Delphi 101 Assembly Manual Download Page 1

Page: 1 / 41

Issued by

CTC Warren, Ohio

STC Saltillo, Mex.

October 2015

2 Way Unsealed OCS 1.2 Inline

Connection System

Female/Male OCS 1.2 Terminal System (Unsealed)

ASSEMBLY MANUALS

PRE - ASSEMBLY

HARNESS ASSEMBLY

CAR ASSEMBLY

ASSEMBLY MANUAL - 33286031

Summary of Contents for 101

Page 1: ...rren Ohio STC Saltillo Mex October 2015 2 Way Unsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed ASSEMBLY MANUALS PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL 33286031 ...

Page 2: ...e part of DELPHI All the information is correct at time of releasing Reprinting or translation is not permitted without written permission from DELPHI Copyright 2015 DELPHI All rights reserved Developed by Deniss Guerrero 52 844 438 90 60 Assembly Manual 2 Way Unsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed ...

Page 3: ...SSEMBLY SECTION ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR 10 List of Components Exploded View 11 ASSEMBLY SEQUENCE Step 1 Identify Cavities for Terminals OCS 1 2 or Equivalent 12 Step 2 Align T erminals Female 1 2 and Female Assembly 12 Step 3 Insert Terminals Female OCS 1 2 or Equivalent 13 Step 4 Lock Connector Hinge to Closed Position 14 Harness Assembly Completed 15 ASSEMBLY OF THE MAL...

Page 4: ...gn Index Features and Mate Female Assembly and Male Assembly Together 26 Step 3 Lock CPA to Full Stage Position 27 Connection System Completed Assembly 28 DISASSEMBLY SECTION DISASSEMBLY OF THE CONNECTION SYSTEM 29 Step 1 Move CPA to Pre Stage Position 30 Step 2 Disconnect 31 Connection System Completed Disassembly 31 REPAIR REPLACEMENT SECTION FEMALE CONNECTOR SUB COMPONENTS 32 TERMINAL F OCS 1 2...

Page 5: ...ale OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System ASSEMBLY OF THE FEMALE CONNECTOR 5 FEMALE CONNECTOR ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ...

Page 6: ...le Smith 1 330 306 1089 Assembly Manual 33286031 6 VIEW OF VERSIONS ASSEMBLY THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS WHICH DIFFER IN THE INDEXING AND COLOR THE METHOD OF ASSEMBLY IS THE SAME FOR ALL CONNECTORS REGARDLESS OF THEIR DIFFERENCES REFER TO LATEST TAXI ASSEMBLY DRAWING FOR DETAILS Type 101 Type 102 Type 103 Type 104 ...

Page 7: ...en Michelle Smith 1 330 306 1089 Assembly Manual 33286031 7 Pictures used in this Assembly Manual and original parts may differ in some details These differences have no influence on the assembly process ASSEMBLY FEMALE CONNECTOR QUANTITY COMPONENTS 1 FEMALE CONNECTOR 1 CPA LIST OF COMPONENTS LIST OF COMPONENTS EXPLODED VIEW CPA ...

Page 8: ...t CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 8 STEP 1a Assemble CPA to Pre Stage Position STEP 1b Assemble CPA to Pre Stage Position ASSEMBLY IDENTIFY THE CORRECT ORIENTATIONOF THE CPAAND INSERT IT ONTO THE CONNECTOR VERIFYAUDIBLE CLICK ON BOTH LOCKS CPA IS NOW IN PRE STAGE POSITION SECTION VIEW ...

Page 9: ...y Unsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 9 FEMALE CONNECTOR ASSEMBLY COMPLETED ASSEMBLY ASSEMBLY ...

Page 10: ...Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System 10 FEMALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY ...

Page 11: ...6 1089 Assembly Manual 33286031 11 Pictures used in this Assembly Manual and original parts may differ in some details these differences have no influence on the assembly process ASSEMBLY FEMALE CONNECTOR ASSEMBLY QUANTITY COMPONENTS 1 FEMALE CONNECTOR ASSEMBLY 2 TERMINAL OCS 1 2 LIST OF COMPONENTS EXPLODED VIEW TERMINAL LIST OF COMPONENTS EXPLODED VIEW ...

Page 12: ...089 Assembly Manual 33286031 12 STEP 1 Identify Cavities for Terminals OCS 1 2 or Equivalent STEP 2 Align Terminals Female 1 2 and Female Assembly ASSEMBLY CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR BACK VIEW INSERT FEMALETERMINALS INTO RECEPTACLEHOUSING ACCORDING TO INSERTION PLAN PROPER ORIENTATIONOF TERMINAL REQUIRED INDEX FEATURE BACK VIEWS ...

Page 13: ...mbly Manual 33286031 13 STEP 3a Insert Terminals Female OCS 1 2 or Equivalent STEP 3b Insert Terminals Female OCS 1 2 or Equivalent ASSEMBLY TERMINAL FULLYENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 2 PUSH THE TERMINAL STRAIGHT INTO THE CAVITY GENTLY PULL ON THE CABLE TO VERIFY THE LOCK SYSTEM 3 USE THE SAME PROCESS TO INSERT THE REST OF THE TERMINALS NEEDED ...

Page 14: ...TC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 14 STEP 4a Lock Connector Hinge to Closed Position STEP 4b Lock Connector Hinge to Closed Position ASSEMBLY CAREFULLY PUSH THE HINGE FORWARD VERIFY AUDIBLE CLICK DO NOT FORCE THE HINGE IF IT CAN T BE CLOSED REVIEW IF TERMINALS ARE PROPERLYLOCKED LOCKED HINGE ...

Page 15: ...l System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 15 FEMALE ASSEMBLY COMPLETED HARNESS ASSEMBLY ASSEMBLY PERFORM TESTS APPLY COVERINGS AS REQUIRED INSPECT THE ASSEMBLY CONNECTORHINGE MUST BE COMPLETELYCLOSED BEFORE TAPING OR DRESSING WIRES HARNESS ...

Page 16: ...e Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System 16 MALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ASSEMBLY OF THE MALE HARNESS ASSEMBLY ...

Page 17: ...chelle Smith 1 330 306 1089 Assembly Manual 33286031 17 VIEW OF VERSIONS ASSEMBLY THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS WHICH DIFFER IN THE INDEXING AND COLOR THE METHOD OF ASSEMBLY IS THE SAME FOR ALL CONNECTORS REGARDLESS OF THEIR DIFFERENCES REFER TO LATEST TAXI DRAWING FOR DETAILS Type 101 Type 102 Type 103 Type 104 ...

Page 18: ...th 1 330 306 1089 Assembly Manual 33286031 18 Pictures used in this Assembly Manual and original parts may differ in some details these differences have no influence on the assembly process ASSEMBLY MALE CONNECTOR QUANTITY COMPONENTS 1 MALE CONNECTOR 2 TERMINAL OCS 1 2 LIST OF COMPONENTS EXPLODED VIEW LIST OF COMPONENTS EXPLODED VIEW TERMINAL ...

Page 19: ...06 1089 Assembly Manual 33286031 19 STEP 1 Identify Cavities for Terminals OCS or Equivalent STEP 2 Align Terminals Male 1 2 and Male Assembly ASSEMBLY CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR BACK VIEW INSERT MALE TERMINALS INTO RECEPTACLEHOUSING ACCORDING TO INSERTION PLAN PROPER ORIENTATIONOF TERMINAL REQUIRED INDEX FEATURES BACK VIEWS ...

Page 20: ...embly Manual 33286031 20 STEP 3a Insert Terminals Male OCS 1 2 or Equivalent STEP 3b Insert Terminals Male OCS 1 2 or Equivalent ASSEMBLY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 2 PUSH THE TERMINAL STRAIGHT INTO THE CAVITY GENTLY PULL ON THE CABLE TO VERIFY THE LOCK SYSTEM 3 USE THE SAME PROCESS TO INSERT THE REST OF THE TERMINALS NEEDED ...

Page 21: ...led Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 21 STEP 4a Lock Connector Hinge to Closed Position STEP 4b Lock Connector Hinge to Closed Position ASSEMBLY VERIFY AUDIBLE CLICK DO NOT FORCE THE HINGE IF IT CAN T BE CLOSED REVIEW IF TERMINALS ARE PROPERLYLOCKED LOCKED HINGE ...

Page 22: ...al System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 22 MALE ASSEMBLY COMPLETED HARNESS ASSEMBLY ASSEMBLY PERFORM TESTS APPLY COVERINGS IF REQUIRED INSPECT THE ASSEMBLY CONNECTORHINGE MUST BE COMPLETELYCLOSED BEFORE TAPING OR DRESSING WIRES HARNESS ...

Page 23: ... OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System ASSEMBLY OF THE CONNECTION SYSTEM 23 FEMALE ASSEMBLY MALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ...

Page 24: ...6 1089 Assembly Manual 33286031 24 ASSEMBLY MALE ASSEMBLY QUANTITY COMPONENTS OF 2 WAY UNSEALED OCS 1 2 INLINE CONNECTION SYSTEM 1 MALE ASSEMBLY 1 FEMALE ASSEMBLY LIST OF COMPONENTS EXPLODED VIEW Pictures used in this Assembly Manual and original parts may differ in some details These differences have no influence on the assembly process FEMALE ASSEMBLY ...

Page 25: ...sealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 25 3D MODEL VIEW CLICK IMAGE TO START 3D VISUALIZATION ASSEMBLY ...

Page 26: ...minal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 26 STEP 1 Identify Index Features STEP 2a Align Index Features and Mate Female Assembly and Male Assembly Together ASSEMBLY IMPORTANT IF THE INDEXES DON T LINE UP DO NOT CONTINUE FRONT VIEWS ...

Page 27: ... Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 27 STEP 2b Align Index Features and Mate Female Assembly and Male Assembly Together STEP 3a Lock CPA to Full Stage Position ASSEMBLY VERIFY AUDIBLE CLICK SLIDE THE CPAFORWARD AS SHOWN BELOW TO SECURE THE CONNECTION ...

Page 28: ...Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 28 STEP 3b Lock CPA to Full Stage Position CONNECTION SYSTEM COMPLETED ASSEMBLY ASSEMBLY CPA IS NOW IN FULL STAGE POSITION VERIFY AUDIBLE CLICK ...

Page 29: ...S 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System DISASSEMBLY OF THE CONNECTION SYSTEM 29 FEMALE ASSEMBLY MALE ASSEMBLY DISASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ...

Page 30: ...inal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 30 STEP 1a Move CPA to Pre Stage Position STEP 1b Move CPA to Pre Stage Position DISASSEMBLY HOLD THE CPA TAB THEN SLIDE BACK THE CPA TO PLACE IT IN PRE STAGE CPA IS NOW IN PRE STAGE POSITION ...

Page 31: ...CS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 31 STEP 2 Disconnect CONNECTION SYSTEM COMPLETED DISASSEMBLY DISASSEMBLY LOCATE AND PRESS DOWN THE CONNECTORLOCK 1 WITH THE LOCK DEFLECTED DISENGAGE THE CONNECTORS 2 1 2 ...

Page 32: ... System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System REPAIR REPLACEMENT OF THE FEMALE ASSEMBLY 32 REPAIR REPLACEMENT FEMALE ASSEMBLY ...

Page 33: ...Assembly Manual 33286031 33 FEMALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1a FEMALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1b REPAIR REPLACEMENT IDENTIFY THE SIDE OF THE HINGE WITH A CHAMFER THEN INSERT TOOLTBD BETWEEN THE CONNECTORBODY AND HINGE CONNECTOR HINGE RELEASED ROTATE THE TOOLCAREFULLY TOUNLOCK THE CONNECTORHINGE ...

Page 34: ... Assembly Manual 33286031 34 FEMALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2a FEMALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2b REPAIR REPLACEMENT REMOVE TERMINALS This graph justrepresents how this kind of terminals are removed Removal Window IDENTIFY Removal Window Terminal Mating End Cable End Flex Lock FLEX LOCK TERMINAL REMOVAL WINDOW ...

Page 35: ...MINAL OCS 1 2 REPLACEMENT Insert Terminal STEP 3 REPAIR REPLACEMENT REFER TO HARNESS ASSEMBLY SECTION REMOVE TERMINALS Locate Removal Window at the front of the Connector Insert Operation 1 tool TBD straight into the window deflect the Flex Lock to unseat the Terminal and gently pull on the cable to remove Operation 2 the Female Terminal from the receptacle OPERATION 1 OPERATION 2 Removal Tool Thi...

Page 36: ...on System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System REPAIR REPLACEMENT OF THE MALE ASSEMBLY 36 REPAIR REPLACEMENT MALE ASSEMBLY ...

Page 37: ...9 Assembly Manual 33286031 37 MALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1a MALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1b REPAIR REPLACEMENT IDENTIFY THE SIDE OF THE HINGE WITH A CHAMFER THEN INSERT TOOLTBD BETWEEN THE CONNECTORBODY AND HINGE CONNECTOR HINGE RELEASED ROTATE THE TOOLCAREFULLY TOUNLOCK THE CONNECTORHINGE ...

Page 38: ...1089 Assembly Manual 33286031 38 MALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2a MALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2b REPAIR REPLACEMENT REMOVE TERMINALS This graph justrepresents how this kind of terminals are removed IDENTIFY Flex Locks Mating End Cable End REMOVAL WINDOW TERMINAL FLEX LOCK Removal Window Terminal Flex Lock ...

Page 39: ...INAL OCS 1 2 REPLACEMENT Insert Terminal STEP 3 REPAIR REPLACEMENT REFER TO HARNESS ASSEMBLY SECTION REMOVE TERMINALS Locate Removal Window at the front of the Connector Insert Operation 1 tool TBD straight into the window deflect the Flex Lock to unseat the Terminal and gently pull on the cable to remove Operation 2 the Male Terminal from the receptacle OPERATION 1 OPERATION 2 Removal Tool This g...

Page 40: ...nsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 40 RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER 1 2 3 TBD ...

Page 41: ...onnection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 DATE REV REVISION HISTORY AUTH 09OC15 01 RELEASED 430721 18JA17 02 REVISED PAGES 11 AND 18 435401 41 REVISIONS ...

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