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Assembly Manual

1.5 OCS Sealed Connection System

emale/Male 1.5 Terminal System

Contact at STC Saltillo: David 52 844 438 9060
Assembly Manual - 13987928

PLR REPLACEMENT (Install)

– STEP 2

FEMALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Remove)

– STEP 1a

REPAIR / REPLACEMENT

REFER TO PRE-ASSEMBLY

MANUAL SECTION

FRONT VIEWS

IMPORTANT!

PLR MUST BE RELEASED FROM CONNECTOR

BEFORE TERMINAL/PLUG REMOVAL

TERMINAL

LOCK

TERMINAL

LOCK

CAVITY

PLUG

TERMINAL

LOCK

CAVITY

PLUG

TERMINAL

LOCK

Summary of Contents for 1.5 OCS Series

Page 1: ...Issued by CTC Warren Ohio STC Saltillo Mex February 2016 1 5 OCS Sealed Connection System 1 5 Terminal System ASSEMBLY MANUALS PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL 13987928 ...

Page 2: ... on the part of DELPHI All the information is correct at time of releasing Reprinting or translation is not permitted without written permission from DELPHI Copyright 2012 DELPHI All rights reserved Developed by Deniss Guerrero Javier Esquivel 52 844 438 90 60 Assembly Manual 1 5 OCS Sealed Connection System Female Male 1 5 Terminal System ...

Page 3: ...or Seal 10 Step 2 Align and Insert PLR to Pre Stage Position 11 Step 3 Lock CPA to Pre Stage Position 12 Step 4 Install Cable Seal 14 Step 5 Insert Retainer 15 Female Connector Completed Assembly 16 ASSEMBLY OF THE MALE CONNECTOR 17 View of Versions 18 List of Components Exploded View 20 Step 1 Align and Insert PLR to Pre Stage Position 21 Step 2 Install Cable Seal 22 Step 3 Insert Retainer 23 Mal...

Page 4: ...Components Exploded View 32 Step 1 Identify Cavities 33 Step 2 Align Cavity Plug Optional Terminals Male 1 5 and Male Assembly 33 Step 3 Insert Cavity Plug Optional Terminals OCS Male 1 5 34 Step 4 Close PLR to Full Stage 36 Male Assembly Completed 36 CAR ASSEMBLY SECTION ASSEMBLY OF THE CONNECTION SYSTEM 37 3D Model 38 Step 1 Identify and Align Index Features 39 Step 2 Mate Female Assembly and Ma...

Page 5: ...ETAINER Replacement Step 1 Remove 50 Step 2 Install 51 CABLE SEAL Replacement Step 1 Remove 52 Step 2 Install 53 CPA Replacement Step 1 Remove 53 Step 2 Insert 54 CONNECTOR SEAL Replacement Step 1 Remove 55 Step 2 Install 56 MALE CONNECTOR SUB COMPONENTS 57 TERMINAL M OCS 1 5 CAVITY PLUG Replacement Step 1 Move PLR to Pre Stage 58 Step 2 Remove 59 Step 3 Insert 61 RETAINER Replacement Step 1 Remov...

Page 6: ...em Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System ASSEMBLY OF THE FEMALE CONNECTOR 6 FEMALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ...

Page 7: ...CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 3 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 4 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 6 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES WHICH DIFFER IN THE INDEXING AND COLOR REFER TO LATEST DRAWINGS FOR DETAILS ...

Page 8: ...NNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 10 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 12 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 16 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES WHICH DIFFER IN THE INDEXING AND COLOR REFER TO LATEST DRAWINGS FOR DETAILS ...

Page 9: ...ictures used in this Assembly Manual and original parts may differ in some details these differences have no influence on the assembly process ASSEMBLY PLR CONNECTOR SEAL QUANTITY COMPONENTS OF 1 5 OCS FEMALE CONNECTOR 1 PLR 1 CONNECTOR SEAL 1 FEMALE CONNECTOR 1 CABLE SEAL 1 RETAINER 1 CPA LIST OF COMPONENTS EXPLODED VIEW FEMALE CONNECTOR RETAINER CPA CABLE SEAL ...

Page 10: ...IFY THAT CONNECTOR SEAL IS NOT OVER SEATED BUNCHED OR ROLLED DURING THE INSERTION 10 STEP 1a Insert Connector Seal STEP 1b Insert Connector Seal SECTION VIEW ASSEMBLY CONNECTOR WALL SEALING SURFACE AREA CONNECTOR WALL SEALING SURFACE AREA IDENTIFY THE SEALING SURFACE AREA TO INSERT THE CONNECTOR SEAL THEN PUSH THE CONNECTOR SEAL INTO THE CONNECTOR CONNECTOR SEAL INSERTED ...

Page 11: ...inal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 11 STEP 2a Align and Insert PLR to Pre Stage Position STEP 2b Align and Insert PLR to Pre Stage Position ASSEMBLY PLR IS NOW IN PRE STAGE POSITION VERIFY AUDIBLE CLICK ON BOTH SIDES ...

Page 12: ... Torres 52 844 438 9060 Assembly Manual 13987928 12 STEP 3a Lock CPA to Pre Stage Position STEP 3b Lock CPA to Pre Stage Position ASSEMBLY ALIGN CPA WITH THE CONNECTOR LOCK BACK VIEW PRESS DOWN THE CPA UNTIL MATING FEATURES LINE UP AND THE CONNECTOR LOCK DEFLECTS TOP VIEW THEN PUSH DOWN THE CPA MATING FEATURES ...

Page 13: ...David Torres 52 844 438 9060 Assembly Manual 13987928 13 STEP 3c Lock CPA to Pre Stage Position STEP 3d Lock CPA to Pre Stage Position ASSEMBLY WITH THE FEATURES ALIGNED MOVE THE CPA TO FRONT TOP VIEW VERIFY AUDIBLE CLICK THE CONNECTOR LOCK RETURNS TO ITS ORIGINAL POSITION CPA IS NOW IN PRE STAGE POSITION ...

Page 14: ... Assembly Manual 13987928 14 STEP 4 Install Cable Seal ASSEMBLY PROCESS FOR 3W 4W CONNECTORS PROCESS FOR 2W 6W 8W 10W 12W 16W CONNECTORS IDENTIFY THE CORRECT ORIENTATION OF THE SEAL 1 PUSH CABLE SEAL INTO THE CONNECTOR 2 INSERTION COMPLETED 3 LOCATE AND ALIGN MATING FEATURES 1 PUSH CABLE SEAL INTO THE RETAINER 2 INSERTION COMPLETED 3 ...

Page 15: ...nual 13987928 15 STEP 5 Insert Retainer ASSEMBLY RETAINER LOCKED VERIFY AUDIBLE CLICK ON BOTH SIDES THE INSERTION PROCESS OF THE RETAINER IS THE SAME REGARDLESS THE INSERTION PROCESS OF THE CABLE SEAL PRESS RETAINER ONTO CONNECTOR 1 2 INSERTION COMPLETED 3 PRESS RETAINER ONTO CONNECTOR 1 2 INSERTION COMPLETED 3 VERIFY AUDIBLE CLICK ON BOTH SIDES ...

Page 16: ...sembly Manual 1 5 OCS Sealed Connection System Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 16 FEMALE CONNECTOR COMPLETED ASSEMBLY ASSEMBLY ...

Page 17: ...tem Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System ASSEMBLY OF THE MALE CONNECTOR 17 MALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ...

Page 18: ...CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 3 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 4 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 6 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES WHICH DIFFER IN THE INDEXING AND COLOR REFER TO LATEST DRAWINGS FOR DETAILS ...

Page 19: ...ONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 10 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 12 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 16 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES WHICH DIFFER IN THE INDEXING AND COLOR REFER TO LATEST DRAWINGS FOR DETAILS ...

Page 20: ...928 20 Pictures used in this Assembly Manual and original parts may differ in some details these differences have no influence on the assembly process ASSEMBLY PLR QUANTITY COMPONENTS OF 1 5 OCS MALE CONNECTOR 1 PLR 1 MALE CONNECTOR 1 CABLE SEAL 1 RETAINER LIST OF COMPONENTS EXPLODED VIEW MALE CONNECTOR RETAINER CABLE SEAL LIST OF COMPONENTS EXPLODED VIEW ...

Page 21: ...ystem Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 21 STEP 1a Align and Insert PLR to Pre Stage Position STEP 1b Align and Insert PLR to Pre Stage Position ASSEMBLY PLR IS NOW IN PRE STAGE POSITION FRONT VIEW VERIFY AUDIBLE CLICK ON BOTH SIDES ...

Page 22: ...52 844 438 9060 Assembly Manual 13987928 22 STEP 2 Install Cable Seal ASSEMBLY IDENTIFY THE CORRECT ORIENTATION OF THE SEAL 1 PUSH CABLE SEAL INTO CONNECTOR 2 LOCATE AND ALIGN MATING FEATURES 1 PUSH CABLE SEAL ONTO RETAINER 2 INSERTION COMPLETED 3 PROCESS FOR 3W 4W CONNECTORS PROCESS FOR 2W 6W 8W 10W 12W 16W CONNECTORS ...

Page 23: ... STEP 3 Insert Retainer ASSEMBLY RETAINER LOCKED VERIFY AUDIBLE CLICK THE INSERTION PROCESS OF THE RETAINER IS THE SAME REGARDLESS THE INSERTION PROCESS OF THE CABLE SEAL LOCATE AND ALIGN MATING FEATURES 1 2 3 LOCATE AND ALIGN MATING FEATURES 1 2 3 PRESS RETAINER ONTO THE CONNECTOR PRESS RETAINER ONTO THE CONNECTOR TO FULLY SEAT CABLE SEAL VERIFY AUDIBLE CLICK ...

Page 24: ...ssembly Manual 1 5 OCS Sealed Connection System Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 24 MALE CONNECTOR COMPLETED ASSEMBLY ASSEMBLY ...

Page 25: ... Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY 25 FEMALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY TERMINALS ...

Page 26: ...iffer in some details these differences have no influence on the assembly process ASSEMBLY QUANTITY COMPONENTS OF 1 5 OCS FEMALE CONNECTION 1 FEMALE ASSEMBLY 16 TERMINALS FEMALE 1 5 UNSEALED LIST OF COMPONENTS FEMALE ASSEMBLY TERMINAL THE QUANTITY OF TERMINALS REQUIRED MIGHT VARY DEPENDING ON THE TYPE OF ASSEMBLY 2W 3W 4W 6W 8W 10W 12W 16W LIST OF COMPONENTS EXPLODED VIEW USE OF CAVITY PLUGS IF RE...

Page 27: ...ty Plug Optional Terminals Female 1 5 and Female Assembly CAVITY IDENTIFICATION NUMBERS INSERT FEMALE TERMINAL INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN PROPER ORIENTATION OF TERMINAL REQUIRED BACK VIEWS BACK VIEW ASSEMBLY ORIENTATION FEATURE ORIENTATION FEATURE TERMINAL CAVITY PLUG IMPORTANT USE OF CAVITY PLUG IS ACCEPTABLE BUT USE OF RETAINER WITH MULTIPLE CAVITY CONFIGURATIONS IS PREF...

Page 28: ...987928 2 28 STEP 3a Insert Cavity Plug Optional Terminals OCS Female 1 5 ASSEMBLY TERMINAL IS FULLY ENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 PUSH THE TERMINAL STRAIGHT INTO THE CAVITY CAVITY PLUG INSERTION TERMINAL INSERTION 2 CAVITY PLUG IS FULLY ENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 PUSH THE CAVITY PLUG STRAIGHT INTO THE CAVITY ...

Page 29: ... 3b Insert Cavity Plug Optional Terminals OCS Female 1 5 ASSEMBLY USE THE SAME PROCESS TO INSERT THE REST OF THE TERMINALS 4 3 CAVITY PLUG INSERTION TERMINAL INSERTION IF REQUIRED FOLLOW THE SAME PROCEDURE TO INSERT THE NEEDED CAVITY PLUGS 4 3 OPTIONAL AFTER INSERTION CAVITY PLUGS CAN BE TRIMMED FLUSH TO AVOID WIRE CHAFING DON T TRIM WHEN TERMINALS ARE INSTALLED GENTLY PULL ON THE PLUG TO VERIFY I...

Page 30: ...System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 30 STEP 4 Close PLR to Full Stage FEMALE ASSEMBLY COMPLETED ASSEMBLY VERIFY AUDIBLE CLICK ON BOTH SIDES PUSH PLR TO THE END POSITION TO SECURE THE TERMINALS PLR IS NOW IN FULL STAGE POSITION ...

Page 31: ...le Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System 31 MALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY TERMINALS ASSEMBLY OF THE MALE HARNESS ASSEMBLY ...

Page 32: ...G ON THE TYPE OF ASSEMBLY 2W 3W 4W 6W 8W 10W 12W 16W 32 Pictures used in this Assembly Manual and original parts may differ in some details these differences have no influence on the assembly process ASSEMBLY EXPLODED COMPONENTS QUANTITY COMPONENTS OF 1 5 OCS MALE CONNECTION 1 MALE ASSEMBLY 16 TERMINALS MALE 1 5 UNSEALED LIST OF COMPONENTS MALE ASSEMBLY TERMINAL USE OF CAVITY PLUGS IF REQUIRED OPT...

Page 33: ...avity Plug Optional Terminals Male 1 5 and Male Assembly ASSEMBLY CAVITY IDENTIFICATION NUMBERS BACK VIEW INSERT MALE TERMINAL INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN PROPER ORIENTATION OF TERMINAL REQUIRED BACK VIEWS ORIENTATION FEATURE ORIENTATION FEATURE CAVITY PLUG IMPORTANT USE OF CAVITY PLUG IS ACCEPTABLE BUT USE OF RETAINER WITH MULTIPLE CAVITY CONFIGURATIONS IS PREFERABLE TERMI...

Page 34: ...3987928 2 34 STEP 3a Insert Cavity Plug Optional Terminals OCS Male 1 5 ASSEMBLY TERMINAL IS FULLY ENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 PUSH THE TERMINAL STRAIGHT INTO THE CAVITY CAVITY PLUG INSERTION TERMINAL INSERTION 2 CAVITY PLUG IS FULLY ENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 PUSH THE CAVITY PLUG STRAIGHT INTO THE CAVITY ...

Page 35: ...P 3b Insert Cavity Plug Optional Terminals OCS Male 1 5 ASSEMBLY USE THE SAME PROCESS TO INSERT THE REST OF THE TERMINALS 4 3 CAVITY PLUG INSERTION TERMINAL INSERTION GENTLY PULL ON THE PLUG TO VERIFY ITS COMPLETE INSERTION IF REQUIRED FOLLOW THE SAME PROCEDURE TO INSERT THE NEEDED CAVITY PLUGS 4 3 OPTIONAL AFTER INSERTION CAVITY PLUGS CAN BE TRIMMED FLUSH TO AVOID WIRE CHAFING DON T TRIM WHEN TER...

Page 36: ... System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 36 STEP 4 Close PLR to Full Stage MALE ASSEMBLY COMPLETED ASSEMBLY PLR IS NOW IN FULL STAGE POSITION VERIFY AUDIBLE CLICK ON BOTH SIDES PUSH PLR TO THE END POSITION TO SECURE THE TERMINALS ...

Page 37: ...e Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System ASSEMBLY OF THE CONNECTION SYSTEM 37 FEMALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MALE ASSEMBLY ...

Page 38: ...anual 1 5 OCS Sealed Connection System Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 38 3D MODEL VIEW CLICK IMAGE TO START 3D VISUALIZATION ASSEMBLY ...

Page 39: ... Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 39 STEP 1 Identify and Align Index Features STEP 2 Mate Female Assembly and Male Assembly Together Axially ASSEMBLY IMPORTANT IF THE INDEXES DON T LINE UP DO NOT CONTINUE FRONT VIEWS VERIFY AUDIBLE CLICK ...

Page 40: ... Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 40 STEP 3 Close CPA to Full Stage CONNECTION SYSTEM COMPLETED ASSEMBLY ASSEMBLY SLIDE CPA TO THE END POSITION TO SECURE THE ASSEMBLY VERIFY AUDIBLE CLICK ...

Page 41: ...ale 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System DISASSEMBLY OF THE CONNECTION SYSTEM 41 DISASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY FEMALE ASSEMBLY MALE ASSEMBLY ...

Page 42: ... System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 42 STEP 1a Move CPA to Pre Stage Position STEP 1b Move CPA to Pre Stage Position DISASSEMBLY PULL BACK THE CPA TO RELEASE THE ASSEMBLY VERIFY AUDIBLE CLICK CPA IS NOW IN PRE STAGE POSITION ...

Page 43: ...5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 43 STEP 2a Release the Connector Lock STEP 3 Disconnect LOCATE AND PRESS DOWN THE CONNECTOR LOCK DISASSEMBLY WITH THE CONNECTOR LOCK DEFLECTED PULL BACK BOTH ASSEMBLIES ...

Page 44: ...ly Manual 1 5 OCS Sealed Connection System Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 44 CONNECTION SYSTEM COMPLETED DISASSEMBLY DISASSEMBLY ...

Page 45: ...ection System Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System REPAIR REPLACEMENT OF THE FEMALE ASSEMBLY 45 REPAIR REPLACEMENT FEMALE ASSEMBLY ...

Page 46: ... Manual 13987928 46 PLR REPLACEMENT Remove STEP 1a PLR REPLACEMENT Remove STEP 1b REPAIR REPLACEMENT LOCATE THE SLOTS AT THE BOTTOM SIDE OF THE CONNECTOR INSERT TOOL 12122647 OR 12094430 INTO THE SLOT PLR LOCK OF PLR TOOL MUST BE PLACED BETWEEN PLR LOCK AND CONNECTOR SECTION VIEWS LIFT THE PLR CAREFULLY TO RELEASE THE LOCK FROM THE CONNECTOR ...

Page 47: ... 52 844 438 9060 Assembly Manual 13987928 47 PLR REPLACEMENT Remove STEP 1c PLR REPLACEMENT Remove STEP 1d REPAIR REPLACEMENT REPEAT THE PROCESS TO RELEASE THE OTHER SIDE OF PLR FROM FULL STAGE USE THE SAME PROCEDURE TO RELEASE PLR FROM PRE STAGE POSITION PLR IS NOW IN PRE STAGE POSITION THEN REMOVE PLR FROM CONNECTOR ...

Page 48: ...al 13987928 48 PLR REPLACEMENT Install STEP 2 FEMALE TERMINAL OCS 1 5 CAVITY PLUG REPLACEMENT Remove STEP 1a REPAIR REPLACEMENT REFER TO PRE ASSEMBLY MANUAL SECTION FRONT VIEWS IMPORTANT PLR MUST BE RELEASED FROM CONNECTOR BEFORE TERMINAL PLUG REMOVAL TERMINAL TERMINAL LOCK TERMINAL TERMINAL LOCK CAVITY PLUG TERMINAL LOCK CAVITY PLUG TERMINAL LOCK ...

Page 49: ...epresents how this kind of terminals are removed IDENTIFY Flex Lock Mating End Cable End Terminal Flex Lock REMOVE TERMINALS Locate Flex Lock at the front of the Connector Insert Operation 1 tool 12094429 straight into the window deflect the Flex Lock to unseat the Terminal Cavity Plug and gently pull on the cable to remove Operation 2 the Female Terminal Cavity Plug from the receptacle Needle Nos...

Page 50: ...rres 52 844 438 9060 Assembly Manual 13987928 50 FEMALE TERMINAL OCS 1 5 CAVITY PLUG REPLACEMENT Insert STEP 2 RETAINER REPLACEMENT Remove STEP 1a REPAIR REPLACEMENT REFER TO HARNESS MANUAL SECTION PLACE TOOL 12094441 BETWEEN THE CONNECTOR AND RETAINER ROTATE THE TOOL CAREFULLY TO RELEASE THAT SIDE OF THE RETAINER ...

Page 51: ...ontact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 51 RETAINER REPLACEMENT Remove STEP 1b RETAINER REPLACEMENT Install STEP 2 REPAIR REPLACEMENT REPEAT THE PROCEDURE TO RELEASE THE OTHER SIDE OF RETAINER REFER TO PRE ASSEMBLY MANUAL SECTION RETAINER REMOVED ...

Page 52: ... STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 52 CABLE SEAL REPLACEMENT Remove STEP 1a CABLE SEAL REPLACEMENT Remove STEP 1b REPAIR REPLACEMENT INSERT TOOL 12094441 BETWEEN THE CONNECTOR AND CABLE SEAL WITH THE TIP OF TOOL REMOVE THE SEAL FROM THE SHROUD RETAINER REMOVED ...

Page 53: ...CABLE SEAL REPLACEMENT Install STEP 2 CPA REPLACEMENT Remove STEP 1a REPAIR REPLACEMENT PRESS DOWN THE CONNECTOR LOCK IMPORTANT RETAINER MUST BE COMPLETELY REMOVED FROM CONNECTOR BEFORE CPA REMOVAL REFER TO PRE ASSEMBLY MANUAL SECTION CABLE SEAL is not a reusable sub component REPLACE ENTIRE CABLE SEAL WITH THE LOCK DEFLECTED SLIDE THE CPA BACKWARDS TO REMOVE IT ...

Page 54: ...m Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 54 CPA REPLACEMENT Remove STEP 1b CPA REPLACEMENT Install STEP 2 REPAIR REPLACEMENT REFER TO PRE ASSEMBLY MANUAL SECTION RETAINER REMOVED ...

Page 55: ...EAL REPLACEMENT Remove STEP 1a CONNECTOR SEAL REPLACEMENT Remove STEP 1b REPAIR REPLACEMENT IDENTIFY THE PERMISIBLE AREAS FOR THE TOOL CONNECTOR SEAL FRONT VIEW IMPORTANT PLR MUST BE COMPLETELY REMOVED FROM THE CONNECTOR BEFORE THE SEAL REMOVAL PERMISSIBLE AREA THE HOOK OF TOOL SHOULD BE PLACED BEHIND THE CONNECTOR SEAL SECTION VIEW INSERT TOOL 15313892 INTO THE CONNECTOR ...

Page 56: ...mbly Manual 13987928 56 CONNECTOR SEAL REPLACEMENT Remove STEP 1c CONNECTOR SEAL REPLACEMENT Install STEP 2 REPAIR REPLACEMENT EXTRACT SEAL FROM THE SHROUD CONNECTOR SEAL REMOVED REFER TO PRE ASSEMBLY MANUAL SECTION CONNECTOR SEAL is not a reusable sub component REPLACE CONNECTOR SEAL TOOL 12150860 COULD BE USED TO PLACE SEAL INTO SHROUD ...

Page 57: ...nnection System Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 1 5 OCS Sealed Connection System REPAIR REPLACEMENT OF THE MALE ASSEMBLY 57 REPAIR REPLACEMENT MALE ASSEMBLY ...

Page 58: ...o Pre Stage STEP 1a MALE TERMINAL OCS 1 5 CAVITY PLUG REPLACEMENT Move PLR to Pre Stage STEP 1b REPAIR REPLACEMENT LOCATE THE AREAS TO INSERT TOOL 15313892 INSERT TOOL INTO THE SHROUD WITH THE HOOK FACING TOWARD THE CENTER OF CONNECTOR AND PLACE IT BEHIND THE PLR ONCE THE TOOL IS IN PLACE ROTATE IT TO GRASP THE PLR ARM TWIST THE TOOL TO DEFLECT THE PLR ARM AND CAREFULLY PULL THE TOOL BACKWARDS TO ...

Page 59: ...INAL OCS 1 5 CAVITY PLUG REPLACEMENT Move PLR to Pre Stage STEP 1c MALE TERMINAL OCS 1 5 CAVITY PLUG REPLACEMENT Remove STEP 2a REPAIR REPLACEMENT USE THE SAME PROCESS TO MOVE THE OTHER SIDE IF NEEDED PLR IS NOW IN PRE STAGE POSITION TERMINAL TERMINAL LOCK FRONT VIEWS TERMINAL TERMINAL LOCK REMOVAL WINDOW REMOVAL WINDOW CAVITY PLUG TERMINAL LOCK TERMINAL LOCK CAVITY PLUG ...

Page 60: ...resents how this kind of terminals are removed IDENTIFY Flex Lock Mating End Cable End Terminal Flex Lock Locate Flex Lock at the front of the Connector Insert Operation 1 tool 12094429 straight into the window deflect the Flex Lock to unseat the Terminal Cavity Plug and gently pull on the cable to remove Operation 2 the Female Terminal Cavity Plug from the receptacle Needle Nose Pliers can be use...

Page 61: ... 844 438 9060 Assembly Manual 13987928 61 MALE TERMINAL OCS 1 5 CAVITY PLUG REPLACEMENT Insert STEP 3 RETAINER REPLACEMENT Remove STEP 1a REPAIR REPLACEMENT REFER TO HARNESS MANUAL SECTION ADDITIONAL VIEW PLACE TOOL 12094441 BETWEEN THE CONNECTOR AND RETAINER ROTATE THE TOOL CAREFULLY TO RELEASE THAT SIDE OF THE RETAINER ...

Page 62: ...ontact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 62 RETAINER REPLACEMENT Remove STEP 1b RETAINER REPLACEMENT Install STEP 2 REPAIR REPLACEMENT REFER TO PRE ASSEMBLY MANUAL SECTION REPEAT THE PROCEDURE TO RELEASE THE OTHER SIDE OF RETAINER RETAINER REMOVED ...

Page 63: ... STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 63 CABLE SEAL REPLACEMENT Remove STEP 1a CABLE SEAL REPLACEMENT Remove STEP 1b REPAIR REPLACEMENT INSERT TOOL 12094441 BETWEEN THE CONNECTOR AND CABLE SEAL WITH THE TIP OF TOOL REMOVE THE SEAL FROM THE SHROUD RETAINER REMOVED ...

Page 64: ...s 52 844 438 9060 Assembly Manual 13987928 64 CABLE SEAL REPLACEMENT Install STEP 2 PLR REPLACEMENT Remove STEP 1a REPAIR REPLACEMENT REFER TO PRE ASSEMBLY MANUAL SECTION CABLE SEAL is not a reusable sub component REPLACE ENTIRE CABLE SEAL LOCATE THE AREAS TO INSERT TOOL 15313892 INSERT THE TOOL BEHIND THE PLR DETAIL ...

Page 65: ... at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 65 PLR REPLACEMENT Remove STEP 1b PLR REPLACEMENT Remove STEP 1c REPAIR REPLACEMENT PLR REMOVED CAREFULLY PULL THE TOOL BACKWARDS TO REMOVE THAT SIDE OF PLR REPEAT THE PROCESS ON THE OTHER SIDE AN REMOVE PLR COMPLETELY ...

Page 66: ... Sealed Connection System Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 66 PLR REPLACEMENT Install STEP 2 REPAIR REPLACEMENT REFER TO PRE ASSEMBLY MANUAL SECTION ...

Page 67: ...ystem Female Male 1 5 Terminal System Contact at STC Saltillo David Torres 52 844 438 9060 Assembly Manual 13987928 67 RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER 1 12122647 OR 12094430 2 12094441 3 12094429 4 15313892 5 12150860 1 2 4 5 3 ...

Page 68: ... Assembly Manual 13987928 DATE REV REVISION HISTORY AUTH 12OC12 01 RELEASED 419944 12JL13 02 ADDED CAR ASM REPAIR SECTIONS UPDATED GRAPHICS MATTE SEAL ASM CHANGED NAME OF THE MANUAL AND ADDED VIEW OF VERSIONS SHEETS 420327 23FE16 03 UPDATED GRAPHICS WITH LATEST DESIGNS REPAIR SECTION AND ADDED REPAIR TOOL NUMBERS 431453 68 REVISIONS ...

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