09600-03270 PUMP ASSY, INJECTI Denso Cross

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(1) Correctly Routed Harness (2) Correctly Inserted Plug (3) Incorrectly Routed Harness (4) Incorrectly Inserted Plug
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Proper Installation of Plug
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DT Type sealing plugThe 8T-8729 Connector Pin (2) and the 8T-8730 Connector Socket (1) is designed to accept only one 16/18 AWG wire. Do not insert multiple wires of a smaller wire size. An incorrect method would be using two 24 AWG wires. The 9W-0852 Connector Pin and the 9W-0844 Connector Socket is designed to accept only one 14 AWG wire. Do not insert multiple wires of a smaller wire size. An example of an incorrect method is the use of two 20 AWG wires.
CHECK THE CONNECTORS.
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. Verify that the latch tab of the connector is fully latched. Expected Result: The connector will securely lock. The connector and the locking mechanism are without cracks or breaks.Results:OK - The connector will securely lock. The connector and the locking mechanism are without cracks or breaks. Proceed to test Step 2. NOT OK - A problem exists with the connector.Repair: Repair the connector or replace the connector, as required.STOP.
CHECK THE ALLEN HEAD SCREW ON THE HARNESS CONNECTOR OF THE ECM.
Ensure that the connector bolt is properly tightened. Be careful not to tighten the bolt too much. The bolt may break.
Do not exceed 6.0 N m (53.0 lb in) of torque on the connector bolt of the harness when the connector is being installed on the ECM. Expected Result: The harness connector is secure and the connector bolt of the ECM is properly torqued.Results:OK - The harness connector is secure and the connector is properly torqued. Proceed to test Step 3.NOT OK - A problem exists with the connector.Repair: Secure the harness connector of the ECM. Ensure that the connector bolt is properly torqued.STOP.
PERFORM A PULL TEST ON EACH CONNECTOR CONTACT.
Each connector contact should withstand 45 N (10 lb) of pull. Each wire should remain in the connector body. This test checks whether the wire was properly crimped in the contact and whether the contact was properly inserted into the connector.
The DT connectors use an orange wedge to lock the terminals in place.
Check in order to ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors.Note: A Crimp Tool should ALWAYS be used in order to crimp wires on connector contacts. Do not solder the terminals. Use the proper Crimp Tool.Expected Result: Each connector contact should withstand 45 N (10 lb) of pull. Each wire remains in the connector body. Results:OK - Each connector contact withstands 45 N (10 lb) of pull. Each wire remains in the connector body. Proceed to test Step 4.NOT OK - A problem exists with the connector.Repair: Repair the wiring or replace the connector contact.STOP.
CHECK THE WIRES FOR NICKS OR ABRASIONS IN THE