Delphi Connectors (12-Way)

Delphi Connectors (12-Way)

Special Tools

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Removal Procedure

Follow the steps below in order to remove terminals from the connector.




1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body.
2. Disconnect the connector from the component.




3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs.




4. Release the lower wire dress cover locking tab.




5. Release the upper wire dress cover locking tab.
6. Once the locks are unlocked, lift the dress cover off.





Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it.

7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector.




8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector.




9. Insert the EL-38125-12A tool to release the terminals by inserting the tool into the terminal release cavity.




10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector.

Terminal Repair Procedure

The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals.

1. Cut the wire as close to the terminal as possible.

Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire.

2. Strip 5 mm (3/16 in) of insulation from the wire.




3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible.




4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal.
6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator.

Terminated Lead Repair

1. Remove the terminal.
2. Find the appropriate terminated lead.
3. Use the appropriate splice sleeves depending on the gauge size.
4. Refer to Splicing Copper Wire Using Splice Sleeves (Splicing Copper Wire Using Splice Sleeves).