KIT-GASKET 3156669 - Caterpillar

System Operation Description:Most electrical problems are caused by poor connections. The following procedure will assist in detecting problems due to connectors. If a problem is found in an electrical connector, repair the connector and verify that the problem does not return. Do not cut connector wires unless terminals are being replaced. Repair the connectors with a 1U-5804 Crimp Tool. The wedges on the DT connectors are easily removed with a 147-6456 Removal Tool.Intermittent electrical problems often disappear by disconnecting and reconnecting connectors. It is very important to check for diagnostic codes immediately before disconnecting a connector. Also check for diagnostic codes after reconnecting any connectors. If the status of a diagnostic code is changed due to disconnecting and reconnecting a connector, there are several possible reasons. The likely problems are loose or improperly crimped terminals, moisture, corrosion, or connectors not mated securely.ALWAYS crimp the terminals on the wires with the 1U-5804 Crimp Tool. Do not solder the terminals.
Illustration 1 g00675955
Connector receptacles (Deutsch) and connector plugs (Deutsch)
Illustration 2 g00665457
Harness routing and seal plugs
Test Step 1. Check the Locking of the DT Connector (Deutsch) and Check the Lock Ring of the HD Style Connector (Deutsch)
Ensure that the connector is properly locked. Also ensure that the two halves of the connector can not be pulled apart.
Verify that the latch tab of the connector is properly latched. Also verify that the latch tab of the connector returns to the locked position. Expected Result:The connector will securely lock. The connector and the locking mechanism are without cracks or breaks.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connector or replace the connector, as required.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Allen Head Screw on the Connector for the Electronic Control Module (ECM)
Ensure that the allen head screw is properly tightened. Be careful not to overtighten the screw and break the screw.
Do not exceed 2.25 N m (20 lb in) of torque on the allen head screw. Expected Result:The ECM connector is secure and the allen head screw is properly torqued.Results:
OK - Proceed to Test Step 3.
Not OK - Repair: Repair the connector or replace the connector, as required.Verify that the repair eliminates the problem.STOPTest Step 3. Perform a Pull Test on Each Wire Terminal Connection
Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
The DT connectors use a green wedge to lock the terminals in place. Ensure that the green wedge is not missing and that the green wedge is installed properly on the DT connectors. Note: Terminals should always be crimped onto the wires by using a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool.Expected Result:Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector