Servicing the Tong Hae (Dong Hae) Wiring Harness
Figure 8. Identification of wiring harness connectors.:
Servicing the Tong Hae (Dong Hae) Wiring Harness
1. Disconnect the negative (-) battery cable.
2. Referring to Figure 8, disconnect the following ECU wiring harness connectors and ground wires located underneath the driver's side of the dashboard: Connectors C50-1, C50-2, C50-3; Ground Wire G08; and Connectors MC01, MC02.
3. Referring to Figure 8, disconnect the following ECU wiring harness connectors and ground wires located in the engine compartment: C18 (A/C pressure switch); C20 (A/C compressor bullet); C21 (distributor); C39 (purge control solenoid valve); C41 (EGR control solenoid valve) (California specs. only); C40 (pre-excitation resistor); and G07 (ground wire attached to bulkhead).
Figure 9. Removal of wiring loom cover.:
Remove the three bolts attaching the square shaped ECU wiring loom cover. The cover is attached to the surge tank in the engine compartment. (Figure 9)
Remove the tie wrap holding the EGR/ purge control solenoid valve wiring (connectors C39, C40, and C41) to the accelerator cable.
Figure 10.:
4. Remove the rubber ECU wiring harness grommet from the bulkhead and carefully pull the passenger compartment side of the harness into the engine compartment only six inches.
The Throttle Position Sensor (TPS) crimp connection splice is located between the square shaped ECU wiring loom cover and the bulkhead grommet. Refer to Figure 10.
Figure 11. Exposing the crimp connection splice.:
5. Carefully slice the tape wrapping around the plastic wiring conduit. Open the conduit to expose the TPS crimp connection splice.
The splice will have four or five wires going into one side, and two wires going into the other. Refer to Figure 11.
Figure 12. Removing the crimp connection splice.:
6. Cut one inch on each side of the crimp connection splice and discard it. Strip off 1/2 inch of insulation from ends of the remaining wires. See Figure 12.
Figure 13. Soldering new crimp connection splice.:
7. Fabricate a jumper harness to replace the discarded crimp connector splice. The jumper harness should be the same length as the splice. Use black, 12-gauge wire, and strip 1/2 inch of insulation from each end.
Crimp a 12-gauge, non-plastic crimp connector onto each end of the new jumper harness. Solder the crimp connectors according to instruction on Page 2 of this service bulletin. Also, refer to Figure 13.
8. Place the four or five wires into one end of the new jumper wire, and the remaining two wires into the other end. Crimp both ends and solder according to instructions on Page 2 of this service bulletin.
Figure 14. Re-taping the wiring harness.:
9. Wrap both soldered ends of the new jumper wire with electrical tape and place the wires back into the plastic wire conduit. Wrap the conduit tightly with electrical tape. See Figure 14.
10. Carefully feed the wiring harness back through the bulkhead and reinstall the rubber grommet. Install the square shaped ECU wiring loom cover. Reconnect all ground wires and connectors detached in Steps 2 and 3.
Replace all tie straps that were removed. Reconnect the negative battery cable.
IMPORTANT: Be sure all wiring is clear from moving parts and hot surfaces.
11. Use the Multi-Use Tester (MUT) to verify that idle speed and TPS voltages are within specification. If necessary, adjust idle speed and TPS voltages according to the 1990 Precis Service Manual, Pages 31-16/31-18, or the 1991 Precis Service Manual, Pages 31-20/ 31-22.
WARRANTY INFORMATION
Standard warranty procedures apply.