Delphi GT 280 Assembly Manual
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Delphi GT 280 Assembly Manual

Delphi GT 280 Assembly Manual

4 way sealed connection system
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ASSEMBLY MANUALS
PRE - ASSEMBLY
HARNESS ASSEMBLY
CAR ASSEMBLY
ASSEMBLY MANUAL - 33278895
4 Way GT 280 Sealed Connection System
GT 2.8 Female Terminal System (Sealed)
February 2017
Issued by
CTC Warren, Ohio
STC Saltillo, Mex.

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Summary of Contents for Delphi GT 280

  • Page 1 ASSEMBLY MANUALS PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL - 33278895 4 Way GT 280 Sealed Connection System GT 2.8 Female Terminal System (Sealed) February 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 2017 DELPHI. All rights reserved.
  • Page 3 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) TABLE OF CONTENTS PRE–ASSEMBLY SECTION ASSEMBLY OF THE FEMALE CONNECTOR List of Components & Exploded View Step 1 – Insert Connector Seal Step 2 – Install PLR to Pre-Stage Position Step 3 –...

  • Page 4: Table Of Contents

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) TABLE OF CONTENTS CAR ASSEMBLY SECTION ASSEMBLY OF THE CONNECTION SYSTEM List of Components & Exploded View 3D Model Step 1 – Identify Index Features Step 2 – Align Index Features and Mate Female Assembly and Mating Part Together Step 3 –...

  • Page 5: Car Assembly Section

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY ASSEMBLY OF THE FEMALE CONNECTOR PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 4 Way GT 280 Sealed Connection System CONNECTOR ASSEMBLY © Delphi Corporation. All Rights Reserved www.delphi.com...
  • Page 6 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS CONNECTOR SEAL FEMALE CONNECTOR OPTIONAL COMPONENT FEMALE CONNECTOR CONNECTOR SEAL Pictures used in this Assembly Manual and original parts may differ in some ©...
  • Page 7 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 1a – Insert Connector Seal VERIFY THE ORIENTATION OF THE SEAL AND INSERT IT INTO THE CONNECTOR STEP 1b – Insert Connector Seal IMPORTANT!
  • Page 8 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 2a – Install PLR to Pre-Stage Position IDENTIFY THE CORRECT ORIENTATION INSERT PLR ONTO THE CONNECTOR OF THE PLR STEP 2b – Install PLR to Pre-Stage Position...
  • Page 9 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 3 – Assemble CPA to Pre-Stage Position (Optional Component) IDENTIFY THE CORRECT ORIENTATION OF VERIFY AUDIBLE CLICK CPA AND PUSH IT ONTO THE CONNECTOR...
  • Page 10 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 4 Way GT 280 Sealed Connection System FEMALE ASSEMBLY © Delphi Corporation. All Rights Reserved www.delphi.com...
  • Page 11 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS FEMALE CONNECTOR ASSEMBLY 4 MAX SEALED TERMINAL GT 2.8 AS REQUIRED CAVITY PLUG OPTIONAL COMPONENT CAVITY PLUG SEALED TERMINAL GT 2.8...
  • Page 12 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 1 – Identify Cavities BACK VIEW CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR STEP 2a – Assemble Cavity Plug (If Required)
  • Page 13 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 2b – Assemble Cavity Plug (If Required) 0 mm CAVITY PLUG INSTALLED STEP 3 – Align Terminals Female GT 2.8 (Or Equivalent) and Female Assembly INSERT FEMALE TERMINALS INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN.
  • Page 14 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 4a – Insert Terminals Female GT 2.8 (Or Equivalent) PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 4b –...
  • Page 15 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 5a – Lock PLR to Full-Stage Position PUSH THE PLR FORWARD DO NOT FORCE THE PLR, IF IT CAN’T BE LOCKED REVISE IF TERMINALS ARE PROPERLY SEATED STEP 5b –...
  • Page 16 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY FEMALE HARNESS ASSEMBLY – COMPLETED PERFORM TESTS. APPLY COVERINGS AS REQUIRED. INSPECT THE ASSEMBLY. © Delphi Corporation. All Rights Reserved www.delphi.com Assembly Manual - 33278895...

  • Page 17: Assembly Of The Connection System

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY ASSEMBLY OF THE CONNECTION SYSTEM PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 4 Way GT 280 Sealed Connection System FEMALE ASSEMBLY MATING PART © Delphi Corporation. All Rights Reserved www.delphi.com...

  • Page 18: List Of Components & Exploded View

    4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS OF 4 WAY GT 280 SEALED CONNECTION SYSTEM MATING PART FEMALE ASSEMBLY MATING PART FEMALE ASSEMBLY Pictures used in this Assembly Manual and original parts may differ in some ©...

  • Page 19: Model

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY 3D MODEL VIEW CLICK IMAGE TO START 3D VISUALIZATION © Delphi Corporation. All Rights Reserved www.delphi.com Assembly Manual - 33278895...

  • Page 20: Step 1 - Identify Index Features

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 1 – Identify Index Features IMPORTANT! IF THE INDEXES DON'T LINE UP, DO NOT CONTINUE. STEP 2a – Align Index Features and Mate Female Assembly and Mating Part Together ©...

  • Page 21: Step 3 - Lock Cpa To Full - Stage Position (Optional Component)

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 2b – Align Index Features and Mate Female Assembly and Mating Part Together VERIFY AUDIBLE CLICK STEP 3a – Lock CPA to Full-Stage Position (Optional Component) SLIDE THE CPA FORWARD, AS SHOWN BELOW, TO SECURE THE ASSEMBLY ©...

  • Page 22: Connection System - Completed Assembly

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) ASSEMBLY STEP 3b – Lock CPA to Full-Stage Position (Optional Component) VERIFY AUDIBLE CLICK CPA IS FLUSH WITH THE CONNECTOR LOCK CPA IS NOW IN FULL-STAGE POSITION CONNECTION SYSTEM –...

  • Page 23: Disassembly Of The Connection System

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) DISASSEMBLY DISASSEMBLY OF THE CONNECTION SYSTEM PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY 4 Way GT 280 Sealed Connection System FEMALE ASSEMBLY MATING PART © Delphi Corporation. All Rights Reserved www.delphi.com...

  • Page 24: Step 1 - Move Cpa To Pre-Stage Position (Optional Component)

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) DISASSEMBLY STEP 1a – Move CPA to Pre-Stage Position (Optional Component) SLIDE THE CPA BACK TO PLACE IT IF NECESSARY, TOOL 12122647 COULD BE IN PRE-STAGE USED TO PULL THE CPA BACK STEP 1b –...

  • Page 25: Step 2 - Disconnect

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) DISASSEMBLY STEP 2 – Disconnect LOCATE AND PRESS DOWN THE CONNECTOR LOCK (1); WITH THE LOCK DEFLECTED, DISENGAGE THE CONNECTORS (2) CONNECTION SYSTEM – COMPLETED DISASSEMBLY ©...

  • Page 26: Repair / Replacement Section

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE FEMALE ASSEMBLY 4 Way GT 280 Sealed Connection System FEMALE ASSEMBLY © Delphi Corporation. All Rights Reserved www.delphi.com Assembly Manual - 33278895...

  • Page 27: Plr Replacement - Step 1 (Remove Plr)

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) REPAIR / REPLACEMENT PLR REPLACEMENT (Remove PLR) – STEP 1a PLACE TOOL 12122647 BETWEEN THE PLR ROTATE THE TOOL AND PULL THE PLR UNTIL IT’S PLACED IN PRE-STAGE POSITION AND CONNECTOR PLR REPLACEMENT (Remove PLR) –...

  • Page 28: Step 2 (Install Plr)

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) REPAIR / REPLACEMENT PLR REPLACEMENT (Install PLR) – STEP 2 REFER TO PRE-ASSEMBLY SECTION FEMALE TERMINAL GT 2.8 REPLACEMENT (Remove Terminal) – STEP 1a PLR MUST BE RELEASED BEFORE TERMINAL REMOVAL...
  • Page 29 Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) REPAIR / REPLACEMENT FEMALE TERMINAL GT 2.8 REPLACEMENT (Remove Terminal) – STEP 1b REMOVE TERMINALS IDENTIFY Terminal Flex Lock Mating End Terminal Cable End Flex Lock * This graph just represents how this kind of terminals are removed.

  • Page 30: Step 2 (Insert Terminal)

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) REPAIR / REPLACEMENT FEMALE TERMINAL GT 2.8 REPLACEMENT (Insert Terminal) – STEP 2 REFER TO HARNESS ASSEMBLY SECTION © Delphi Corporation. All Rights Reserved www.delphi.com Assembly Manual - 33278895...

  • Page 31: Recommended Repair Tools

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER J-38125-H NUMBER 10914973 12122647 15315247 * J-38125-553 * Alternative Tool for Item 3 12094429 J-38125-12A © Delphi Corporation. All Rights Reserved www.delphi.com...

  • Page 32: Revisions

    Assembly Manual 4 Way GT 280 Sealed Connection System GT 2.8 Terminal System (Sealed) REVISIONS DATE REVISION HISTORY AUTH 10FE17 RELEASED 430448 © Delphi Corporation. All Rights Reserved www.delphi.com Assembly Manual - 33278895...

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