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SERVICE BULLETIN

NUMBER: SB-724-005
DATE: 8/10/01
MODEL: V-MAC® III
(Also applies to Mack Trucks Australia)

ENGINE ELECTRONIC CONTROL UNIT CONNECTOR TERMINAL,


COOLANT LEVEL SENSOR AND J1939 HARNESS SECTION
REPLACEMENT
Replacement terminals, wire seals and plugs used for the EJ1 and EJ2 connector
assemblies for the V-MAC® III Engine Electronic Control Unit (EECU) are available through
the MACK Parts System. Part numbers for the connector replacement components are as
follows:

Part No. Description


296-9299371 Terminal, female, for 2.0 wire size
296-9299391 Terminal, female, for 0.5 wire size
296-9680152 Micro-terminal, female, for 0.5 wire size
296-8289051 Seal, for 2.0 wire size
296-9635301 Seal, for micro-terminal, 0.5 wire size
296-8289041 Seal, for 0.5 wire size
296-8289221 Plug, for 2.0 connector cavities
296-9635311 Plug, for 0.5 and 0.5 micro-terminal connector cavities

When damaged connector terminals are encountered, the damaged terminals should be
replaced rather than replacing the entire harness assembly.

The most common type of connector damage is corrosion caused by moisture that has
entered the EECU connectors. Moisture can enter the EECU connectors in either of the
following ways:
앫 The seal on the J1939 connector located on the cab bulkhead may be distorted or
missing entirely. A missing or distorted seal may allow moisture to “wick” down the
J1939 harness and collect inside the EJ2 connector.
앫 The coolant level sensor may be leaking internally, allowing coolant to enter into the
electrical connection side of the sensor. Cooling system pressure may then force
coolant into the harness. Coolant may then migrate along the wire (inside the
insulation) and eventually collect in the EJ2 connector.

When repairing corroded connector terminals, the source of the moisture entry into the
connector must be identified and corrected before the vehicle is put back in service. If the
source of moisture entry is not repaired, repeat failures will occur.

SB-724-005 — Page 1 of 11
SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 ©MACK TRUCKS, INC. 2001
If the source of moisture entry into the EECU connectors was determined to be either the
J1939 line or the coolant level sensor, the following replacement harnesses are available.
These harnesses are supplied complete with cable or wire seals and terminals so that the
harness is ready to be connected to the EJ2 connector.
앫 41MR31306M — J1939 line, unshielded (2-wire harness)
앫 41MR31307M — J1939 line, shielded (3-wire harness)
앫 41MR31308M — Coolant level sensor harness
“Enhanced seal” connectors are available through the MACK Parts System to replace the
existing harness connectors on the cab section of the J1939 line. Part numbers for the
connectors are as follows:

Part No. Description


955AM27 Connector, J1939 line, cab harness side, heat shrink application
955AM23 Connector, J1939 line, cab harness side, non-heat shrink application
971AM49 Wedge lock, blue

When the section of the J1939 harness from the EECU to the cab harness is to be replaced,
the mating connector on the cab harness section MUST be replaced with a new “enhanced
seal” connector to avoid repeated terminal pin corrosion damage due to moisture. If the
J1939 cab harness section has heat shrink applied to the back of the connector body and a
long terminal pin (approximately 2 inches) is used for the bare shield wire (connector cavity
C), use the replacement connector body part No. 955AM27 and a blue wedge lock part No.
971AM49. Heat shrink must be re-applied to the back of the connector body and harness as
it was on the original harness connector.

If the J1939 cab harness section does not have heat shrink applied to the harness and a
short terminal is used for the shield wire (connector cavity C), or if the harness is the un-
shielded-type, use replacement connector body part No. 955AM23 and a blue wedge lock
part No. 971AM49. Do not apply heat shrink to the connector body or harness for this
application.

When replacing a harness section, do not cut the main harness apart in an attempt to
remove the wires being replaced. Release the wires from the connector and trace them
back to the point where they enter the harness loom. Cut the wires at that point. Trace the
wires from the opposite end (at the coolant level sensor or the J1939 connector) to where
they enter the main harness loom and cut the wires at that point. Starting at the EECU
connector, overlay the replacement harness and route it along the main harness to the point
where the original wires exited the harness loom. At that point, route the overlay harness as
required to reach the intended connection point. Use tie wraps to secure the overlay
harness to the main harness.

SB-724-005 — Page 2 of 11
For warranty reimbursement, both ends of the harness being
replaced must be returned to the Warranty Department to verify
installation of the overlay harness. Additionally, if a J1939
harness is replaced, the connector from the cab harness section
must also be returned to the Warranty Department. For
instructions on returning warranty parts, refer to CD No. 3,
Service Standards Manual and Warranty Administration Manual.

Terminal Replacement Procedures

Procedures for terminal replacement are as follows:


1. Identify the damaged or corroded terminal. Select the terminal type. The following will
aid in identifying the terminal type, part numbers, circuit and wire identification.
1

Figure 1 — EJ1 Connector Pin Locations

EJ1 CONNECTOR
Terminal Terminal Part Nos. Circuit Connection Circuit
No. Type Identification
1 Plug 296-9635311, plug Unused —
or or or or
0.5 296-9680152, micro-terminal Oil level sensor EJ1-1-0.5
296-9635301, micro-seal
2 Plug 296-9635311, plug Unused —
3 Plug 296-9635311, plug Unused —
4 Plug 296-9635311, plug Unused —
5 0.5 296-9680152, micro-terminal Engine oil temperature EJ1-5A-0.5
296-9635301, micro-seal
6 Plug 296-9635311, plug Unused —

SB-724-005 — Page 3 of 11
Terminal Terminal Part Nos. Circuit Connection Circuit
No. Type Identification
7 0.5 296-9680152, micro-terminal Freon high pressure switch EJ1-7-0.5
296-9635301, micro-seal
8 Plug 296-8289221, plug Unused —
9 2.0 296-9299371, terminal Fan clutch solenoid EJ1-9-2.0
296-8289051, seal
10 2.0 296-9299371, terminal Unit pump No. 1 (Low side) EJ1-10-2.0
296-8289051, seal
11 2.0 296-9299371, terminal Unit pump No. 5 (Low side) EJ1-11-2.0
296-8289051, seal
12 2.0 296-9299371, terminal Unit pump No. 6 (Low side) EJ1-12-2.0
296-8289051, seal
13 Plug 296-9635311, plug Unused —
14 Plug 296-9635311, plug Unused —
15 0.5 296-9680152, micro-terminal Inlet air pressure EJ1-15-0.5
296-9635301, micro-seal
17 0.5 296-9680152, micro-terminal V-MAC coolant temperature EJ1-17-0.5
296-9635301, micro-seal sensor
18 0.5 296-9680152, micro-terminal Engine position sensor (1) EJ1-18-0.5
296-9635301, micro-seal
19 0.5 296-9680152, terminal Engine position sensor (2) EJ1-19-0.5
296-9635301, seal
20 2.0 296-9299371, terminal Engine brake, unit 2 EJ1-20-2.0
296-8289051, seal
21 2.0 296-9299371, terminal Engine brake, unit 1 EJ1-21-2.0
296-8289051, seal
22 2.0 296-9299371, terminal Unit pump No. 2 (low side) EJ1-22-2.0
296-8289051, seal
23 2.0 296-9299371, terminal Unit pump No. 3 (low side) EJ1-23-2.0
296-8289051, seal
24 2.0 296-9299371, terminal Unit pump No. 4 (low side) EJ1-24-2.0
296-8289051, seal
25 0.5 296-9680152, micro-terminal Ground, engine oil pressure EJ1-25-0.5
296-9635301, micro-seal sensor
26 0.5 296-9680152, micro-terminal Ground, engine oil, fuel, coolant EJ1-26-0.5
296-9635301, micro-seal and inlet air temperature sensors
27 0.5 296-9680152, micro-terminal Inlet air temperature sensor EJ1-27-0.5
296-9635301, micro-seal
28 0.5 296-9680152, micro-terminal Fuel temperature sensor EJ1-28-0.5
296-9635301, micro-seal
29 Plug 296-9635311, plug Unused —
30 0.5 296-9680152, micro-terminal Engine speed sensor (1) EJ1-30-0.5
296-9635301, micro-seal
31 0.5 296-9680152, micro-terminal Engine speed sensor (2) EJ1-31-0.5
296-9635301, micro-seal

SB-724-005 — Page 4 of 11
Terminal Terminal Part Nos. Circuit Connection Circuit
No. Type Identification
32 0.5 296-9680152, micro-terminal Engine oil pressure sensor (B) EJ1-32-0.5
296-9635301, micro-seal
33 Plug 296-9635311, plug Unused —
34 0.5 296-9680152, micro-terminal Engine oil pressure sensor (C) EJ1-34-0.5
296-9635301, micro-seal
35 0.5 296-9680152, micro-terminal Inlet air pressure sensor (B) EJ1-35-0.5
296-9635301, micro-seal
36 0.5 296-9680152, micro-terminal Inlet air pressure sensor (C) EJ1-36-0.5
296-9635301, micro-seal
37 Plug 296-9635311, plug Unused —
38 Plug 296-9635311, plug Unused —
39 Plug 296-8289221, plug Unused —
40 Plug 296-8289221, plug Unused —
41 2.0 296-9299371, terminal Unit pumps 4, 5, 6 (high side) EJ1-41-2.0
296-8289051, seal
42 2.0 296-9299371, terminal Unit pumps 1, 2, 3 (high side) EJ1-42-2.0
296-8289051, seal
43 Plug 296-8289221, plug Unused —

Figure 2 — EJ2 Connector Pin Locations

EJ2 CONNECTOR
Terminal Terminal Part Nos. Circuit Connection Circuit
No. Type Identification
1 Plug 296-9635311,plug Unused —
2 Plug 296-9635311, plug Unused —
3 0.5 296-9680152, micro-terminal Engine coolant level EJ2-3-0.5
296-9635301, micro-seal

SB-724-005 — Page 5 of 11
Terminal Terminal Part Nos. Circuit Connection Circuit
No. Type Identification
4 Plug 296-9635311, plug Unused —
5 Plug 296-9635311, plug Unused —
6 Plug 296-9635311, plug Unused —
7 Plug 296-9635311, plug Unused —
8 0.5 296-9299391, terminal J1939 (A) yellow VJ3-1-0.8
296-8289041, seal
9 Plug 296-8289221, plug Unused —
10 2.0 296-9299371, terminal 12V+ fuse 40 EPDM EJ2-10-2.0
296-8289051, seal
11 Plug 296-8289221, plug Unused —
12 2.0 296-9299371, terminal Ground at engine block BK-5-2.0
296-8289051, seal
13 Plug 296-9635311, plug Unused —
14 Plug 296-9635311, plug Unused —
15 Plug 296-9635311, plug Unused —
16 Plug 296-9635311, micro-plug Unused —
or or or or
0.5 296-9680152, micro-terminal Air cleaner restriction EJ2-16-0.5
296-9635301, micro-seal
17 Plug 296-9635311, plug Unused —
18 Plug 296-9635311, plug Unused —
19 Plug 296-9635311, plug Unused —
20 0.5 296-9299391, terminal J1939 (C) bare wire (when used) VJ3-3-0.5
296-8289041, seal
21 Plug 296-8289221, plug Unused —
22 2.0 296-9299371, terminal 12V + fuse 40 EPDM EJ2-22-2.0
296-8289051, seal
23 Plug 296-8289221, plug Unused —
24 2.0 296-9299371, terminal Ground at engine block BK-T-2.0
296-8289051, seal
25 Plug 296-9635311, plug Unused —
26 0.5 296-9680152, micro-terminal Engine coolant level sensor EJ2-26-0.5
296-9635301, micro-seal
27 0.5 296-9680152, micro-terminal Ground, ambient air temperature EJ2-27-0.5
296-9635301, micro-seal sensor
28 Plug 296-9635311, plug Unused —
29 0.5 296-9680152, micro-terminal Ambient air temperature sensor EJ2-29-0.5
296-9635301, micro-seal
30 Plug 296-9635311, plug Unused —
31 0.5 296-9680152, micro-terminal J1587+ VJ3-14-0.5
296-9635301, micro-seal
32 Plug 296-9635311, plug Unused —

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Terminal Terminal Part Nos. Circuit Connection Circuit
No. Type Identification
33 Plug 296-9635311, plug Unused —
34 Plug 296-9635311, plug Unused —
35 0.5 296-9680152, micro-terminal Torque limit EJ2-35-0.5
296-9635301, micro-seal
36 Plug 296-9635311, plug Unused —
37 Plug 296-9635311, plug Unused —
38 0.5 296-9680152, micro-terminal J1587 VJ3-15-0.5
296-9635301, micro-seal
39 0.5 296-9299391, terminal J1939 green VJ3-2-0.8
296-8289041, seal
40 Plug 296-8289221, plug Unused —
41 2.0 296-9299371, terminal 12V+ fuse 40 EPDM EJ2-41-2.0
296-8289051, seal
42 Plug 296-8289221, plug Unused —
43 2.0 296-9299371, terminal Ground at engine block BK-U-2.0
296-8289051, seal

2. Select the correct release tool for the terminal to be replaced. There are two different
tools for releasing the different terminals from the connector. Tool part numbers are as
follows:
앫 Tool No. J 44786 — releases micro-terminal part No. 296-9680152 for 0.5 wire
size
앫 Tool No. J 44787 — releases terminal part No. 296-9299371 for 2.0 wire size and
terminal part No. 296-9299391 for 0.5 wire size

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3. Cut the tie wrap that secures the connector to the harness.
3

Figure 3 — Cutting Connector Tie Wrap

4. Remove approximately two inches of black tape from the harness.


5. Unlock the rear portion of the connector cover from the main connector body. This
procedure requires two small screwdrivers to disengage the tabs at the four locations,
and prying the connector cover away from the connector body.

It may be easier to disengage the tabs at one end of the


connector and pry the cover away from the connector body at
that end, then disengaging the tabs at the other end of the
connector. Use care so as to not break or crack any component.

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4

Figure 4 — Unlocking Rear Portion of Connector

Figure 5 — Unlocking Front Portion of Connector

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6. Remove the cover. This allows access to the rear of the main connector body.
6

Figure 6 — Removing Strain Relief

7. Move the secondary locks in the front (mating end) of the connector to the unlocked
position.
7

Figure 7 — Secondary Locks in Unlocked Position

8. Insert the proper terminal removal tool into the connector cavity and make sure that the
tool is fully inserted. If the tool is not fully inserted, the terminal locking tabs will remain
engaged and prevent releasing the terminal. To facilitate removal, pull firmly on the
wire while holding the connector body securely in place. If the terminal does not
release, re-check the position of the secondary locks, and check for proper installation
of the release tool.

SB-724-005 — Page 10 of 11
9. Cut the wire just behind the damaged terminal. Remove the terminal seal.

If there is not enough wire to allow installation of the new


terminal and cable or wire seal, splice a section of the correct
gauge wire to the main harness to provide sufficient length.
When selecting wire for the splice, be sure to use wire having
the same temperature and fluid resistance properties as the
harness wire. Additionally, the outside diameter of the wire
(insulation) must be of the proper size to be compatible with the
cable seals. A section of wire from a discarded engine harness
would be a good choice for the splice.

10. Install a new terminal seal, and then strip approximately 3/8" of insulation from the wire.
11. Crimp the new terminal to the wire, and then crimp the terminal seal in place.

Proper crimping is essential. It will be difficult to insert an


improperly crimped terminal into the connector body, and it may
also not be possible to set the secondary locks. Be sure to use
the proper crimping tools supplied with the terminal tool kit.

12. Reinstall the terminal into the proper connector cavity. Apply firm pressure to the wire
to ensure that the terminal locking tabs engage in the connector body.
13. When the terminal locks in place, gently tug on the wire to ensure that the terminal
locking tabs have engaged the connector body.
14. Set the secondary locks.
15. After replacing all damaged terminals, reassemble the connector cover to the body, re-
tape the harness and install a new tie wrap.

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