Power Solutions International — Weather-Pack Terminal Repair
Repair & overhaul · Connector
From a Power Solutions International service manual — check it applies to your exact model before use.
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Before you start
- Do not solder oxygen sensor wire terminals (used for sensor oxygen reference).
Procedure
- Open secondary lock hinge on connector.
- Remove terminal using tool.
- Cut wire immediately behind cable seal.
- Replace terminal: slip new seal onto wire, strip 5 mm (.2") insulation, crimp terminal over wire and seal.
- Push terminal into connector and engage locking tangs.
- Close secondary lock hinge.
Tools required
- Tool J M28742, or BT8234-A or equivalent Amazon
- Tachometer adapter J 35812 Amazon
- Connector test adapter kit J 35616 Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Strip 5 mm (.2") of insulation from wire
Source: Power Solutions International service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.