Distributor Wiring Harness Connector Repair (TS 4-09 10300)

WARNING: This page is about the Sidekick JL, which is a different variant/trim than selected.

Publication date: 1970-01-01
Reference number: TS 4-09 10300

DISTRIBUTOR WIRING HARNESS CONNECTOR REPAIR

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 4-09 10300, Date of Issue:

REPAIR OF DISTRIBUTOR HARNESS CONNECTOR

Model(s): 1991 Suzuki Sidekick

Bulletin No.: TS 4-09 10300

Group: Engine Mechanical

SERVICE INFORMATION

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

PROCEDURE FOR REMOVING DISTRIBUTOR CONNECTOR CONTACTS

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. See Fig 1 .

Fig 1: Distributor Connector Location

STEP 2

Fashion a special tool from an old hacksaw blade using the dimensions in Fig 2 .

Fig 2: Special Tool Illustration

STEP 3

Using the special tool, pull the orange plastic connector cap out of the connector housing as shown in Fig 3 . The cap fits tightly so this will require some force.

Fig 3: Connector Housing View

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. (See Fig 4 ).

Fig 4: Contact Latch Location

STEP 5

The existing contact and gasket will need to be reused. And the new wire will have to be soldered onto the contact. (See Fig 5 ).

Fig 5: Connector Contact Illustration

STEP 6

After wires have been secured 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.