Delphi 101 Assembly Manual
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Delphi 101 Assembly Manual

2 way unsealed ocs 1.2 inline connection system
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ASSEMBLY MANUALS
PRE - ASSEMBLY
HARNESS ASSEMBLY
CAR ASSEMBLY
ASSEMBLY MANUAL - 33286031
2 Way Unsealed OCS 1.2 Inline
Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
October 2015
Issued by
CTC Warren, Ohio
STC Saltillo, Mex.

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  • Page 1 ASSEMBLY MANUALS PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL - 33286031 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) October 2015 Issued by CTC Warren, Ohio STC Saltillo, Mex.
  • Page 2 The information contained in these assembly instructions is subject to alteration without prior notice and does not represent any obligation on the part of DELPHI. All the information is correct at time of releasing. Reprinting or translation is not permitted without written permission from DELPHI. © Copyright 2015 DELPHI. All rights reserved.

  • Page 3: Table Of Contents

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) TABLE OF CONTENTS PRE–ASSEMBLY SECTION ASSEMBLY OF THE FEMALE CONNECTOR View of Versions List of Components & Exploded View ASSEMBLY SEQUENCE: Step 1 – Assemble CPA to Pre-Stage Position Connector Assembly –...
  • Page 4 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) TABLE OF CONTENTS Step 3 – Insert Terminals Male OCS 1.2 (or Equivalent) Step 4 – Lock Connector Hinge to Closed Position Harness Assembly – Completed CAR ASSEMBLY SECTION ASSEMBLY OF THE CONNECTION SYSTEM List of Components &...

  • Page 5: Assembly Of The Female Connector

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY ASSEMBLY OF THE FEMALE CONNECTOR PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 2 Way Unsealed OCS 1.2 Inline Connection System FEMALE CONNECTOR ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...

  • Page 6: View Of Versions

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY VIEW OF VERSIONS Type 101 Type 102 Type 103 Type 104 THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS, WHICH DIFFER IN THE INDEXING AND COLOR.

  • Page 7: List Of Components & Exploded View

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW LIST OF COMPONENTS QUANTITY COMPONENTS FEMALE CONNECTOR FEMALE CONNECTOR Pictures used in this Assembly Manual and original parts may differ in some details.
  • Page 8 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1a – Assemble CPA to Pre-Stage Position IDENTIFY THE CORRECT ORIENTATION OF THE CPA AND INSERT IT ONTO THE CONNECTOR STEP 1b – Assemble CPA to Pre-Stage Position VERIFY AUDIBLE CLICK ON BOTH LOCKS SECTION VIEW...

  • Page 9: Connector Assembly - Completed

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY FEMALE CONNECTOR ASSEMBLY – COMPLETED ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...

  • Page 10: Assembly Of The Female Harness Assembly Connector

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 2 Way Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...

  • Page 11: List Of Components & Exploded View

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS FEMALE CONNECTOR ASSEMBLY TERMINAL OCS 1.2 TERMINAL FEMALE CONNECTOR ASSEMBLY Pictures used in this Assembly Manual and original parts may differ in some details, these differences have no influence on the assembly process.

  • Page 12: Step 1 - Identify Cavities For Terminals Ocs 1.2 (Or Equivalent)

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1 – Identify Cavities for Terminals OCS 1.2 (or Equivalent) BACK VIEW CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR. STEP 2 –...

  • Page 13: Step 3 - Insert Terminals Female Ocs 1.2 (Or Equivalent)

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 3a – Insert Terminals Female OCS 1.2 (or Equivalent) PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 3b –...

  • Page 14: Step 4 - Lock Connector Hinge To Closed Position

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 4a – Lock Connector Hinge to Closed Position CAREFULLY PUSH THE HINGE FORWARD DO NOT FORCE THE HINGE, IF IT CAN’T BE CLOSED REVIEW IF TERMINALS ARE PROPERLY LOCKED STEP 4b –...

  • Page 15: Harness Assembly - Completed

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY FEMALE ASSEMBLY – COMPLETED HARNESS ASSEMBLY CONNECTOR HINGE MUST BE COMPLETELY CLOSED BEFORE TAPING OR DRESSING WIRES/HARNESS PERFORM TESTS, APPLY COVERINGS AS REQUIRED. INSPECT THE ASSEMBLY. Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...

  • Page 16: Assembly Of The Male Harness Assembly Connector

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY ASSEMBLY OF THE MALE HARNESS ASSEMBLY PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 2 Way Unsealed OCS 1.2 Inline Connection System MALE ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...

  • Page 17: View Of Versions

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY VIEW OF VERSIONS Type 101 Type 102 Type 103 Type 104 THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS, WHICH DIFFER IN THE INDEXING AND COLOR.

  • Page 18: List Of Components & Exploded View

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS MALE CONNECTOR TERMINAL OCS 1.2 MALE CONNECTOR TERMINAL Pictures used in this Assembly Manual and original parts may differ in some details, these differences have no influence on the assembly process.

  • Page 19: Step 1 - Identify Cavities For Terminals Ocs (Or Equivalent)

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1 – Identify Cavities for Terminals OCS (or Equivalent) BACK VIEW CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR STEP 2 – Align Terminals Male 1.2 and Male Assembly INSERT MALE TERMINALS INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN.

  • Page 20: Contact At Ctc Warren: Michelle Smith +1 (330) 306 1089

    Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 3a – Insert Terminals Male OCS 1.2 (or Equivalent) PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 3b –...
  • Page 21 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 4a – Lock Connector Hinge to Closed Position DO NOT FORCE THE HINGE, IF IT CAN’T BE CLOSED REVIEW IF TERMINALS ARE PROPERLY LOCKED STEP 4b –...
  • Page 22 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY MALE ASSEMBLY – COMPLETED HARNESS ASSEMBLY CONNECTOR HINGE MUST BE COMPLETELY CLOSED BEFORE TAPING OR DRESSING WIRES/HARNESS PERFORM TESTS, APPLY COVERINGS IF REQUIRED. INSPECT THE ASSEMBLY. Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 23 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY ASSEMBLY OF THE CONNECTION SYSTEM PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 2 Way Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY MALE ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 24 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW COMPONENTS OF 2 WAY UNSEALED OCS 1.2 INLINE QUANTITY CONNECTION SYSTEM MALE ASSEMBLY FEMALE ASSEMBLY MALE ASSEMBLY FEMALE ASSEMBLY Pictures used in this Assembly Manual and original parts may differ in some details.
  • Page 25 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY 3D MODEL VIEW CLICK IMAGE TO START 3D VISUALIZATION Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 26 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1 – Identify Index Features FRONT VIEWS STEP 2a – Align Index Features and Mate Female Assembly and Male Assembly Together IMPORTANT! IF THE INDEXES DON'T LINE UP, DO NOT CONTINUE.
  • Page 27 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 2b – Align Index Features and Mate Female Assembly and Male Assembly Together VERIFY AUDIBLE CLICK STEP 3a – Lock CPA to Full-Stage Position SLIDE THE CPA FORWARD, AS SHOWN BELOW, TO SECURE THE CONNECTION Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 28 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 3b – Lock CPA to Full-Stage Position VERIFY AUDIBLE CLICK CPA IS NOW IN FULL-STAGE POSITION CONNECTION SYSTEM – COMPLETED ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 29 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) DISASSEMBLY DISASSEMBLY OF THE CONNECTION SYSTEM PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 2 Way Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY MALE ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 30 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) DISASSEMBLY STEP 1a – Move CPA to Pre-Stage Position HOLD THE CPA TAB THEN SLIDE BACK THE CPA TO PLACE IT IN PRE-STAGE STEP 1b – Move CPA to Pre-Stage Position CPA IS NOW IN PRE-STAGE POSITION Contact at CTC Warren: Michelle Smith +1 (330) 306 1089...
  • Page 31 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) DISASSEMBLY STEP 2 – Disconnect LOCATE AND PRESS DOWN THE CONNECTOR LOCK (1); WITH THE LOCK DEFLECTED, DISENGAGE THE CONNECTORS (2) CONNECTION SYSTEM – COMPLETED DISASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 32 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE FEMALE ASSEMBLY 2 Way Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 33 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT FEMALE TERMINAL OCS 1.2 REPLACEMENT (Release Connector Hinge) – STEP 1a IDENTIFY THE SIDE OF THE HINGE WITH A ROTATE THE TOOL CAREFULLY TO UNLOCK THE CHAMFER, THEN INSERT TOOL TBD BETWEEN CONNECTOR HINGE THE CONNECTOR BODY AND HINGE...
  • Page 34 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT FEMALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2a TERMINAL FLEX LOCK REMOVAL WINDOW FEMALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2b REMOVE TERMINALS IDENTIFY Removal Window...
  • Page 35 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT FEMALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2c REMOVE TERMINALS Locate Removal Window at the front of the Connector. Insert (Operation 1) tool TBD straight into the window, deflect the Flex Lock to unseat the Terminal and gently pull on the cable to remove (Operation 2) the Female Terminal from the receptacle.
  • Page 36 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE MALE ASSEMBLY 2 Way Unsealed OCS 1.2 Inline Connection System MALE ASSEMBLY Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 37 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT MALE TERMINAL OCS 1.2 REPLACEMENT (Release Connector Hinge) – STEP 1a IDENTIFY THE SIDE OF THE HINGE WITH A ROTATE THE TOOL CAREFULLY TO UNLOCK THE CHAMFER, THEN INSERT TOOL TBD BETWEEN CONNECTOR HINGE THE CONNECTOR BODY AND HINGE...
  • Page 38 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT MALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2a TERMINAL REMOVAL WINDOW FLEX LOCK MALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2b REMOVE TERMINALS IDENTIFY Flex Locks...
  • Page 39 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT MALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2c REMOVE TERMINALS Locate Removal Window at the front of the Connector. Insert (Operation 1) tool TBD straight into the window, deflect the Flex Lock to unseat the Terminal and gently pull on the cable to remove (Operation 2) the Male Terminal from the receptacle.
  • Page 40 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...
  • Page 41 Assembly Manual 2 Way Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REVISIONS DATE REVISION HISTORY AUTH 09OC15 RELEASED 430721 18JA17 REVISED PAGES 11 AND 18 435401 Contact at CTC Warren: Michelle Smith +1 (330) 306 1089 Assembly Manual - 33286031...

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