Wiring Harness and Connector Repair

Inspect the sensor wiring and the wiring harness for any damage that may have occurred due to the accident. Service or replace any damaged wiring, terminals, insulation or connectors as required before attempting diagnostic prove out. Unrepaired wiring shorts could cause the diagnostic module thermal fuse to open. If splices are required in adjacent wiring, the splices should be staggered 50 mm (2 inches) from each other. Service as follows:

A waterproof butt splice connector should be used on all wiring serviced in the engine compartment. A heat-shrink nylon splice prevents water, salt, condensation and heat from affecting the serviced wiring.

The inner wall of the splice connector is lined with an adhesive that melts when heated with a heat gun and flows under pressure from the tubing, sealing the splice. The connectors can be crimped with a standard insulated connector crimping tool. The splices are color-coded for gauge identification, and are transparent to allow inspection of the finished splice.





Part Name Class
Butt Connector Gauge: 18-22, Color:Red C
Butt Connector Gauge: 14-16, Color: Blue C
Butt Connector Gauge: 10-12, Color: Yellow C