1994 2.3l crank shaft position sensor removal

[STPL]

Got a “cylinder ID circuit failure” code from a CEL and decided to swap out the crank shaft position sensor because the wires are frayed and possibly causing intermittent problems. I got the fan, shroud, timing belt cover off and everything else that’s in the way. There is no way the plug on the end of this harness is going to fit behind the plastic rear timing belt cover. I’ve tried everything short of taking the pulleys and belt off the front of the motor. How is it possible to change out this sensor without removing the rear timing belt cover. There has to be a better way!

 

[STPL]

Got a “cylinder ID circuit failure” code from a CEL and decided to swap out the crank shaft position sensor because the wires are frayed and possibly causing intermittent problems. I got the fan, shroud, timing belt cover off and everything else that’s in the way. There is no way the plug on the end of this harness is going to fit behind the plastic rear timing belt cover. I’ve tried everything short of taking the pulleys and belt off the front of the motor. How is it possible to change out this sensor without removing the rear timing belt cover. There has to be a better way!

I found very limited information about having to disassemble and re assemble the connector in the engine bay. Updating this post with my own solution, hopefully preventing a headache for someone else in the future.

I recommend removing the AC condenser completely and unbolt the power steering pump and shift it out of the way in addition to what your workshop manual says. The crankshaft sensor harness snakes from the front to behind the back of the timing belt cover. There is a little bump molded into the back for the cable to fit though. The connectors on the ends however, will not fit through this passage. I disconnected the old harness from the main harness and cut it out, leaving a decent amount of wire on each end. The reason for this is because if you mess up the plug on the new harness, you can swap in the old one providing its in decent condition. On the plugs that connects to the trucks main wiring harness, remove the middle plastic piece in between the four wires and pry out the rubber boot on the back side of the plug. Mark each cable color to the position on the plug and GENTLY with a small screwdriver pry back each tab inside the plug holding the wire down and pull it from the back to remove it. Once you have all four wires out, run a scrap piece of wire or very thin rope through the passage behind the timing belt plate, tie it to the four exposed wires and gently pull them through to the top. Re-attach the plug, making sure the wires are in the same position, replace the rubber boot on the bottom and the plastic tab on the top. Now you can plug that into the main harness, install the crack shaft position sensor and reassemble the front of the engine.