Distributor Harness - Connector Repair Procedure

90suzuki05
Division: Automotive

Category: Technical
TSB No. TS 4-09 10300

Section Title: Engine
SUBJECT: REPAIR OF DISTRIBUTOR HARNESS CONNECTOR

MODEL: SIDEKICK

YEAR: 1991


The purpose of this bulletin is to provide a repair procedure for the harness connector at the distributor on 1991 Sidekicks.



STEP 1

To remove the connector from the distributor: Press the tab at the bottom, rear of the connector. Then pull the connector away from the distributor.



STEP 2

Fashion a special tool from an old hacksaw blade as illustrated. The illustration is drawn full sized so it can be used as a template.



STEP 3

Using the special tool, pull the "orange plastic connector cap" out of the "connector housing" as shown. The cap fits tightly so this will require some force.



STEP 4

Pry the "contact latch" down and hold in the direction indicated by the arrow. While holding, pull the contact out the back of the connector housing.



STEP 5

The existing contact and gasket will need to be reused. And the new wire will have to be soldered onto the contact.
STEP 6

After wires have been resecured to the contact, push the contact back into the housing -- the latch will "snap" into position when the connector is full seated.
STEP 7

Snap the "orange plastic connector cap" back into position.