Injector Wiring Harness Replacement

TM 9-2320-363-34-1 · Chapter 4 — Electrical System Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                        Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31                   Reference              Condition Description
Tool Kit, SC 5180-90-CL-N05
                                                    Page 3-71              Rocker Cover Removed

                                      CAUTION
        l    Grasp connector and terminal body when removing wiring harness
            connectors. Do not pull on wires or harness to prevent damage to
            equipment.

        l    Injector wiring harness connectors are top and bottom connectors at rear of
            electronic control module. Do not remove center outboard connector.

1.    DISCONNECT LOCKING TANGS ON TWO INJECTOR WIRING HARNESS CONNECTORS (1) AT
      REAR OF ELECTRONIC CONTROL MODULE (2) AND PULL CONNECTORS (1) OUT OF TOP AND
      BOTTOM OUTBOARD TERMINALS.

TM page 4-3

Illustration from TM 9-2320-363-34-1 (PDF page 363)

2. REMOVE TWO BOLTS (3) AND HARNESS PROTECTOR (4) FROM HARNESS PLATE (5) AT REAR OF CYLINDER HEAD (6).

3. DISCONNECT HARNESS LEADS (7) FROM THREE ENGINE RETARDER SOLENOID TERMINALS (8).

NOTE

Do not remove terminal screws from injector. Loosen terminal screws only enough to allow larger opening in terminal to be moved under screw head, allowing terminal to be lifted off. Tag terminals prior to removal to aid in installation.

4. LOOSEN TWO TERMINAL SCREWS (9) ON EACH INJECTOR AND REMOVE TERMINALS (10).

5. REMOVE GUIDE CLIP (11) IN REAR CORNER DRAIN HOLE OF CYLINDER HEAD (6).

NOTE Feed wires and terminals thru hole at rear of cylinder head carefully.

6. REMOVE HARNESS (12).

Use general cleaning methods to clean all parts (page 2-30).

Inspect all parts for wear or damage.

TM page 4-4

Illustration from TM 9-2320-363-34-1 (PDF page 364)

CAUTION Do not pull on injector wires or terminals when installing harness in cylinder head to prevent damage to equipment. **NOTE**

All connectors should reach terminals without strain or repositioning of injector wire when harness is installed correctly.

1. FEED HARNESS (1) INTO CYLINDER HEAD HARNESS HOLE (2) AT REAR OF CYLINDER HEAD (3).

2. POSITION INJECTOR WIRES (4) IN CYLINDER HEAD (3) SO WIRES FOLLOW INSIDE RAIL OF CYLINDER HEAD ON OIL COOLER SIDE OF ENGINE UNDER ENGINE RETARDER ASSEMBLY.

3. BEGIN WITH TWO LONGEST INJECTOR WIRES AND INSTALL TERMINALS (5) OVER SCREWS (6) ON NO. 1 (FRONT) INJECTOR. TIGHTEN SCREWS TO 12-17 LB-IN. (1.25-1.92 N.m).

4. FOLLOW SAME PROCEDURE FOR INSTALLING REMAINING INJECTOR WIRES.

TM page 4-5

Illustration from TM 9-2320-363-34-1 (PDF page 365)

5. INSTALL HARNESS LEAD (7) ON ENGINE RETARDER SOLENOID TERMINAL (8).

6. FOLLOW SAME PROCEDURE FOR INSTALLING REMAINING TWO HARNESS LEADS ON ENGINE RETARDER SOLENOID TERMINALS.

7. ALINE BOLT HOLES OF HARNESS PROTECTOR (9) AND HARNESS PLATE (10) WITH BOLT HOLES IN CYLINDER HEAD. INSTALL TWO BOLTS (11) AND HARNESS PROTECTOR (9) ON HARNESS PLATE (10). TIGHTEN BOLTS TO 7-11 LB-FT (10-15 N.m).

NOTE

Make sure injector wires are positioned against cylinder head rail away from possible contact with exhaust valve springs.

8. INSERT GUIDE CLIP (12) INTO OIL DRAIN HOLE AT REAR OF CYLINDER HEAD (3) TO RETAIN INJECTOR WIRES IN CORNER AWAY FROM EXHAUST VALVE SPRINGS.

NOTE

Install black connector in bottom terminal and grey connector in top terminal. Connectors have different guide ridges that correspond to grooves in terminals.

9. INSERT TWO INJECTOR WIRING HARNESS CONNECTORS (13) INTO TOP AND BOTTOM OUTBOARD TERMINALS OF ELECTRONIC CONTROL MODULE (14). MAKE SURE LOCKING TANGSON INJECTOR WIRING HARNESS CONNECTORS ARE ENGAGED.

NOTE Follow-on Maintenance:

Install rocker cover (page 3-71).

TM page 4-6