Electrical Connector Tools and Service
91SUBARU02
NUMBER 14-17-91
DATE 02-08-91
APPLICABILITY ALL LEGACY VEHICLES
SUBJECT: ELECTRICAL CONNECTOR TOOLS AND SERVICE
The purpose of this bulletin is to introduce two new electrical connector servicing tools for Legacy vehicles and to provide information on their use.
Please refer to Subaru Service Bulletin Number 07-38-88 dated 10-12-88 "Electrical Connector Diagnosis and Repair" for background information and details on electrical tools and repairs.
The tools consist of two new connector remover inserts. These inserts are designed to service Legacy vehicles and can be used with the previously released pin vise handle. Parts information is listed in the table below. Please note that the part received may display a different number than the P/N ordered. Parts are available through normal parts channels.
S0A P/N PACKAGE NUMBER DESCRIPTION
S0A638654 J-38654 Set of two insert tools, CKZ and DLI
S0A638654 A J-38654-1 One CKZ insert tool
S0A638654 B J-38654-2 One DLI insert tool
S0A622800 J-22800-3 Pin vise handle
Many different terminal configurations are used for the nearly 300 connectors found throughout the Legacy. It's not necessary or practical to display all the different plastic terminal configurations along with the proper tool.
More important is to understand the characteristics of the metal terminals and how they are secured into the plastic housing connector. The proper tool can then be selected and used.
All metal terminals are released from the plastic housing by inserting the tool into the front of the housing (not the wire side) and depressing a lock tab. The terminal is then pulled from the rear (wire side) of the housing. The proper tool is selected by comparing the release opening in the plastic housing connector with the two remover inserts. Select the insert that provides the best fit.
Several items to be aware of when using the tools are:
Figure 1. Tool Unlocking Terminal:
1. Many plastic housings incorporate some kind of locking device on the back (wire) side of the housing which must be released prior to terminal removal. See Figure 1.
2. On almost all terminals, the remover insert should be placed into the plastic housing with the long shank portion of the tool oriented closest to the center of the housing. The terminal closest to the shank portion could then be removed. See Figure 1. In this example, the upper-terminal could be serviced.
3. After the tool is inserted it may be helpful to slightly angle the tool to move the lock away and free the metal terminal. See Figure 1. Avoid heavy pressure, the tool may bend or break. Heavy pressure should not be required to release any terminal.
These tools are essential in the diagnosis of any electrical malfunction. Whenever a fuel system diagnosis is being performed, confirm the integrity of the connections for sliding resistance. Any suspect connections can be repaired using these tools.