Bosch Connectors (ECM)

Bosch Connectors (ECM)

Special Tools

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

Removal Procedure




1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.




2. Disconnect the connector from the component.




3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover.




4. The terminal positive assurance (TPA) is located in the front of the connector.




5. Use a small flat-blade tool to remove TPA from the connector.




6. Use the EL-38125-213 or the EL-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity.
7. 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





Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component.

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).