Terminal Wiring Repair
Special Tools
- EL-38125-10: Splice Sleeve Crimp Tool
- EL-38125-580: Terminal Release Tool Kit
- J-38125-5: Ultra Torch
- EL-35616: Connector Test Adapter Kit
For equivalent regional tools, refer to Special Tools .
NOTE:
All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures.
- Find the appropriate connector end view within the connector end view section. The connector end view has the following information:
- Diagnostic probe tool
- Terminal release tool
- Terminal/terminated lead part numbers
- Determine if a terminal is damaged.NOTE: Not using the proper test kit probe may cause damage to the terminal(s) that are probed.
- Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool.
- Connect the probe tool to the Digital Multimeter.
- Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter .
- Disconnect the connector body to perform the repair.
NOTE:
Several procedures for specific connector bodies are called out in Wiring Repairs .
Use the following repair procedures to repair the following terminals:
Delphi Connectors (Weather Pack) or Delphi Connectors (Push To Seat) or Delphi Connectors (Pull To Seat) or Delphi Connectors (Micro-Pack 100W) or Delphi Connectors (Micro .64) or Delphi Connectors (12-Way)
- The TPA and CPA should be removed before releasing the terminal for the connector body.
- Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit.
- Insert the terminal release tool into the cavity.
NOTE:
Using the incorrect terminal release tool can damage the connector body.
NOTE:
Some terminals have a lever that must be disengaged before the terminal can be released.
Gently pull the wire out of the back of the connector.