Electrical Connector - Moisture Sealing Kit

CATEGORY
Electrical

SECTION
3

ISSUE
09/96-0707

PAGE
95

CODE
371

Subject:
Repair Kit to Seal Bosch Electrical Connectors from Moisture

Application:
All -1994 9000 Models
All -1993 and 1994 900 Models

A kit is now available for sealing moisture out of Bosch 2-pin up to 7-pin connectors used in the engine compartment wiring.

Cars Affected:

All-1994 9000 models.
All-1993 and 1994 900 models.

Parts:

Kit 46 68 737
(includes shrink hose and adhesive)
Kontakt 61 Connector cleaner 30 04 520

Action:

NOTE:
This kit is for use with 2-pin up to 7-pin Bosch connectors (item 1, Figure 1), but not the new scat-sealed connectors (item 2, Figure 1).

1. Unplug the connector from the component.





2. Peel back the connector's rubber shroud (item 3, Figure 2).

3. Mark the leads and remove them from the connector.

4. Slide the rubber shroud off the electrical cable.

5. Inspect the cable terminals for moisture and corrosion.

Note:
To avoid future corrosion problems, replace goldplated pins with gold-plated pins, and tin-plated pins with tin-plated pins.

Note:
Do not spray contact cleaner on oxygen sensor contacts.

6. If the cable contact pins are corroded, replace the pins. Otherwise, blow away any moisture or dirt, then spray the terminals (except oxygen sensor contacts) with Kontakt 61 contact cleaner (P/N 30 04 520).





7. If the cable has PVC sheathing, cut away 70mm of sheathing (see Figure 3).

8. Slide the shrink hose, then the adhesive sleeve, and then the rubber shroud over the cable.

9. Put the leads back in the connector and pull the end of the rubber shroud back over the connector.

10. Position the adhesive sleeve about 20 mm from the rear edge of the rubber shroud (see Figure 3).

11. Pull the shrink hose forwards so that it covers the edge of the rubber shroud (leave a space between the shrink hose and PVC sheathing, if any, at the other end).

Warning
Risk of fire or explosion. The use of a cigarette lighter or other kind of exposed flame can cause a fire or ignite gasoline vapor in the engine compartment. Use a heat gun to apply heat to the shrink hose and adhesive.





12. Starting at the edge of the rubber shroud and working back (see Figure 4), carefully heat the shrink hose with a heat gun. Continue to apply heat until shrinking is complete and the adhesive has melted.

13. Plug the connector into the component.

Warranty Information:

Regular warranty rules apply. Damage reporting in accordance with standard times. Submit a claim using the following information:

Failure coding: 37110-66-5-01-05.

Straight time 0.3 hr. for first repair and 0.2 for hr. for each additional repair.

Note:
Claim text must identify specific connector.