part of the connector becomes damaged, replace the connector with the appropriate repair connector.

 
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Connector Replacement

TOC

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.

The connector is
not repairable. If any part of the connector becomes damaged, replace the connector with the appropriate repair connector.

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The connectors have different keying and can
not be interchanged with each other.

Make sure the correct wires are connected to pin 1, pin 2, and pin 3, when replacement is necessary.

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Measure 152 mm [6 in] back from the face of the connector, and remove the wiring harness protective cover.

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Before cutting the wires, measure and tag the three wires.

Use wire cutters to cut wire 1 117 mm [4-½ in] from the face of the connector.

Use wire cutters to cut wire 2 104 mm [4 in] from the face of the connector.

Use wire cutters to cut wire 3 91 mm [3-½ in] from the face of the connector.

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

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Install the pin repair wires and connector onto the bare wires of the harness and use the wire crimping tool to crimp each repair wire onto the harness.

Use heat gun, Part Number 3822860, to shrink the tubing. The tubing will shrink and make the connection waterproof.

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Wrap the wires with tape, for added protection, to complete the repair.

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Last Modified:  19-Mar-2009