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Broken wire on crank sensor


 

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This seems to be a common issue. Likely due to location given the heat and vibration and the 90 degree bend of the cable right at the sensor it’s kind of doomed to fail. This is a sohc na 2.5, 2002.?

What I found on my harness is that the injector connectors are the same as the crank sensor connector, the wiring is copper shielded however so I was careful not to lose too much of the copper braid. I ended up soldering the ends of the wire or “tinning” them as it’s called and then used heat shrink crimped connectors and covered the whole thing in 3 to 1 glued heat shrink. While the heat shrink was cooling I put a 90 degree bend in the whole package so it wouldn’t be bent against its will down the road.?

Finally I tested the whole mess at the engine bay harness connector (grey one) for resistance with a sensor connected and got 1.9 kilo ohms which seems to be inline with what that sensor puts out.?

All in all stressful but it seems successful.?

Picture of before. I also added a picture of my rebuilt heads as that was a much more successful mission yesterday lol?

John?


 

You’re right. That 90 degree bend kills the crank sensor wires. On mine the cover was frayed and worn but the wires were intact. I re-wrapped them and hope for the best. ?
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Warren
89 Westy?
88 Tintop
70 Westy