Wiring Connector Service - MerCruiser 305 CID (5.0L) Service Manual

FUEL INJECTION DESCRIPTIONS AND SYSTEM OPERATION
WIRE REPAIR
1. Locate damaged wire.
2. Remove insulation as required.
3. Splice two wires together using splice clips and rosin core solder.
4. Cover splice with heat shrink sleeve to insulate from other wires.

Wiring Connector Service

Most connectors in the engine compartment are protected against moisture and dirt that
could create oxidation and deposits on the terminals. This protection is important because
of the very low voltage and current levels found in the electronic system. The connectors
have a lock which secures the male and female terminals together. A secondary lock holds
the seal and terminal into the connector.
When diagnosing, open circuits are often difficult to locate by sight because oxidation or ter-
minal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor
or in the wiring harness may locate the open circuit condition. This should always be consid-
ered when an open circuit or failed sensor is indicated. Intermittent problems may also be
caused by oxidized or loose connections.
Before making a connector repair, be certain of the type of connector. Some connectors look
similar but are serviced differently. Replacement connectors and terminals are listed in the
Parts Catalog.
Ensure that the connector seals are not deformed or crushed when mating the connectors
together.
Index
Page 5D-6
SERVICE MANUAL NUMBER 24
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90-861327 OCTOBER 1999