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SMCS - 1408
Do not perform any procedure in this Special Instruction until you read this information and you understand
this information. This Special Instruction is intended for the installation of the 257-4183 Injector Wiring
Harness Kit . The 257-4183 Injector Wiring Harness Kit can be used to repair fuel injector connectors.
Table 1
Required Tools
Tool Part Number Part Name Qty
The following steps can be used in order to remove a faulty connector for an injector on the wire harness
that is located under the valve mechanism cover.
1. Identify the connector that needs to be replaced. Wiring for the injector solenoid is not sensitive to
polarity.
2. Cut wire (1) at a distance of 70 mm (2.8 inch) from the rear surface of the connector.
3. Cut wire (2) at a distance of 65 mm (2.6 inch) from the rear surface of the connector.
Illustration 2 g01111314
(3) Wire from the harness for side (B) on the connector
(4) Wire from the harness for side (A) on the connector
Note: The wires on the old connector are cut to length so that the wires on the wire harness will
match up to the new connector. Cutting the wires to the proper length will aid in matching the harness
wires to the wires on the new connector.
The following steps can be used in order to install a new connector for an injector on the wire harness that
is located under the valve mechanism cover.
BDC for engine manuals and specs
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1. Use Tool (A) in order to remove 5 mm (0.2 inch) of the plastic from wires (3) and (4) .
Illustration 3 g01111333
(3) Wire from the harness for side (B) on the new connector
(4) Wire from the harness for side (A) on the new connector
(6) Butt splice on the wire that is on side (A) of the new connector
(7) Butt splice on the wire that is on side (B) of the new connector
2. Use heat shrink tubes (5) from the 257-4183 Injector Wiring Harness Kit . Slide the heat shrink tubes
toward the connector in order to expose the butt splices.
(6) Butt splice on the wire that is on side (A) of the new connector
(7) Butt splice on the wire that is on side (B) of the new connector
5. Use Tool (A) to crimp butt splices (6) and (7) in order to secure the wires together.
Illustration 5 g01035814
6. Slide the heat shrink tubes (5) over the splices. Evenly cover the splices with the heat shrink tubes.
7. Use Tool (B) to heat the heat shrink tubes. Heat the tubes until the tubes shrink around the wires.