Repair Procedure

1. Locate the crankshaft position (CKP) sensor (L5) (arrow, Figure 1 and 2) and disconnect the wiring connector.

2. Cut off the existing wiring connector approximately 120 mm (4.75 inches) from the connector end.

3. Using a suitable tool, carefully remove approximately 60 mm (2.5 inches) of the outer protective covering from the wiring harness end, being careful not to damage any of the other wires located within the wiring harness.





4. Locate both the green and green/white wires within the opened harness. Carefully cut the solid green wire approximately 40 mm (1.5 inches) shorter than the green/white wire. When completed in step 10, the two solder splices should not lay atop each other, but rather above/next to each other as shown (Figure 3).

5. Carefully strip 5 mm (3/16 inch) insulation from the ends of the green and green/white wires, being careful not to damage or nick any of the wires.





6. Carefully twist together the bare wire ends of the green/white wires (corresponding wire from the new CKP connector and corresponding wire from the existing harness) insert and twist the now combined green/white wires fully into the supplied solder splice (Z, Figure 4).

7. Carefully repeat step 6 above for the green wires from both the new supplied CKP connector and the opened harness.

8. Position the two solder splices away from the harness so that other wires and insulation will not be damaged by the hot air gun in the next repair step.





9. Heat the solder splices (Z, Figure 5) with the hot air gun (set gun to 4000 C) (Figure 5). Continue heating the solder splice and covering (2, Figure 5) in a back and forth motion (arrow, Figure 5) until the solder ring (1, Figure 5) has completely melted and the outer covering (2, Figure 5) has shrunk to lay smoothly upon the wires (A, Figure 6). Additionally (B, Figure 6) shows an incorrectly fabricated solder splice connector.





10. The properly heated solder splice connectors (A, Figure 6) are to be positioned into the harness as shown by arrows in Figure 3.

11. Using an Ohmmeter, check the continuity of the fabricated green/white and green wires.

12. Using the supplied cloth tape carefully wrap each of the solder splices and the repaired wiring section by overlapping each wrap by 50%, also insure that all exposed wires are wrapped with at least two thicknesses of cloth tape.

13. Remove and inspect the CKP sensor (L5, Figures 1 and 2) for any damage or corrosion. Clean or replace CKP sensor as necessary.

14. Reinstall and reconnect CKP sensor.

15. Connect the HHT and erase any stored DTC's. Run engine to check for proper function of the CKP sensor.