Need new main wiring harness plug

slag

Chief Petty Officer
Joined
Jul 17, 2009
Messages
471
1998 wellcraft with the 5.7 liter engine. When looking at the engine, there is a large wiring harness with a round plug that plugs in just fore of the exhaust manifold Mine doesn't like to stay plugged in and someone had tried to fix it with a zip tie, but it keeps sliding off and a metal clamp does no better. Is this a common problem and, if so, how do I fix it properly? I've debated using a bit of trim adhesive to hold it together but wonder if this isn't a bad idea.
 

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Fun Times

Moderator
Staff member
Joined
May 16, 2009
Messages
9,124
It's recommended by Volvo & Mercruiser to use either a zip tie or preferably a hose clamp to hold the cannon plug on.

It's a little surprising that it keeps "sliding out". It's more typical to have a bad connection due to the male wire pins are not gapped enough to make good contact with the female engine harness.

Should you need a new cannon plug, here is a short plug or if you don't want to cut and add a new plug then a new wiring harness from the helm to engine is available as well. Here's an example to start with, http://www.hardin-marine.com/p-1322...-pigtail-mercury-plug-instrument-side-12.aspx

Is there enough of the female engine harness sticking out electrical box so the male plug will go on far enough so the clamp would hold it in place?
 

dypcdiver

Lieutenant Junior Grade
Joined
Nov 1, 2005
Messages
1,040
Strange, mine takes a serious effort to pull apart with the hose clamp slacked off, are you quite sure it is fully engaged? When it is, the hose clamp almost butts up to the plastic breaker housing and when tightened it excludes damp getting in and also secures the 2 halves from separating.
 

cte069

Cadet
Joined
Mar 29, 2015
Messages
19
My 4.3 gl volvo does same thing. Radiator clamp is the fix i used. Works fine.
 
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