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Delphi Assembly Manual

Delphi Assembly Manual

Connection system
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ASSEMBLY MANUALS
PRE - ASSEMBLY
HARNESS ASSEMBLY
CAR ASSEMBLY
ASSEMBLY MANUAL - 33265159
Unsealed OCS 1.2 Inline
Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
January 2017
Issued by
CTC Warren, Ohio
STC Saltillo, Mex.

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  • Page 1 ASSEMBLY MANUALS PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL - 33265159 Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) January 2017 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 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 – Install FLS to Pre-Stage Position Step 2 –...
  • Page 4 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) TABLE OF CONTENTS Step 2 – Align Terminals Female 1.2 and Female Assembly Step 3 – Insert Terminals Female OCS 1.2 15542380 (or Equivalent) Step 4 – Identify Cavities for Terminals OCS 1.2 13881788 (or Equivalent) Step 5 –...
  • Page 5 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) TABLE OF CONTENTS DISASSEMBLY SECTION DISASSEMBLY OF THE CONNECTION SYSTEM Step 1 – Move CPA to Pre-Stage Position Step 2 – Disconnect Connection System – Completed Disassembly REPAIR / REPLACEMENT SECTION FEMALE CONNECTOR SUB COMPONENTS: TERMINAL F OCS 1.2 Replacement –...

  • Page 6: Assembly Of The Female Connector

    Assembly Manual 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 Unsealed OCS 1.2 Inline Connection System FEMALE CONNECTOR ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 7: View Of Versions

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY VIEW OF VERSIONS 6 Way Assembly Connector – Type 101 4 Way Assembly Connector -Type 101 8 Way Assembly Connector – Type 101 12 Way Assembly Connector – Type 101 16 Way Assembly Connector –...

  • Page 8: List Of Components & Exploded View

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS FEMALE CONNECTOR FLS (Full Locking System) FEMALE CONNECTOR Pictures used in this Assembly Manual and original parts may differ in some Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 details.

  • Page 9: Step 1 - Install Fls To Pre-Stage Position

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1a – Install FLS to Pre-Stage Position IDENTIFY THE CORRECT ORIENTATION OF THE FLS STEP 1b – Install FLS to Pre-Stage Position INSERT FLS INTO THE CONNECTOR VERIFY AUDIBLE CLICK FLS IS FLUSH WITH THE PROTECTOR RIBS ON CONNECTOR...

  • Page 10: Step 2 - Assemble Cpa To Pre-Stage Position

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1c – Install FLS to Pre-Stage Position VERIFY THE CORRECT POSITION OF THE FLS, FOR PRE-STAGE DIMENSIONS REFER TO LATEST ASSEMBLY DRAWING FLS IS NOW IN PRE-STAGE POSITION STEP 2a –...

  • Page 11: Connector Assembly - Completed

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 2b – Assemble CPA to Pre-Stage Position VERIFY AUDIBLE CLICK SECTION VIEW CPA IS NOW IN PRE-STAGE POSITION FEMALE CONNECTOR ASSEMBLY – COMPLETED Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 12: Assembly Of The Male Connector

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY ASSEMBLY OF THE MALE CONNECTOR PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY Unsealed OCS 1.2 Inline Connection System MALE CONNECTOR ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 13: View Of Versions

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY VIEW OF VERSIONS 6 Way Assembly Connector – Type 101 4 Way Assembly Connector -Type 101 8 Way Assembly Connector – Type 101 12 Way Assembly Connector – Type 101 16 Way Assembly Connector –...

  • Page 14: List Of Components & Exploded View

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS MALE CONNECTOR FLS (Full Locking System) MALE CONNECTOR Pictures used in this Assembly Manual and original parts may differ in some Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 details.

  • Page 15: Step 1 - Install Fls To Pre-Stage Position

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1a – Install FLS to Pre-Stage Position IDENTIFY THE CORRECT ORIENTATION OF THE FLS STEP 1b – Install FLS to Pre-Stage Position INSERT FLS INTO THE CONNECTOR VERIFY AUDIBLE CLICK FLS IS FLUSH WITH THE PROTECTOR RIBS ON CONNECTOR...

  • Page 16: Connector Assembly - Completed

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1c – Install FLS to Pre-Stage Position VERIFY THE CORRECT POSITION OF THE FLS, FOR PRE-STAGE DIMENSIONS REFER TO LATEST ASSEMBLY DRAWING FLS IS NOW IN PRE-STAGE POSITION MALE CONNECTOR ASSEMBLY –...

  • Page 17: Assembly Of The Female Harness Assembly Connector

    Assembly Manual 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 Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 18: List Of Components & Exploded View

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS FEMALE CONNECTOR ASSEMBLY TERMINAL OCS 1.2 15542380 OR EQUIVALENT TERMINAL OCS 1.2 13881788 OR EQUIVALENT REFER TO LATEST APPLICATION DRAWING FOR DETAILS TERMINAL 13881788 TERMINAL 15542380 FEMALE CONNECTOR...

  • Page 19: Step 1 - Identify Cavities For Terminals Ocs 1.2 15542380 (Or Equivalent)

    Assembly Manual 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 15542380 (or Equivalent) BACK VIEW CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR. APPLICABLE CAVITIES: 1, 10, 11, 20. STEP 2 –...

  • Page 20: Step 3 - Insert Terminals Female Ocs 1.2 15542380 (Or Equivalent)

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 3a – Insert Terminals Female OCS 1.2 15542380 (or Equivalent) PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 3b –...

  • Page 21: Step 4 - Identify Cavities For Terminals Ocs 1.2 13881788 (Or Equivalent)

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 4 – Identify Cavities for Terminals OCS 1.2 13881788 (or Equivalent) BACK VIEW CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR. APPLICABLE CAVITIES: 2-9, 12-19. STEP 5 –...

  • Page 22: Step 6 - Insert Terminals Female Ocs 1.2 13881788 (Or Equivalent)

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 6a – Insert Terminals Female OCS 1.2 13881788 (or Equivalent) PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 6b –...

  • Page 23: Step 7 - Lock Fls To Full-Stage Position

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 7a – Lock FLS to Full-Stage Position USE TOOL 12152398 TO PUSH THE FLS FORWARD DO NOT FORCE THE FLS, IF IT CAN’T BE LOCKED REVIEW IF TERMINALS ARE PROPERLY LOCKED STEP 7b –...
  • Page 24 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 7c – Lock FLS to Full-Stage Position VERIFY THE CORRECT FULL-STAGE POSITION OF THE FLS. REFER TO LATEST ASSEMBLY DRAWING FOR FINAL DIMENSIONS FLS IS NOW IN FULL-STAGE POSITION Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 25: Details For Electrical Test

     Always follow the proper techniques to ensure the correct function of the Connection System. The appropriate Ring-Out procedure is to be determined by the Delphi Assembly Tooling Business Unit. Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 26: Harness Assembly - Completed

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY FEMALE ASSEMBLY – COMPLETED HARNESS ASSEMBLY FLS MUST BE IN FULL-STAGE POSITION BEFORE TAPING OR DRESSING WIRES/HARNESS PERFORM TESTS, APPLY COVERINGS AS REQUIRED. INSPECT THE ASSEMBLY. Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 27: Assembly Of The Male Harness Assembly Connector

    Assembly Manual 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 Unsealed OCS 1.2 Inline Connection System MALE ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 28: List Of Components & Exploded View

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS MALE CONNECTOR ASSEMBLY TERMINAL OCS 1.2 33101342 OR EQUIVALENT TERMINAL OCS 1.2 33101341 OR EQUIVALENT REFER TO LATEST APPLICATION DRAWING FOR DETAILS TERMINAL 33101342 TERMINAL 33101341 MALE CONNECTOR...

  • Page 29: Step 1 - Identify Cavities For Terminals Ocs 1.2 33101342 (Or Equivalent)

    Assembly Manual 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 33101342 (or Equivalent) BACK VIEW CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR. APPLICABLE CAVITIES: 1, 10, 11, 20. STEP 2 –...

  • Page 30: Step 3 - Insert Terminals Male Ocs 1.2 33101342 (Or Equivalent)

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 3a – Insert Terminals Male OCS 1.2 33101342 (or Equivalent) PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 3b –...

  • Page 31: Step 4 - Identify Cavities For Terminals Ocs 1.2 33101341 (Or Equivalent)

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 4 – Identify Cavities for Terminals OCS 1.2 33101341 (or Equivalent) BACK VIEW CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR. APPLICABLE CAVITIES: 2-9, 12-19. STEP 5 –...

  • Page 32: Step 6 - Insert Terminals Male Ocs 1.2 33101341 (Or Equivalent)

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 6a – Insert Terminals Male OCS 1.2 33101341 (or Equivalent) PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 6b –...

  • Page 33: Step 7 - Lock Fls To Full-Stage Position

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 7a – Lock FLS to Full-Stage Position USE TOOL 12152398 TO PUSH THE FLS FORWARD DO NOT FORCE THE FLS, IF IT CAN’T BE LOCKED REVIEW IF TERMINALS ARE PROPERLY LOCKED STEP 7b –...

  • Page 34: Harness Assembly - Completed

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 7c – Lock FLS to Full-Stage Position VERIFY THE CORRECT FULL-STAGE POSITION OF THE FLS. REFER TO LATEST ASSEMBLY DRAWING FOR FINAL DIMENSIONS FLS IS NOW IN FULL-STAGE POSITION MALE ASSEMBLY –...

  • Page 35: Car Assembly Section

    Assembly Manual 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 Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY MALE ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.

  • Page 36: List Of Components & Exploded View

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS OF UNSEALED OCS 1.2 INLINE CONNECTION SYSTEM MALE ASSEMBLY FEMALE ASSEMBLY MALE ASSEMBLY FEMALE ASSEMBLY Pictures used in this Assembly Manual and original parts may differ in some Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 details.

  • Page 37: Model

    Assembly Manual 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: Marcia Lytle +1 (330) 306 1113 Matthew A. Antil +1 (330) 306 7027 Assembly Manual - 33265159...

  • Page 38: Step 1 - Identify Index Features

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 1 – Identify Index Features IMPORTANT! IF THE INDEXES DON'T LINE UP, DO NOT CONTINUE. FRONT VIEWS STEP 2a – Align Index Features and Mate Female Assembly and Male Assembly Together VERIFY THAT FLS IN FEMALE CONNECTOR IS CORRECTLY SEATED;...

  • Page 39: Step 2 - Align Index Features And Mate Female Assembly And Male Assembly Together

    Assembly Manual 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 STEP 2c – Align Index Features and Mate Female Assembly and Male Assembly Together VERIFY AUDIBLE CLICK Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113...

  • Page 40: Step 3 - Lock Cpa To Full - Stage Position

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY STEP 3a – Lock CPA to Full-Stage Position SLIDE THE CPA FORWARD, AS SHOWN BELOW, TO SECURE THE CONNECTION STEP 3b – Lock CPA to Full-Stage Position VERIFY AUDIBLE CLICK CPA IS NOW IN FULL-STAGE POSITION...

  • Page 41: Connection System - Completed Assembly

    Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) ASSEMBLY CONNECTION SYSTEM – COMPLETED ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A. Antil +1 (330) 306 7027 Assembly Manual - 33265159...
  • Page 42 Assembly Manual 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 Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY MALE ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.
  • Page 43 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) DISASSEMBLY STEP 1 – Move CPA to Pre-Stage Position GRIP BOTH SIDES OF THE CPA THEN SLIDE VERIFY AUDIBLE CLICK THE CPA BACK TO PLACE IT IN PRE-STAGE CPA IS NOW IN PRE-STAGE POSITION STEP 2 –...
  • Page 44 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) DISASSEMBLY CONNECTION SYSTEM – COMPLETED DISASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A. Antil +1 (330) 306 7027 Assembly Manual - 33265159...
  • Page 45 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE FEMALE ASSEMBLY Unsealed OCS 1.2 Inline Connection System FEMALE ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.
  • Page 46 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT FEMALE TERMINAL OCS 1.2 REPLACEMENT (Move FLS to Pre-Stage Position) – STEP 1a INSERT TOOL 33282333 INTO THE CONNECTOR VERIFY AUDIBLE CLICK SLOT AND PUSH THE FLS FORWARD TO RELEASE IT FROM ITS FULL-STAGE POSITION FEMALE TERMINAL OCS 1.2 REPLACEMENT (Move FLS to Pre-Stage Position) –...
  • Page 47 Assembly Manual 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 REMOVAL WINDOW REMOVAL WINDOW TERMINAL FEMALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2b REMOVE TERMINALS IDENTIFY Removal Window...
  • Page 48 Assembly Manual 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 33148530 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 49 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE MALE ASSEMBLY Unsealed OCS 1.2 Inline Connection System MALE ASSEMBLY Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A.
  • Page 50 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REPAIR / REPLACEMENT MALE TERMINAL OCS 1.2 REPLACEMENT (Move FLS to Pre-Stage Position) – STEP 1a INSERT TOOL 33282333 INTO THE CONNECTOR VERIFY AUDIBLE CLICK SLOT AND PUSH THE FLS FORWARD TO RELEASE IT FROM ITS FULL-STAGE POSITION MALE TERMINAL OCS 1.2 REPLACEMENT (Move FLS to Pre-Stage Position) –...
  • Page 51 Assembly Manual 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 REMOVAL WINDOW TERMINAL MALE TERMINAL OCS 1.2 REPLACEMENT (Remove Terminal) – STEP 2b REMOVE TERMINALS IDENTIFY Flex Locks...
  • Page 52 Assembly Manual 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 33148530 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 53 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER 12152398 33282333 33148530 Contact at CTC Warren: Marcia Lytle +1 (330) 306 1113 Matthew A. Antil +1 (330) 306 7027...
  • Page 54 Assembly Manual Unsealed OCS 1.2 Inline Connection System Female/Male OCS 1.2 Terminal System (Unsealed) REVISIONS DATE REVISION HISTORY AUTH 15JL15 RELEASED 430005 HARNESS SECTION – ADDED ELECTRICAL TEST DETAILS & NOTE FOR WIRE/HARNESS DRESSING AND REVISED LABEL FOR MALE ASSEMBLY ON PAGE #27; DISASSEMBLY SECTION – REVISED STEP 24SE15 430794 FOR CPA DISASSEMBLY;...

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