NHTSA ID Number: 10131020
Manufacturer Communication Number: IK1200166
TSB/Document Date: 2018-04-02
Summary
Replacing Terminal Pins on the Single Box (DLC) Engine Controller (ECM) Chassis Harness Connector
IK1200166 Replacing Terminal Pins on the Single Box (DLC) Engine Controller (ECM... Page 1 of 6
Countries:
AUSTRALIA, BRAZIL,
Document
CANADA, UNITED
IK1200166
STATES, PUERTO
ID:
RICO, SOUTH AFRICA
Availability:
Major
System:
Current
Language:
Other
Languages:
ISIS, Bus ISIS, FleetISIS Revision: 2
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ENGINES
Created:
English
Last
2/5/2014
Modified:
Français, Español,
Author:
10/24/2007
Randy
Geweniger
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Title : Replacing Terminal Pins on the Single Box (DLC) Engine Controller
(ECM) Chassis Harness Connector
Applies To : DLC International
Engines
This procedure allows a technician to replace broken pins on the chassis harness, 60 pin, ECM connector. This
procedure is intended to be used only when one or two pins need replaced. When replacement of a larger
number of pins is required, harness replacement is recommended.
PARTS INFORMATION
Parts Information
Part Number
Part Description
Quantity
2501100C1
1
The terminal and wire, Part Number 2501100C1, is included in Parts Kit ZTSE 4436.
SERVICE PROCEDURE
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Failure to remove the negative battery cables and the ECM power connector from the batteries in the
battery box before working on the ECM connector could cause personal injury as well as damage to
truck components.
Figure 1.
1. KNOB SCREW
2. KNOB ASSEMBLY
3. WIRE DRESS COVER
4. LOCKING TABS
5. FOAM BLOCK
1. Remove all of the negative battery cables and the ECM power connections from the batteries in the battery
box.
2. Remove the chassis harness connector from the ECM.
3. Remove tape from the connector cover end.
4. Remove the knob screw and the knob.
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5. Remove the wire dress cover ( Item 3, Figure 1 ) by prying the four tabs and gently pulling the cover from the
connector body.
6. Remove the RED secondary connector lock which retains the pin(s) to be replaced by prying with a small
screwdriver at the locations shown ( Figure 2 ). This will allow access to the connector lock and the pin.
Figure 2.
7. Gently pry and hold the connector lock away from the pin ( Figure 3 ). Pull the pin through the connector
body from the back side of the connector.
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IK1200166 Replacing Terminal Pins on the Single Box (DLC) Engine Controller (ECM... Page 4 of 6
Figure 3.
8. Cut the wire leading to the damaged connector at a point where good wire is available.
9. Cut the wire on terminal butt splice 2501100C1 ( Figure 4 ) to the appropriate length.
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IK1200166 Replacing Terminal Pins on the Single Box (DLC) Engine Controller (ECM... Page 5 of 6
Figure 4.
10. Splice the new terminal and wire to the old wire.
11. Insert the repaired terminal and wire into the proper cavity until it clicks. The pin should
lock in place.
12. Insert the secondary connector lock.
13. Re-assemble the connector cover and tightly wrap the end with two layers of tape.
14. Re-assemble the knob and tighten the knob screw to 5 in-lbs. of torque.
15. Reconnect the ECM connector and tighten to 35 inlbs. of torque.
16. Reconnect all of the negative battery cables and the ECM power connections to the
batteries in the battery box.
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TSB/Document ID: IK1200166
Replacement Service Bulletin Number:
MFR Communication Date: 2014-02-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
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