ISB/ISBe Series Engines – 019-324   Coolant Level Shorting Plug

The connector is used to connect many different sensors and switches to the engine, OEM interface, and OEM harnesses. The connector can be a two-way or a four-way pin type. All types of connectors are repaired in the same manner. The four-way connector is displayed in this procedure.

NOTE: Make sure the correct wires are connected to the correct connectors. Refer to the wiring diagram in

Section E
of this manual.

To replace a Weather-Pack terminal (1), Lift up the locking tabs (2)
pull the electrical connectors apart (3) remove the sensor shorting plug (4).

NOTE: Verify that the new shorting plug has no cracks in the plastic shell or cuts in the rubber seal.

NOTE: Verify that the shorting wires are

not cut or damaged in the shorting plug.

Verify the continuity of the shorting plug.

Measure continuity from pin A to pin B, and from pin C to pin D.

The measurement should be 10 ohms or less.

If the measurement does

not meet the specification, repair or fabricate a coolant level shorting plug.

Open the wire lock.

NOTE: The wire is held in the connector body by the wire lock (1) and two locking lances (2) on the terminal.

CAUTION  This tool can be easily broken. Care must be taken when using this tool. Do not force the tool into place.

Insert the Weather-Pack extraction tool, Part Number 3822608, over the terminal.

Use a twisting motion to push the tool to the bottom of the cavity.

CAUTION  If more than one wire is being repaired, tag each wire, and install in the original location to reduce the possibility of incorrectly wiring the connector.

Pull the wire and the terminal out of the connector body.

NOTE: The repair wire and terminal is 127 mm [5 in] long.

Use wire cutters to cut 127 mm [5 in] off the terminal and wire.

The shorting plug is assembled as follows:

Connect pin A to pin B.

Connect pin C to pin D.

NOTE: The shroud connector bodies (1) use pin (male) terminals (2). The tower connector bodies (3) use socket (female) terminals (4).

The repair wire for the

pin terminal is Part Number 3822922.

The repair wire for the

socket terminal is Part Number 3822923.

The 4-pin Weather-Pack shroud is Part Number 3823341.

The 4-pin Weather-Pack tower is Part Number 3823342.

CAUTION  If more than one wire is repaired or if the connector body is replaced, be sure to insert the wires into the same locations as they were in the original connector to reduce the possibility of incorrectly wiring the connector to reduce the possibility of incorrectly wiring the connector.

Insert the terminal into the connector body. The terminal locking lances

must click and hold the terminal in the body.

Close and latch the wire lock on the connector body.

Verify the continuity of the shorting plug.

Measure continuity from pin A to pin B, and from pin C to pin D.

The measurement should be 10 ohms or less.

Insert the two connector halves together.