Subaru J-47606 User manual

Harness
Repair
Kit
(Part # J-47606)

© Copyright 2004
Subaru of America, Inc.
All rights reserved. This book may not be
reproduced in whole or in part without the
express permission of Subaru of America, Inc.
Subaru of America, Inc. reserves the right at
any time to make changes or modifications to
systems, procedures, descriptions, and
illustrations contained in this book without
necessarily updating this document.
Information contained herein is considered
current as of December 2004.

Harness Repair Kit - Page 3Harness Repair Kit - Page 3
Harness Repair Kit - Page 3Harness Repair Kit - Page 3
Harness Repair Kit - Page 3
PRECAUTIONSPRECAUTIONS
PRECAUTIONSPRECAUTIONS
PRECAUTIONS ............................................................................................................................................................................................
............................................................................................................................................................................................
.............................................................................................. 44
44
4
COMPONENT LISTCOMPONENT LIST
COMPONENT LISTCOMPONENT LIST
COMPONENT LIST ................................................................................................................................................................................
................................................................................................................................................................................
........................................................................................ 55
55
5
REPAIR EXAMPLEREPAIR EXAMPLE
REPAIR EXAMPLEREPAIR EXAMPLE
REPAIR EXAMPLE..................................................................................................................................................................................
..................................................................................................................................................................................
......................................................................................... 88
88
8
TERMINAL LOCK RELEASE MANUALTERMINAL LOCK RELEASE MANUAL
TERMINAL LOCK RELEASE MANUALTERMINAL LOCK RELEASE MANUAL
TERMINAL LOCK RELEASE MANUAL ..................................................................................................................
..................................................................................................................
......................................................... 1212
1212
12
TERMINAL ADAPTATION TABLETERMINAL ADAPTATION TABLE
TERMINAL ADAPTATION TABLETERMINAL ADAPTATION TABLE
TERMINAL ADAPTATION TABLE ................................................................................................................................
................................................................................................................................
................................................................ 1414
1414
14
NEW SERVICE MANUAL PAGE, WIRING SYSTEM (EXAMPLE)NEW SERVICE MANUAL PAGE, WIRING SYSTEM (EXAMPLE)
NEW SERVICE MANUAL PAGE, WIRING SYSTEM (EXAMPLE)NEW SERVICE MANUAL PAGE, WIRING SYSTEM (EXAMPLE)
NEW SERVICE MANUAL PAGE, WIRING SYSTEM (EXAMPLE) ................................
................................
................ 1515
1515
15
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS

Page 4 - Harness Repair KitPage 4 - Harness Repair Kit
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Page 4 - Harness Repair Kit
PRECAUTIONSPRECAUTIONS
PRECAUTIONSPRECAUTIONS
PRECAUTIONS
(1) Wear protective clothing, including a cap, protec-
tive goggles, and protective shoes during operation.
(2) Remove contamination (including dirt and corro-
sion) before terminal pin removal, installation, or disas-
sembly.
(3) Keep the parts disassembled in order and protect
them from dust or dirt.
(4) Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal,
installation, disassembly, and replacement.
(5) Use caution when working on a vehicle that has
been running since some vehicle components will be
very hot to the touch.
(6) Be sure to tighten fasteners such as bolts and nuts
to the specified torque described on the service
manual if applicable.
(7) Before disconnecting electrical connectors of
sensors, be sure to disconnect the ground cable from
battery.
(8) All removed parts, if to be reused, should be rein-
stalled in the original positions and directions.
(9) Bolts, nuts, and washers should be replaced with
new ones as required.
(10) Be sure to protect the vehicle from dirt and dam-
age.
(11) Do not apply rotational torqure to pin removal
tools. Such torque will damage or break the tool itself.

COMPONENT LISTCOMPONENT LIST
COMPONENT LISTCOMPONENT LIST
COMPONENT LIST
Joint piece (Small size): RK-JFA-001
Joint piece (Large size): RK-JFA-002
Insulation adhesive: RK-BFA-003
Repair terminal: RK-TFA-015 (Gilded
Terminal)
Repair terminal: RK-TFA-019
Repair terminal: RK-TFA-020
Repair terminal: RK-TFA-021
Repair terminal: RK-TFA-022
Repair terminal: RK-TFA-023
Repair terminal: RK-TFA-024 (Gilded
terminal)

Repair terminal: RK-TFA-025
Repair terminal: RK-TFA-026
Repair terminal: RK-TFA-028
Repair terminal: RK-TFA-043
Terminal lock release tools:Terminal lock release tools:
Terminal lock release tools:Terminal lock release tools:
Terminal lock release tools:
Removal Tool No. 5 (J-47606-5)
Removal Tool No. 6 (J-47606-6)
Removal Tool No. 7 (J-47606-7)
Removal Tool No. 8 (15315247)
Removal Tool No. 9 (J-42019)

Terminal crimpers
Heat shrink tubing (J-47606-3)
Heat shrink tubing (J-47606-4)
Kit locator guide
Upper tray
Upper and lower trays

Page 8 - Harness Repair KitPage 8 - Harness Repair Kit
Page 8 - Harness Repair KitPage 8 - Harness Repair Kit
Page 8 - Harness Repair Kit
1. Using a thin screw driver, push up the double lock-
ing piece on the connector.
2. Remove the locking piece from the connector.
3. Insert the terminal pick release tool into the terminal
hole and pull the terminal out.
4. Cut the defective terminal from the harness.
REPAIR EXAMPLEREPAIR EXAMPLE
REPAIR EXAMPLEREPAIR EXAMPLE
REPAIR EXAMPLE

Harness Repair Kit - Page 9Harness Repair Kit - Page 9
Harness Repair Kit - Page 9Harness Repair Kit - Page 9
Harness Repair Kit - Page 9
5. Using a pair of wire strippers, remove 10mm of
insulation from the original harness.
6. Crimp the original harness and the repair harness
with a joint piece (RK-JFA-001 or RK-JFA-002) using
the terminal crimpers.
7. Solder is applied to complete the joint.
8. Wrap insulation tape around the joint of the two
harnesses.

Page 10 - Harness Repair KitPage 10 - Harness Repair Kit
Page 10 - Harness Repair KitPage 10 - Harness Repair Kit
Page 10 - Harness Repair Kit
9. If the joint is installed in a location of moisture,
humidity, and/or dust, apply a piece of waterproof
adhesive around the joint (RK-BFA-003).
10. Wrap insulation tape over the adhesive.
11. Insert the terminal into the terminal hole of the
connector until it stops completely.
12. Fasten the repair harness on the original harness
with insulation tape.

Harness Repair Kit - Page 11Harness Repair Kit - Page 11
Harness Repair Kit - Page 11Harness Repair Kit - Page 11
Harness Repair Kit - Page 11
13. Confirm that harness is not kinked or wound ex-
cessively.
14. Reinstall the double locking piece to the connector.
15. Push down the side of the locking piece until it
locks completely.

Page 12 - Harness Repair KitPage 12 - Harness Repair Kit
Page 12 - Harness Repair KitPage 12 - Harness Repair Kit
Page 12 - Harness Repair Kit
Manual No. RM-5Manual No. RM-5
Manual No. RM-5Manual No. RM-5
Manual No. RM-5
1) Release the lock on the connector.
2) Remove the locking piece from the connector.
3) Using the appropriate terminal pick release tool,
remove the defective terminal.
TERMINAL LOCK RELEASE MANUALTERMINAL LOCK RELEASE MANUAL
TERMINAL LOCK RELEASE MANUALTERMINAL LOCK RELEASE MANUAL
TERMINAL LOCK RELEASE MANUAL

Harness Repair Kit - Page 13Harness Repair Kit - Page 13
Harness Repair Kit - Page 13Harness Repair Kit - Page 13
Harness Repair Kit - Page 13
Manual No. RM-9Manual No. RM-9
Manual No. RM-9Manual No. RM-9
Manual No. RM-9
1) Release the lock on the connector.
2) Remove the locking piece from the connector.

Page 14 - Harness Repair KitPage 14 - Harness Repair Kit
Page 14 - Harness Repair KitPage 14 - Harness Repair Kit
Page 14 - Harness Repair Kit
TERMINAL ADAPTATION TABLETERMINAL ADAPTATION TABLE
TERMINAL ADAPTATION TABLETERMINAL ADAPTATION TABLE
TERMINAL ADAPTATION TABLE
SPX Tool No.SPX Tool No.
SPX Tool No.SPX Tool No.
SPX Tool No. Removal ToolRemoval Tool
Removal ToolRemoval Tool
Removal Tool Part No.Part No.
Part No.Part No.
Part No. WireWire
WireWire
Wire Wire ColorWire Color
Wire ColorWire Color
Wire Color
DELPHI 15315247 No8 RK-TFA-011 1.25 B
DELPHI 15315247 No8 RK-TFA-012 0.5 R
J47606-6 No6 RK-TFA-013 0.5 R
J47606-6 No6 RK-TFA-014 0.5 R/W
J-42019 No9 RK-TFA-015 1.25 B/W
DELPHI 15315247 No8 RK-TFA-016 0.5 R
DELPHI 15315247 No8 RK-TFA-017 0.5 R/W
DELPHI 15315247 No8 RK-TFA-018 2 L
DELPHI 15315247 No8 RK-TFA-019 1.25 B
DELPHI 15315247 No8 RK-TFA-020 0.5 R/W
DELPHI 15315247 No8 RK-TFA-021 0.5 R
J47606-6 No6 RK-TFA-022 0.5 R
J47606-5 No5 RK-TFA-023 1.25 B
J47606-5 No5 RK-TFA-024 0.85 G/W
J47606-5 No5 RK-TFA-025 0.85 G
DELPHI 15315247 No8 RK-TFA-026 0.5 R/W
DELPHI 15315247 No8 RK-TFA-027 0.5 R/W
DELPHI 15315247 No8 RK-TFA-028 2 L
DELPHI 15315247 No8 RK-TFA-029 2 L
J47606-7 No7 RK-TFA-030 2 L
DELPHI 15315247 No8 RK-TFA-031 0.5 R/W
DELPHI 15315247 No8 RK-TFA-032 2 L
DELPHI 15315247 No8 RK-TFA-033 2 L
J47606-7 No7 RK-TFA-034 1.25 B
DELPHI 15315247 No8 RK-TFA-035 2 L
DELPHI 15315247 No8 RK-TFA-036 0.5 R
DELPHI 15315247 No8 RK-TFA-037 0.5 R/W
DELPHI 15315247 No8 RK-TFA-038 0.5 R
DELPHI 15315247 No8 RK-TFA-039 0.5 R/W
DELPHI 15315247 No8 RK-TFA-040 1.25 B
DELPHI 15315247 No8 RK-TFA-041 0.5 R/W
J47606-7 No7 RK-TFA-042 0.5 R/W
DELPHI 15315247 No8 RK-TFA-043 1.25 B
SPX Tool No.SPX Tool No.
SPX Tool No.SPX Tool No.
SPX Tool No. Part No.Part No.
Part No.Part No.
Part No. Parts NameParts Name
Parts NameParts Name
Parts Name
GM 12085271-C RK-JFA-001 Joint piece - S
GM 12085271-B RK-JFA-002 Joint piece - M
RK-BFA-003 Insulation adhesive

Harness Repair Kit - Page 15Harness Repair Kit - Page 15
Harness Repair Kit - Page 15Harness Repair Kit - Page 15
Harness Repair Kit - Page 15
WI-227
WIRING SYSTEM
Harness Repair Kit
B280
(2.5 L Non-turbo and 2.5 L
Non-turbo (U5) model)
1, 8, 21, 22 TFA-023
3 — 7, 10 — 12,
14, 16, 19, 20,
25 — 27, 30
TFA-025
2, 9, 13, 15, 17,
18, 23, 24, 28,
29
Not available
B280
(3.0 L model)
1, 8, 21, 22 TFA-023
3 — 7, 11, 12,
14, 16, 18 — 20,
25 — 28, 30
TFA-025
B280
(2.5 L Turbo model)
2, 9, 10, 13, 15,
17, 23, 24, 29
Not available
B281
(2.5 L Non-turbo and 2.5 L
Non-turbo (U5) model)
1, 2, 8, 9 TFA-023
3 — 7, 10, 11,
13, 15 — 19, 23,
25 — 28
TFA-025
12, 14, 20 — 22,
24
Not available
B281
(3.0 L model)
1, 2, 8, 9, 20, 21 TFA-023
3 — 7, 10, 11,
13, 15 — 19, 23,
25 — 28
TFA-025
B281
(2.5 L Turbo model)
12, 14, 22, 24 Not available
Connector No. Adaptive repair kit Terminal No. Harness repair kit No.
WI-07639
5467
8
21
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
TFA-023 TFA-025
TFA-025 TFA-025
TFA-025
WI-07640
5467
8
21
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
TFA-023
TFA-025 TFA-025
TFA-025 TFA-025
WI-07641
567
8
2
1
9
43
10
2422 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
TFA-023
TFA-025 TFA-025
TFA-025
WI-07642
567
8
2
1
9
43
10
2422 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
TFA-023
TFA-025 TFA-025
TFA-025
EXAMPLEEXAMPLE
EXAMPLEEXAMPLE
EXAMPLE