Delphi Connectors (Push to Seat)

Wiring Systems and Power Management | Diagnostic Information and Procedures | Document ID: 5207167 Special Tools EL-38125-550 Terminal Release Tool Kit EL-38125-580 Terminal Release Tool Kit For equivalent regional tools, refer to Special Tools. Terminal Removal Procedure Follow the steps below in order to repair push to seat connectors.

1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock.

Delphi Connectors (Push to Seat) — figure 1

2. Separate the connector halves (1).

Delphi Connectors (Push to Seat) — figure 2

3. Use the proper pick or removal tool (1) in order to release the terminal.
4. Gently pull the cable and the terminal (2) out of the back of the connector.

Delphi Connectors (Push to Seat) — figure 3

5. Re-form the locking device if you are going to reuse the terminal (1).
6. Repair the terminal by following the Repairing Connector Terminals procedure.
7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminal Insertion Procedure
8. In order to reuse a terminal or lead assembly, refer to Wiring Repairs.
9. Ensure that the cable seal is kept on the terminal side of the splice.
10. Insert the lead from the back until it catches.
11. Install the TPA, CPA, and/or the secondary locks.