Delphi Connectors Pull to Seat Connectors

Terminal Removal Procedure

If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced.

Follow the steps below in order to repair pull-to-seat connectors.

1. Remove the connector position assurance (CPA) device and/or the secondary lock.
2. Disconnect the connector from the component or separate the connectors for in-line connectors.
3. Remove the terminal position assurance (TPA) device.
4. Insert the proper pick or removal tool into the front of the connector body.

Terminal Repair Procedure

Use the appropriate wire assembly repair kits available through Saturn Service Parts.

Delphi Connectors Push to Seat Connectors

Terminal Removal Procedure

Follow the steps below in order to repair push to seat connectors.

1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock.
2. Separate the connector halves (1).



3. Use the proper pick or removal tool (1) in order to release the terminal.
4. Gently pull the cable and the terminal (2) out of the back of the connector.



5. Re-form the locking device if you are going to reuse the terminal (1).
6. To repair the terminal, refer to Terminal Repair.

Terminal Installation Procedure

1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs .
2. Ensure that the cable seal is kept on the terminal side of the splice.
3. Insert the lead from the back until it catches.
4. Install the TPA, CPA and/or the secondary locks.

Delphi Connectors Micro .64 Connectors

Tools Required

J-38125 Terminal Repair Kit

Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a tin terminal and a blue wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis.

Terminal Removal Procedure

1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock.
2. Disconnect the connector from the component.



3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover.
4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector.



5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece.

The nose piece covers the terminal release holes on a specific Micro 64 connector. Not all Micro 64 connectors have this nose piece and only require that the TPA be removed before the terminal can be extracted from the connector using the terminal release tool.





Important: Always use care when removing a terminal positive assurance (TPA) in order to avoid damaging it.

6. Remove the TPA by inserting a small flat-bladed tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector.



7. Insert the J 38125-21 (GM P/N 15381651-2) tool into the 2 triangular cavities on each side of the terminal at the front of the connector.



8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector.

Terminal Repair Procedure

Use the appropriate wire assembly repair kits available through Saturn Service Parts.

Delphi Connectors Micro-Pack 100W Connectors

Terminal Removal Procedure

1. Disconnect the connector from the component or separate the connector halves for inline connectors.



2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.



3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece.
4. Repeat the procedure for the other locking tab and remove the nose piece.
5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary.



6. Use fingers to squeeze the 2 locking legs of the cover.



7. Apply pressure and gently rock the cover until one locking leg is unseated.



8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover.



9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector.

Terminal Repair Procedure

Use the appropriate wire assembly kit available through Saturn Service Parts.

1. Slide the new terminal into the correct cavity at the back of the connector.
2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire.
3. Replace the nose piece.
4. Replace the dress cover.

Delphi Connectors 12-Way

Special Tools

J-38125 Terminal Repair Kit

Removal Procedure

Follow the steps below in order to remove terminals from the connector.

1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body.
2. Disconnect the connector from the component.



3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs.



4. Release the lower wire dress cover locking tab.



5. Release the upper wire dress cover locking tab.
6. Once the locks are unlocked, lift the dress cover off.




Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it.

7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector.



8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector.



9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used.



10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector.

Repair Procedure

Use the appropriate terminal and follow the instructions in the J-38125 .

Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view.