Last Update: Dec. 15/17
Air Temp Sensor Connector Assembly
The GM air temp sensor (and coolant temp sensor if used) connectors are different from most of the other SDS connectors in that the wires are pulled through the connector PRIOR to crimping the pins on.
Step 1: Strip the outer sheath back about 1.75 inches and strip off the wire insulation for about .2-.25 inches as below
Step 2: Insert the wires through the connector with the locking tab facing down as below
Step 3: Crimp the pins onto the wires as shown below
Step 4: Pull the wires and pins backwards into the connector while aligning the top blades with the slots until the pins click into the connector as below
Stripping Tefzel Multi-Conductor Cable
Here's a step by step guide to preparing the engine side ends of your harness
Score the outer insulation down to the braid without cutting through the braid
Pull insulation forward
Compress braid downwards so it bunches up
Using sharp cutters, cut the braid all around the cable
Remove braid and strip conductor insulation
Apply heat shrink tubing so it extends over braid junction by about 3/16 inch
Shrink the tubing with a heat gun and label each cable
Hall Sensor Strain Relief
You must support the cable in the DB9 shell as shown below. We wrap electrical tape around the cable until it fits tight inside the shell exit.
We also put a dab of silicone on the wires where they are soldered into the back of the DB9 connector for extra vibration resistance as shown below.
Tip on Assembling MSD Spark Plug Wires
In order to get the boots to slide over the terminals and wires, lubricate the wire/ terminal OD and boot ID with alcohol based hand sanitizer. This will help things slide together much easier and will evaporate within a few minutes.
YouTube video here: Building MSD plug wires