Professional Documents
Culture Documents
Version 2.0
March 2004
Caution
In order to reduce the chance of personal injury and/or property damage, carefully observe the instructions that follow: The service manuals of General Motors Corporation are intended for use by professional, qualified service technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others. This could also damage the vehicle, or cause the vehicle to operate improperly. Proper vehicle service and repair are important to the safety of the service technician and to the safe, reliable operation of all motor vehicles. If you need to replace a part, use the same part number or an equivalent part. Do not use a replacement part of lesser quality. The service procedures we recommend and describe in this service manual are effective methods of performing service and repair. Some of the procedures require the use of tools that are designed for specific purposes. Accordingly, any person who intends to use a replacement part, a service procedure, or a tool that is not recommended by General Motors, must first establish that there is no jeopardy to personal safety or the safe operation of the vehicle. This manual contains various Cautions and Notices that you must observe carefully in order to reduce the risk of personal injury during service or repair. Improper service or repair may damage the vehicle or render the vehicle unsafe. These Cautions and Notices are not exhaustive. General Motors can not possibly warn of all the potentially hazardous consequences of your failure to follow these instructions. This manual covers service procedures to vehicles that are equipped with a Supplemental Inflatable Restraint (SIR). Refer to the Cautions in Cautions and Notices and in Restraints. Refer to SIR component and wiring location views in Restraints before performing a service on or around SIR components or wiring. Failure to follow these Cautions could cause air bag deployment, personal injury, or otherwise unneeded SIR repairs. In order to help avoid accidental air bag deployment and personal injury, whenever you service a vehicle that requires repair of the SIR and another vehicle system, we recommend that you first repair the SIR, then go on to the other system.
Foreword
This booklet contains illustrations showing the correct terminal removal tools and wiring assembly repairs for connectors used on GM vehicles. Always refer to the applicable vehicle Service Information (SI) and appropriate Technical Service Bulletins for additional information regarding vehicle wiring repairs. All information, illustrations and specifications in this booklet are based on the latest product information available at the time of print. General Motors reserves the right to make changes at any time without notice.
Copyright 2004, by General Motors Corporation ALL RIGHTS RESERVED Printed in the U.S.A No part of this book may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of General Motors Corporation. This applies to all text, illustrations, tables and charts. ii
Table of Contents
J-38125-D Inventory ....................................................................................... 1
J-38125-D Essential Tool Kit ........................................................................................... 3
iii
Tangless 100W Connectors/Terminals Compared .................................................. 40 Micro .64 .................................................................................................................. 41 Yazaki Yazaki Connector Identification ..................................................................................... 42 Yazaki Type 1 Connectors ....................................................................................... 43 Yazaki Type 2 Connectors ....................................................................................... 51 Yazaki Type 3 Connectors ....................................................................................... 52
iv
J-38125-D Inventory
P art No.
12085267 12085266 12188910 12188911 12188912 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 12014012-1 12094430 12094429 12031876-1 15381651-2 N/A N/A N/A N/A 12122523 15313892 15315247 12152110 12093647 12122378 12150860 12180559-1 15314260 N/A 12085270 N/A 12085271 12085115 N/A 12125080 15397700 12085116 N/A N/A N/A
J-Number
J-38125-T R AY1 J-38125-T R AY2 J-38125-T R AY3 J-38125-T R AY4 J-38125-T R AY5 J-38125-T R AY6 J-38125-T R AY7 J-38125-T R AY8 J-38125-T R AY9 J-38125-T R AY10 J-38125-T R AY11 J-38125-T R AY12 J-38125-T R AY13 J-38125-T R AY14 J-38125-T R AY15 J-38125-T R AY16 J-38125-T R AY17 J-38125-T R AY18 J-38125-T R AY19 J-38125-T R AY20 J-38125-10A J-38125-11A J-38125-12A J-38125-13A J-38125-21 J-38125-211 J-38125-212 J-38125-213 J-38125-24 J-38125-33 J-38125-552 J-38125-553 J-38125-554 J-38125-556 J-38125-557 J-38125-558 J-38125-559 J-38125-560 J-38125-561 J-38125-6 J-38125-641 J-38125-7 J-38125-8 J-38125-642 J-38125-101 J-38125-64 J-38125-5 J-38125-610 J-38125-615 J-38125-620
10
11
12
13
1. 2.
COMPRESS CRIMP TOOL HANDLES UNTIL RATCHET MECHANISM AUTOMATICALLY RELEASES CRIMP TOOL HANDLES. PRESS THE SPRING LOCK TO OPEN AND INSERT TERMINAL INTO HOLDING FIXTURE AND RELEASE SPRING LOCK. ONCE THE TERMINAL IS IN PLACE, INSERT STRIPPED CABLE THROUGH BOTH CORE AND INSULATION CRIMP WINGS AND POSITION PROPERLY. THE CRIMP TOOL IS DESIGNED TO HOLD THE TERMINAL IN PLACE ON THE ANVIL WHILE THE CRIMP JAW CRIMPS BOTH THE CORE WINGS AND INSULATION WINGS AT THE SAME TIME.
Insulation Wings Mating End
3.
Mating End
Insulation Wings
Cable
Core Wings
Cable
Core Wings
4. 5.
COMPRESS HANDLES UNTIL THE RATCHET MECHANISM AUTOMATICALLY RELEASES. INSPECT TERMINAL FOR A PROPER CRIMP. IF TERMINAL APPEARS BENT AFTER CRIMPING, IT SHOULD BE GENTLY STRAIGHTENED BY HAND. 14
1. 2.
COMPRESS CRIMP TOOL HANDLES UNTIL RATCHET MECHANISM AUTOMATICALLY RELEASES CRIMP TOOL HANDLES. PRESS THE SPRING LOCK TO OPEN AND INSERT TERMINAL INTO HOLDING FIXTURE AND RELEASE SPRING LOCK. ONCE THE TERMINAL IS IN PLACE, INSERT STRIPPED CABLE THROUGH BOTH CORE AND INSULATION CRIMP WINGS AND POSITION PROPERLY. THE CRIMP TOOL IS DESIGNED TO HOLD THE TERMINAL IN PLACE ON THE ANVIL WHILE THE CRIMP JAW CRIMPS BOTH THE CORE WINGS AND INSULATION WINGS AT THE SAME TIME. COMPRESS HANDLES UNTIL THE RATCHET MECHANISM AUTOMATICALLY RELEASES. INSPECT TERMINAL FOR A PROPER CRIMP. IF TERMINAL APPEARS BENT AFTER CRIMPING, IT SHOULD BE GENTLY STRAIGHTENED BY HAND.
3.
4. 5.
15
16
17
18
19
20
21
22
23
24
Bosch
Bosch Connector Identification
Bosch connectors can be identified by one of three possible markings: 1. The word Bosch may be molded into the connector
25
.64 Connector
Lock Tang Core Wings
Insulation Wings
(must be removed)
TPA
A crimp tool for the Bosch .64 terminal has not been released as of this printing. A terminated cable lead can be obtained if a terminal repair is required before the crimp tool becomes available. A terminated cable lead can be spliced into the harness wiring to replace a damaged terminal.
26
Lock Tang
Insulation Wings
Entry Canals
J-38125-7
J-38125-6
Lock Tangs
Lock Tangs
27
Core Wings
J-38125-7
J-38125-6
Entry Canals
28
29
Weather Pack
Insulation Wings
Seal
Core Wings
30
280 Metri-Pack
Seal
Core Wings
Insulation Wings
12085270 / J-38125-6
31
Insulation Wings
Core Wings
12085271 / J-38125-7
32
480 Metri-Pack
Core Wings
Lock Tang
Insulation Wings
TPA
Entry Canal
12085271 / J-38125-7
33
Core Wings
12085271 / J-38125-7
34
Edgeboard
Entry Canal
Edgeboard Female
12085271 / J-38125-7
35
Seal
Insulation Wings
Entry Canal
Core Wings
12085271 / J-38125-7
36
Micro-Pack 100
Entry Canal
12125080 / J-38125-101
37
Tangless 100W
Insulation Wings
12125080 / J-38125-101
38
Core Wings
Insulation Wings
TPA/Cover
J-38125-101(W)
39
(3.0CL)
(2.54CL)
40
Micro .64
Insulation Wings
Micro .64
15397700 / J-38125-64
41
Yazaki
Yazaki Connector Identification
Yazaki connectors can be identified by the Yazaki TM symbol that is molded into all Yazaki connectors or a connectors accompanying TPA.
42
Yazaki connectors are designated by the type of Terminal Position Assurance (TPA) they utilize. There are three versions of connectors currently used by GM. Type 1 which uses a front loading TPA, type 2 which uses a side loaded TPA and type 3 which uses a locking device at the rear of the connector.
Type 1 Connectors
Insulation Wings
Core Wings
TPA
Entry Canal
12085271 / J-38125-7
43
Insulation Wings
TPA
44
Insulation Wings
Core Wings
12085271 / J-38125-7
45
Entry Canal
Core Wings
Insulation Wings
TPA
46
Entry Canal
12085271 / J-38125-7
47
Core Wings
Seal
Insulation Wings
TPA
12085271 / J-38125-7
48
Insulation Wings
12085271 / J-38125-7
49
Core Wings
150
Insulation Wings
TPA
Entry Canal
12085271 / J-38125-7
50
Type 2 Connectors
Core Wings
TPA
12085271 / J-38125-7
51
Type 3 Connectors
Core Wings
Insulation Wings
7114-3250
Rear Holder
12085271 / J-38125-7
52
Glossary of Terms
53
54
An extruded protective sheath through which one or more individual insulated cables can be run. A molded part which houses one or more terminated cables in a particular arrangement to facilitate the joining of multiple circuits. A type of connector, usually vinyl, molded directly over terminals and cable which provide improved resistance to environmental agents. A channel in the connector where a pick tool is inserted to depress or flex the lock tang for a terminal, so that the terminal can be removed from the connector. A connector to connector mating scheme that insures completed and continuous mating. (ex. redundant locks and bolts) The electrical conductor that is covered by insulation. Part of a wire. That part of the terminal that is crimped over the core of the cable and provides the electrical path between the terminal and the cable. Are built into the harness and act as circuit protectors when there is a short circuit. The fusible link cable insulation is special and each gauge is identified by printing on the insulation. A molded or plastic assembly that provides a means of transitioning between two different environmental areas. The grommet protects cables from contact with other parts and holds them in position. Grommets also provide a barrier against dust, moisture, air, noise and other environmental factors. A material having a high resistance to the flow of electrical current; usually an extruded jacketing over a wire conductor. That part of the terminal that is crimped over the cable insulation. Cable cut to a specific length and spliced or terminated at both ends. Lead or leads in which one end is attached to a device and the other end is mated to the harness. A relatively short (about 1 inch) tube which protects the wing area of a terminal applied to a cable. 55
Fusible Link
Grommet
The process of joining two or more cables together permanently by clipping them together and soldering the entire joint. A metal clip used to securely hold cables in a splice prior to soldering. A splice with a molded-on cover for improved environmental protection. e.g. DuraSeal Crimp & Seal A conductive metal part which is attached to the end of a cable to facilitate the electrical connection to another cable that is terminated with a terminal of the opposite gender. That part of the terminal that locks the terminal in a connector. The lock tang is considered the primary terminal lock. The lock tang may be part of the connector, therefore, the terminal would be referred to as Tangless. A feature on a connector designed to keep the terminal from backing out of the connector. This feature is also known as the secondary lock.
56
Continuin g
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TRAINING PROVIDER
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ducation
Printed in USA