Electrical Connections and Circuits
PRIMARY CONNECTIONSFully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling.
CAUTION:
- Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure.
- Do not use a self powered test lamp to check continuity.
- Do not create any arcing to check the continuity of a circuit.
IGNITION SECONDARY CONNECTORS
- Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters.
- When removing a spark plug wire, twist the boot one quarter turn and pull on the boot only, never the lead itself.
WIRING HARNESS SERVICE
Replace the wire harnesses with the proper part number replacement. When splicing signal wires into a harness, use the wiring that has high temperature insulation.
Consider the low amperage and voltage levels utilized in the Powertrain control systems. Make the best possible bond at all splices. Use rosin-core solder in these areas.
Molded-on connectors require complete replacement of the connector. Splice a new connector into the harness. Replacement connectors and terminals are listed in Group 8.965 in the Standard Parts Catalog.
CONNECTORS AND TERMINALS
In order to prevent shorting between opposite terminals, use care when probing a connector and when replacing terminals. Damage to the components could result.
Always use jumper wires between connectors for circuit checking.
Never probe through Weather-Pack seals. The connector test adapter kit J35616, or the equivalent, contains an assortment of flexible connectors used to probe terminals during diagnosis. Fuse remover and test tool BT-861 6, or the equivalent, is used for removing a fuse and to adapt the fuse holder to a DVOM for diagnosis.
Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor, or in the wiring harness may temporarily correct the open circuit. Oxidized or loose connections may cause intermittent problems.
Be certain the type of connector and terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently.