Delphi 1.5 OCS Series Assembly Manual
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Delphi 1.5 OCS Series Assembly Manual

Delphi 1.5 OCS Series Assembly Manual

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ASSEMBLY MANUALS
PRE - ASSEMBLY
HARNESS ASSEMBLY
CAR ASSEMBLY
ASSEMBLY MANUAL - 13987928
1.5 OCS Sealed Connection System
1.5 Terminal System
February 2016
Issued by
CTC Warren, Ohio
STC Saltillo, Mex.

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Summary of Contents for Delphi 1.5 OCS Series

  • Page 1 ASSEMBLY MANUALS PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL - 13987928 1.5 OCS Sealed Connection System 1.5 Terminal System February 2016 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 2012 DELPHI. All rights reserved.

  • Page 3: Table Of Contents

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System TABLE OF CONTENTS PRE–ASSEMBLY SECTION ASSEMBLY OF THE FEMALE CONNECTOR View of Versions List of Components & Exploded View Step 1 - Insert Connector Seal Step 2 - Align and Insert PLR (to Pre-Stage Position) Step 3 - Lock CPA (to Pre-Stage Position) Step 4 - Install Cable Seal Step 5 - Insert Retainer...
  • Page 4 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System TABLE OF CONTENTS List of Components & Exploded View Step 1 - Identify Cavities Step 2 - Align Cavity Plug (Optional)/Terminals Female 1.5 and Female Assembly Step 3 - Insert Cavity Plug (Optional)/Terminals OCS Female 1.5 Step 4 - Close PLR to Full-Stage Female Assembly - Completed ASSEMBLY OF THE MALE HARNESS ASSEMBLY CONNECTOR...
  • Page 5 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System TABLE OF CONTENTS REPAIR / REPLACEMENT SECTION FEMALE CONNECTOR SUB COMPONENTS: PLR Replacement – Step 1 (Remove) Step 2 (Install) TERMINAL F OCS 1.5/CAVITY PLUG Replacement – Step 1 (Remove) Step 2 (Insert) RETAINER Replacement –...

  • Page 6: Assembly Of The Female Connector

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY ASSEMBLY OF THE FEMALE CONNECTOR PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 1.5 OCS Sealed Connection System FEMALE ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 7: View Of Versions

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY VIEW OF VERSIONS 2 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 3 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 4 WAY CONNECTOR...
  • Page 8 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY VIEW OF VERSIONS 8 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 10 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 12 WAY CONNECTOR...

  • Page 9: List Of Components & Exploded View

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS OF 1.5 OCS FEMALE CONNECTOR CONNECTOR SEAL FEMALE CONNECTOR CABLE SEAL RETAINER FEMALE CONNECTOR RETAINER CABLE SEAL CONNECTOR SEAL Pictures used in this Assembly Manual and original parts may differ in some details, these differences have no influence on the assembly process.

  • Page 10: Step 1 - Insert Connector Seal

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 1a – Insert Connector Seal IDENTIFY THE SEALING SURFACE AREA TO THEN, PUSH THE CONNECTOR SEAL INTO THE INSERT THE CONNECTOR SEAL CONNECTOR SEALING SURFACE AREA CONNECTOR WALL STEP 1b –...

  • Page 11: Step 2 - Align And Insert Plr (To Pre-Stage Position)

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 2a – Align and Insert PLR (to Pre-Stage Position) VERIFY AUDIBLE CLICK ON BOTH SIDES STEP 2b – Align and Insert PLR (to Pre-Stage Position) PLR IS NOW IN PRE-STAGE POSITION Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 12: Step 3 - Lock Cpa (To Pre-Stage Position)

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3a – Lock CPA (to Pre-Stage Position) ALIGN CPA WITH THE CONNECTOR LOCK THEN, PUSH DOWN THE CPA TOP VIEW STEP 3b – Lock CPA (to Pre-Stage Position) PRESS DOWN THE CPA UNTIL MATING FEATURES LINE UP AND THE CONNECTOR LOCK DEFLECTS MATING...
  • Page 13 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3c – Lock CPA (to Pre-Stage Position) WITH THE FEATURES ALIGNED, VERIFY AUDIBLE CLICK MOVE THE CPA TO FRONT TOP VIEW STEP 3d – Lock CPA (to Pre-Stage Position) THE CONNECTOR LOCK RETURNS TO ITS ORIGINAL POSITION CPA IS NOW IN PRE-STAGE POSITION...

  • Page 14: Step 4 - Install Cable Seal

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 4 – Install Cable Seal PROCESS FOR: PROCESS FOR: 3W & 4W CONNECTORS 2W, 6W, 8W, 10W, 12W & 16W CONNECTORS IDENTIFY THE CORRECT ORIENTATION LOCATE AND ALIGN MATING FEATURES OF THE SEAL PUSH CABLE SEAL INTO THE CONNECTOR PUSH CABLE SEAL INTO THE RETAINER...

  • Page 15: Step 5 - Insert Retainer

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 5 – Insert Retainer THE INSERTION PROCESS OF THE RETAINER IS THE SAME REGARDLESS THE INSERTION PROCESS OF THE CABLE SEAL PRESS RETAINER ONTO CONNECTOR PRESS RETAINER ONTO CONNECTOR VERIFY AUDIBLE CLICK VERIFY AUDIBLE CLICK ON BOTH SIDES...

  • Page 16: Female Connector - Completed Assembly

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY FEMALE CONNECTOR – COMPLETED ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 17: Assembly Of The Male Connector

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY ASSEMBLY OF THE MALE CONNECTOR PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 1.5 OCS Sealed Connection System MALE ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 18: View Of Versions

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY VIEW OF VERSIONS 2 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 3 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 4 WAY CONNECTOR...
  • Page 19 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY VIEW OF VERSIONS 8 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 10 WAY CONNECTOR TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106 12 WAY CONNECTOR...

  • Page 20: List Of Components & Exploded View

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS OF 1.5 OCS MALE CONNECTOR MALE CONNECTOR CABLE SEAL RETAINER RETAINER MALE CONNECTOR CABLE SEAL Pictures used in this Assembly Manual and original parts may differ in some details, these differences have no influence on the assembly process.

  • Page 21: Step 1 - Align And Insert Plr (To Pre-Stage Position)

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 1a – Align and Insert PLR (to Pre-Stage Position) FRONT VIEW VERIFY AUDIBLE CLICK ON BOTH SIDES STEP 1b – Align and Insert PLR (to Pre-Stage Position) PLR IS NOW IN PRE-STAGE POSITION Contact at STC Saltillo: David Torres +52 844 438 9060...

  • Page 22: Step 2 - Install Cable Seal

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 2 – Install Cable Seal PROCESS FOR: PROCESS FOR: 3W & 4W CONNECTORS 2W, 6W, 8W, 10W, 12W & 16W CONNECTORS IDENTIFY THE CORRECT ORIENTATION OF LOCATE AND ALIGN MATING FEATURES THE SEAL PUSH CABLE SEAL ONTO RETAINER PUSH CABLE SEAL INTO CONNECTOR...

  • Page 23: Step 3 - Insert Retainer

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3 – Insert Retainer THE INSERTION PROCESS OF THE RETAINER IS THE SAME REGARDLESS THE INSERTION PROCESS OF THE CABLE SEAL LOCATE AND ALIGN MATING FEATURES LOCATE AND ALIGN MATING FEATURES PRESS RETAINER ONTO THE CONNECTOR PRESS RETAINER ONTO THE CONNECTOR TO FULLY SEAT CABLE SEAL...

  • Page 24: Male Connector - Completed Assembly

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY MALE CONNECTOR – COMPLETED ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 25 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 1.5 OCS Sealed Connection System FEMALE ASSEMBLY TERMINALS Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 26: List Of Components & Exploded View

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW LIST OF COMPONENTS QUANTITY COMPONENTS OF 1.5 OCS FEMALE CONNECTION FEMALE ASSEMBLY TERMINALS (FEMALE 1.5 UNSEALED) THE QUANTITY OF TERMINALS REQUIRED MIGHT VARY DEPENDING ON THE TYPE OF ASSEMBLY: 2W, 3W, 4W, 6W, 8W, 10W, 12W &...

  • Page 27: Step 1 - Identify Cavities

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 1 – Identify Cavities BACK VIEW CAVITY IDENTIFICATION NUMBERS STEP 2 – Align Cavity Plug (Optional)/Terminals Female 1.5 and Female Assembly INSERT FEMALE TERMINAL INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN. - PROPER ORIENTATION OF TERMINAL REQUIRED - BACK VIEWS ORIENTATION...

  • Page 28: Step 3 - Insert Cavity Plug (Optional)/Terminals Ocs Female

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3a – Insert Cavity Plug (Optional)/Terminals OCS Female 1.5 CAVITY PLUG INSERTION: TERMINAL INSERTION: PUSH THE CAVITY PLUG STRAIGHT PUSH THE TERMINAL STRAIGHT INTO THE CAVITY INTO THE CAVITY VERIFY AUDIBLE CLICK VERIFY AUDIBLE CLICK CAVITY PLUG IS FULLY ENGAGED UNDER...
  • Page 29 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3b – Insert Cavity Plug (Optional)/Terminals OCS Female 1.5 CAVITY PLUG INSERTION: TERMINAL INSERTION: GENTLY PULL ON THE PLUG TO VERIFY GENTLY PULL ON THE CABLE TO VERIFY ITS COMPLETE INSERTION THE LOCKING SYSTEM IF REQUIRED, FOLLOW THE SAME...

  • Page 30: Step 4 - Close Plr To Full-Stage

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 4 – Close PLR to Full-Stage PUSH PLR TO THE END POSITION VERIFY AUDIBLE CLICK TO SECURE THE TERMINALS ON BOTH SIDES PLR IS NOW IN FULL-STAGE POSITION FEMALE ASSEMBLY - COMPLETED Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 31: Assembly Of The Male Harness Assembly Connector

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY ASSEMBLY OF THE MALE HARNESS ASSEMBLY PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 1.5 OCS Sealed Connection System MALE ASSEMBLY TERMINALS Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 32: List Of Components & Exploded View

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY LIST OF COMPONENTS QUANTITY COMPONENTS OF 1.5 OCS MALE CONNECTION MALE ASSEMBLY TERMINALS (MALE 1.5 UNSEALED) THE QUANTITY OF TERMINALS REQUIRED MIGHT VARY DEPENDING ON THE TYPE OF ASSEMBLY: 2W, 3W, 4W, 6W, 8W, 10W, 12W &...

  • Page 33: Step 1 - Identify Cavities

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 1 – Identify Cavities BACK VIEW CAVITY IDENTIFICATION NUMBERS STEP 2 – Align Cavity Plug (Optional)/Terminals Male 1.5 and Male Assembly INSERT MALE TERMINAL INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN. - PROPER ORIENTATION OF TERMINAL REQUIRED - TERMINAL CAVITY PLUG...

  • Page 34: Step 3 - Insert Cavity Plug (Optional)/Terminals Ocs Male

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3a – Insert Cavity Plug (Optional)/Terminals OCS Male 1.5 CAVITY PLUG INSERTION: TERMINAL INSERTION: PUSH THE CAVITY PLUG STRAIGHT PUSH THE TERMINAL STRAIGHT INTO THE CAVITY INTO THE CAVITY VERIFY AUDIBLE CLICK VERIFY AUDIBLE CLICK CAVITY PLUG IS FULLY ENGAGED UNDER...
  • Page 35 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3b – Insert Cavity Plug (Optional)/Terminals OCS Male 1.5 CAVITY PLUG INSERTION: TERMINAL INSERTION: GENTLY PULL ON THE PLUG TO VERIFY GENTLY PULL ON THE CABLE TO VERIFY ITS COMPLETE INSERTION THE LOCKING SYSTEM IF REQUIRED, FOLLOW THE SAME...

  • Page 36: Step 4 - Close Plr To Full-Stage

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 4 – Close PLR to Full-Stage PUSH PLR TO THE END POSITION VERIFY AUDIBLE CLICK TO SECURE THE TERMINALS ON BOTH SIDES PLR IS NOW IN FULL-STAGE POSITION MALE ASSEMBLY - COMPLETED Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 37: Assembly Of The Connection System

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY ASSEMBLY OF THE CONNECTION SYSTEM PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 1.5 OCS Sealed Connection System FEMALE ASSEMBLY MALE ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 38: Model

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY 3D MODEL VIEW CLICK IMAGE TO START 3D VISUALIZATION Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 39: Step 1 - Identify And Align Index Features

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 1 – Identify and Align Index Features FRONT VIEWS STEP 2 – Mate Female Assembly and Male Assembly Together Axially IF THE INDEXES DON’T LINE UP, IMPORTANT! VERIFY AUDIBLE CLICK DO NOT CONTINUE Contact at STC Saltillo: David Torres +52 844 438 9060...

  • Page 40: Step 3 - Close Cpa To Full-Stage

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System ASSEMBLY STEP 3 – Close CPA to Full-Stage SLIDE CPA TO THE END POSITION TO SECURE VERIFY AUDIBLE CLICK THE ASSEMBLY CONNECTION SYSTEM – COMPLETED ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 41: Disassembly Of The Connection System

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System DISASSEMBLY DISASSEMBLY OF THE CONNECTION SYSTEM PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 1.5 OCS Sealed Connection System FEMALE ASSEMBLY MALE ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 42: Step 1 - Move Cpa To Pre-Stage Position

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System DISASSEMBLY STEP 1a – Move CPA to Pre-Stage Position PULL BACK THE CPA TO RELEASE THE ASSEMBLY STEP 1b – Move CPA to Pre-Stage Position CPA IS NOW IN PRE-STAGE POSITION Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 43: Step 2 - Release The Connector Lock

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System DISASSEMBLY STEP 2a – Release the Connector Lock LOCATE AND PRESS DOWN THE CONNECTOR LOCK STEP 3 – Disconnect WITH THE CONNECTOR LOCK DEFLECTED, PULL BACK BOTH ASSEMBLIES Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...

  • Page 44: Connection System - Completed Disassembly

    Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System DISASSEMBLY CONNECTION SYSTEM – COMPLETED DISASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 45 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE FEMALE ASSEMBLY 1.5 OCS Sealed Connection System FEMALE ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 46 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT PLR REPLACEMENT (Remove) – STEP 1a LOCATE THE SLOTS AT THE BOTTOM SIDE OF INSERT TOOL 12122647 OR 12094430 THE CONNECTOR INTO THE SLOT LOCK OF PLR REPLACEMENT (Remove) –...
  • Page 47 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT PLR REPLACEMENT (Remove) – STEP 1c REPEAT THE PROCESS TO RELEASE THE OTHER SIDE OF PLR FROM FULL-STAGE PLR IS NOW IN PRE-STAGE POSITION PLR REPLACEMENT (Remove) – STEP 1d THEN REMOVE PLR FROM CONNECTOR USE THE SAME PROCEDURE TO RELEASE PLR FROM PRE-STAGE POSITION...
  • Page 48 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT PLR REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION FEMALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Remove) – STEP 1a IMPORTANT! PLR MUST BE RELEASED FROM CONNECTOR BEFORE TERMINAL/PLUG REMOVAL CAVITY PLUG...
  • Page 49 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT FEMALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Remove) – STEP 1b REMOVE TERMINALS IDENTIFY Flex Lock Mating End Terminal Cable End Flex Lock * This graph just represents how this kind of terminals are removed. FEMALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Remove) –...
  • Page 50 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT FEMALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Insert) – STEP 2 REFER TO HARNESS MANUAL SECTION RETAINER REPLACEMENT (Remove) – STEP 1a PLACE TOOL 12094441 BETWEEN THE ROTATE THE TOOL CAREFULLY TO RELEASE CONNECTOR AND RETAINER THAT SIDE OF THE RETAINER...
  • Page 51 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT RETAINER REPLACEMENT (Remove) – STEP 1b REPEAT THE PROCEDURE TO RELEASE THE OTHER SIDE OF RETAINER RETAINER REMOVED RETAINER REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 52 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT CABLE SEAL REPLACEMENT (Remove) – STEP 1a INSERT TOOL 12094441 BETWEEN THE CONNECTOR AND CABLE SEAL CABLE SEAL REPLACEMENT (Remove) – STEP 1b WITH THE TIP OF TOOL REMOVE THE SEAL FROM THE SHROUD RETAINER REMOVED Contact at STC Saltillo: David Torres +52 844 438 9060...
  • Page 53 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT CABLE SEAL REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION CABLE SEAL is not a reusable sub-component. REPLACE ENTIRE CABLE SEAL CPA REPLACEMENT (Remove) – STEP 1a PRESS DOWN THE CONNECTOR LOCK WITH THE LOCK DEFLECTED, SLIDE THE CPA BACKWARDS TO REMOVE IT...
  • Page 54 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT CPA REPLACEMENT (Remove) – STEP 1b RETAINER REMOVED CPA REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 55 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT CONNECTOR SEAL REPLACEMENT (Remove) – STEP 1a IDENTIFY THE PERMISIBLE AREAS FOR THE TOOL FRONT VIEW CONNECTOR SEAL PERMISSIBLE AREA IMPORTANT! PLR MUST BE COMPLETELY REMOVED FROM THE CONNECTOR BEFORE THE SEAL REMOVAL CONNECTOR SEAL REPLACEMENT (Remove) –...
  • Page 56 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT CONNECTOR SEAL REPLACEMENT (Remove) – STEP 1c EXTRACT SEAL FROM THE SHROUD CONNECTOR SEAL REMOVED CONNECTOR SEAL REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION CONNECTOR SEAL is not a reusable sub-component.
  • Page 57 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE MALE ASSEMBLY 1.5 OCS Sealed Connection System MALE ASSEMBLY Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 58 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT MALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Move PLR to Pre-Stage) – STEP 1a LOCATE THE AREAS TO INSERT TOOL 15313892 INSERT TOOL INTO THE SHROUD, WITH THE HOOK FACING TOWARD THE CENTER OF CONNECTOR AND PLACE IT BEHIND THE PLR DETAIL...
  • Page 59 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT MALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Move PLR to Pre-Stage) – STEP 1c USE THE SAME PROCESS TO MOVE THE OTHER SIDE IF NEEDED PLR IS NOW IN PRE-STAGE POSITION MALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Remove) –...
  • Page 60 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT MALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Remove) – STEP 2b REMOVE TERMINALS IDENTIFY Flex Lock Mating End Cable End Flex Lock Terminal * This graph just represents how this kind of terminals are removed. MALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Remove) –...
  • Page 61 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT MALE TERMINAL OCS 1.5/CAVITY PLUG REPLACEMENT (Insert) – STEP 3 REFER TO HARNESS MANUAL SECTION RETAINER REPLACEMENT (Remove) – STEP 1a PLACE TOOL 12094441 BETWEEN THE ROTATE THE TOOL CAREFULLY TO RELEASE CONNECTOR AND RETAINER THAT SIDE OF THE RETAINER...
  • Page 62 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT RETAINER REPLACEMENT (Remove) – STEP 1b REPEAT THE PROCEDURE TO RELEASE THE OTHER SIDE OF RETAINER RETAINER REMOVED RETAINER REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 63 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT CABLE SEAL REPLACEMENT (Remove) – STEP 1a INSERT TOOL 12094441 BETWEEN THE WITH THE TIP OF TOOL REMOVE THE SEAL CONNECTOR AND CABLE SEAL FROM THE SHROUD CABLE SEAL REPLACEMENT (Remove) –...
  • Page 64 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT CABLE SEAL REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION CABLE SEAL is not a reusable sub-component. REPLACE ENTIRE CABLE SEAL PLR REPLACEMENT (Remove) – STEP 1a LOCATE THE AREAS TO INSERT TOOL 15313892 INSERT THE TOOL BEHIND THE PLR DETAIL...
  • Page 65 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT PLR REPLACEMENT (Remove) – STEP 1b CAREFULLY PULL THE TOOL BACKWARDS TO REPEAT THE PROCESS ON THE OTHER SIDE REMOVE THAT SIDE OF PLR AN REMOVE PLR COMPLETELY PLR REPLACEMENT (Remove) –...
  • Page 66 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REPAIR / REPLACEMENT PLR REPLACEMENT (Install) – STEP 2 REFER TO PRE-ASSEMBLY MANUAL SECTION Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 67 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER 12122647 OR 12094430 12094441 12094429 15313892 12150860 Contact at STC Saltillo: David Torres +52 844 438 9060 Assembly Manual - 13987928...
  • Page 68 Assembly Manual 1.5 OCS Sealed Connection System emale/Male 1.5 Terminal System REVISIONS DATE REVISION HISTORY AUTH 12OC12 RELEASED 419944 ADDED CAR-ASM & REPAIR SECTIONS, UPDATED GRAPHICS & 12JL13 MATTE SEAL ASM, CHANGED NAME OF THE MANUAL AND 420327 ADDED VIEW OF VERSIONS SHEETS UPDATED GRAPHICS WITH LATEST DESIGNS &...

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