Terminal Wiring Repair

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 (Tools and Equipment).

Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures.

1. 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

2. 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 (Troubleshooting with a Digital Multimeter).

3. Disconnect the connector body to perform the repair.

Note: Several procedures for specific connector bodies are called out in Wiring Repairs (Wiring Repairs).

Use the following repair procedures to repair the following terminals:

Delphi Connectors (Weather Pack) (Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (Delphi Connectors (Push to Seat))Delphi Connectors (Pull To Seat) (Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (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.

Note: Using the incorrect terminal release tool can damage the connector body.

* Insert the terminal release tool into the cavity.

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.