Service Procedure - Tong Hae (Dong Hae)

1. Disconnect the battery ground cable.

2. Under the crash pad on the drivers side, disconnect the ECU wiring harness connectors (C50-1,-2,-3) and ground wires (G08) from the ECU. Disconnect the two main wiring harness connectors (MC01,02). Remove the tie-strap from around the ECU wiring harness and main wiring harness.

3. In the engine compartment, disconnect the A/C pressure switch connector (C18), A/C compressor bullet connector (C20), distributor connector (C21), purge control solenoid valve connector (C39), EGR control solenoid valve connector (California spec. only) (C41), preexcitation resistor connector (C40), and ground wires leading to the firewall (G07). Remove the three bolts attaching the square ECU wiring loom cover to the surge tank. Remove the tie wrap holding the EGR/purge control solenoid valve wiring to the accelerator cable.

4. Pull the ECU wiring harness grommet out of the firewall and pull the wiring harness into the engine compartment about 6 inches.

5. The T.P.S. crimp connection splice is between the square E.C.U. wiring loom cover and the firewall grommet. Carefully slice the tape wrapped around the corrogated plastic wiring conduit and open up the conduit to expose the splice.


6. Cut the crimp connection out, about one inch on each side of the connector. Pull the wires apart. Strip approximately 1/2 inch of insulation from the end of each wire.
7. Make a jumper harness to replace the crimp connection that was cut out. The jumper should be about the same length as the piece of the connection that was cut out. The jumper is to be made from a length of black 12 gauge wire stripped 1/2 inch on each end. Install 12 gauge crimp connectors on both ends. The crimp connectors should be a solder type wfth no plastic insulation. Crimp the connectors onto both ends of the jumper wire and then solder following technique given on page 2.


8. Insert the two ground wires on the ECU wiring harness into one of the jumper wire connectors and crimp and solder. Insert the four (or five) black wires from the other end of the ECU wiring harness into the other connector of the jumper harness. Crimp and solder.


9. Wrap the two soldered connectors with electrical tape. Put the wire bundle back into the plastic conduit and rewrap tightly with electrical tape.


10. Push the wiring harness back through the firewall and reinstall the grommet. Reconnect all electrical connectors removed in steps 2 and 3 and screw the square ECU wiring loom cover back onto surge tank.

11. Verify that all wiring is clear of moving parts or hot components.

12. Check that the idle speed and TPS and MPS voltages are within specifications. If necessary, adjust according to the procedure given in the 1990 Excel Shop Manual pages 31-16 through 31-18.