0323169 JOHNSON HOOK, Lower rear port

Illustration 1 g00700045
The MS connectors have a metal housing. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected by a chemical potting which prevents access to the solder point.
Illustration 2 g00700064
Deutsch connectors have a plastic housing. The pins and the sockets are crimped onto the electrical wires. The connector has a locking mechanism in order to hold the pins and the sockets. These connectors are repairable without cutting the wires.Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem.Test Step 1. Check the Connectors.
Always set the engine control to the OFF/RESET mode before you inspect electrical conductors. Remove the electrical power from the engine.
For the MS connectors, make sure that the receptacle is turned fully in the clockwise direction. Check that the threading is properly aligned and securely mated.
For the Deutsch HD connectors, make sure that the plug and the receptacle are aligned properly with the index markings. Make sure that the receptacle is turned fully in the clockwise direction. Verify that the receptacle is clicked into the locked position. Make sure that the two halves cannot be pulled apart.
For the Deutsch DT style, make sure that the orange wedge is used in order to lock the pins. Check that the receptacle has clicked into the locked position. Make sure that the two halves cannot be pulled apart.Expected Result:All connectors are properly mated and free of damage.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connectors and/or replace the connectors. Reconnect all of the connectors.STOPTest Step 2. Perform a Pull Test on Each Wire Connection.
Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
The DT connectors use an orange wedge to lock the terminals in place. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors.Note: Terminals should ALWAYS be crimped onto the wires with a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool .Expected Result:Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body.Results:
OK - Proceed to Test Step 3.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 3. Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled.
There is a strong electrical shock hazard when the crankshaft is rotating. Do not touch wires that are associated with the ignition transformer circuit when the engine is cranking or running.
If there is an active diagnostic code that pertains to the circuit, perform the following steps:
Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.
Connect an electronic service tool to the engine.
Restore the electrical power to the engine. Set the engine control to the STOP mode. Then start the engine. Run the engine under normal operating conditions.
Monitor the electronic service tool while you pull on all harnesses and connectors for the circuit with the active code.If the harness is being pulled and the diagnostic code disappears, there is a problem in the wiring or the connector.
If there are no diagnostic codes that pertain to the circuit, perform the following test:
Run the engine under normal operating conditions.
Monitor the electronic service tool while you pull on all harnesses and connectors for the circuit.If the harness is being pulled and the reading changes erratically, there is a problem in the wiring or the connector.
If there are no diagnostic codes and there are complaints about intermittent changes in speed or power cutouts, perform the following test:
Run the engine under normal operating conditions.
Listen for speed burps or power cutouts while the wiring and/or the connectors are pulled.If the harness is being pulled and the engine has a speed burp or a power cutout, there could be a problem in the wiring or the connector.Expected Result:The problem appears to be external to the harnesses and connectors. Pulling on the harness and on the connectors does not affect the active diagnostic code, component status, or engine performance.Results:
OK - Proceed to Test Step 4.
Not OK - Repair: Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine. Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 4. Check Wires for Nicks or Abrasion in the Insulation.
Set the engine control to the STOP mode. Allow the engine to coast to a stop.
Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.
Carefully inspect each wire for signs of abrasion, of nicks, or of cuts.The following areas are likely locations:
Places with exposed insulation
Points with wiring that rubs against the engine
Places with wiring that rubs against a sharp point
Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also, check all of the hold down clamps in order to verify that the harness is not compressed by the clamps. Pull back the harness sleeves in order to check for flattening of the wires by the clamps.Expected Result:The wires do not have abrasion, nicks, or cuts and the harness is properly clamped.Results:
OK - Proceed to Test Step 5.
Not OK - Repair: Repair the wires or replace the wires, as required.Verify that the repair eliminates the problem.STOPTest Step 5. Check the Connectors for Moisture or Corrosion.
Illustration 3 g00690571
Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector.
Illustration 4 g00690568