General Motors

Terminals & Connectors

18043.05B Reference Guide

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

Terminal Replacement and Wire Repair ....................................................... 5

Terminal Removal Instructions ........................................................................................ 7 Standard Terminal Replacement ............................................................................... 8 Terminal Replacement Sealed Weatherpack, Metri-pack ........................................ 10 Terminal Crimp Tool ................................................................................................. 12 Splice Crimp Tool ..................................................................................................... 13 Visual Standards ...................................................................................................... 16 Splice Clip ................................................................................................................ 19 Crimp and Seal Splice Sleeve ................................................................................. 21

Terminals and Connectors .......................................................................... 23

Bosch Bosch Connector Identification ................................................................................ 25 .64 Connector .......................................................................................................... 26 Bosch Sensor Connector (BSK) .............................................................................. 27 Junior Power Timer (JPT) ........................................................................................ 28 Delphi Automotive Systems Delphi Connector Identification ..................................................................................... 29 Weatherpack ........................................................................................................... 30 280 Metri-pack ......................................................................................................... 31 280 Metri-pack (Tangless) ....................................................................................... 32 480 Metri-pack ......................................................................................................... 33 630 Metri-pack (Pull to Seat) ................................................................................... 34 Edgeboard ............................................................................................................... 35 Metri-pack 150 Series .............................................................................................. 36 Micro-pack 100W .................................................................................................... 37 Tangless 100W ........................................................................................................ 38 Tangless 100W (2.54mm Center Line [CL]) ............................................................ 39

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

Glossary of Terms ........................................................................................ 53

iv

J-38125-D Inventory

J38125-D E S S E NT IAL T OOL K IT Des cription

T erminal tray #1 (Delphi) T erminal tray #2 (Delphi) T erminal tray #3 (Delphi) T erminal tray #4 (Delphi) T erminal tray #5 (Delphi) T erminal tray #6 (S umitomo) T erminal tray #7 (L ear) T erminal tray #8 (Delphi) T erminal tray #9 (Yazaki) T erminal tray #10 (Yazaki) T erminal tray #11 (Yazaki) T erminal tray #12 (Yazaki) T erminal tray #13 (Yazaki) T erminal tray #14 (Yazaki) T erminal tray #15 (Yazaki) T erminal tray #16 (L ear) T erminal tray #17 (L ear) T erminal tray #18 (Delphi) T erminal tray #19 (Delphi) T erminal tray #20 (Delphi) R eleas e T ool-Weather Pack (Yellow) R eleas e T ool-S tandard L arge (Blue) R eleas e T ool-S tandard S mall (Green) R eleas e T ool-Micro Pack (R ed) R eleas e T ool-Micro .64 (R ed) R eleas e T ool- .64 JAE (Blue) R eleas e T ool- Bos ch JPT 280 (Black) R eleas e T ool- Molex .64 (Gray) R eleas e T ool- .64 T yco (Green) R eleas e T ool-Micro Pack 100 W (Gray) R eleas e T ool-R ound T PA Hook (Blue) R eleas e T ool-Micro Pack 280,480 (Black) R eleas e T ool- Molex PM 280 (White) R eleas e T ool- Bos ch JPT 280 (Yellow) R eleas e T ool- Bos ch JPT 280 (White) R eleas e T ool- BE C T erminal (Blue) Pin Vis e R eleas e T ool-Bos ch BMK .64 (White) R eleas e T ool-Bos ch BS K 280 (White) Crimper - 1 thru 5 Crimper - 6 thru 8 Crimper - A thru E Crimper - F&G - S ealed S plice Crimper - H thru K Crimper - W Crimper - M Ultra T orch Cabinet (Holds 5 trays ) 2 each T ool T ray R eference Guide

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

Terminal Replacement and Wire Repair

Terminal Removal Instructions

Terminal retention within the connector generally takes two forms: 1. A flexible primary lock, either part of the terminal or part of the connector. 2. A hinged or loose piece secondary lock. To remove a terminal, both must be disengaged or removed. First, locate and remove the secondary lock (Terminal Position Assurance TPA). 1. The secondary lock or TPA may be located in the rear, the side or the front of the connector. These can generally be removed with a small screwdriver. 2. Some secondary locks may require the use of a release tool such as: 15313892 to hook the lock and lift it out of the connector. If such a tool is used it should be used with caution as the tool may become deformed easily. Now remove the terminal by disengaging the primary lock. 1. Determine the terminal part number or family, then get the appropriate removal tool using the cross-reference matrix included in the J-38125 Reference Guide found in the J-38125 Terminal Repair Kit. 2. Locate the area in the front of the connector where the removal tool is to be inserted. The tool should never be inserted into the mating end of the terminal, instead it should be inserted next to the terminal where the primary lock is located. Inserting the tool into the terminal itself will cause damage to the terminal and create a loose connection between mating terminals. 3. Position the terminal by using the attached wire. For push to seat terminals, slide the terminal forward. For pull to seat terminals, slide it rearward. This allows the lock tang to disengage from the lock shoulder. 4. Flex the primary lock tang, whether it is part of the connector or part of the terminal, by lightly prying it with the removal tool selected, then gently remove the terminal from the connector by pulling or pushing on the wire connected to the terminal. NOTE: When using the terminal removal tools, only light pressure is needed to flex the primary locks. If excessive force must be applied to release the lock, it is possible that the wrong tool may have been selected or the secondary lock is not released or disengaged.

10

11

TERMINAL CRIMP TOOL

J 38125-6 (1-5) J 38125-7 (A-E) J 38125-8 (F-G) P/N (1-5) 12085270 P/N (A-E) 12085271 P/N (F-G) 12085115

12

13

TERMINAL CRIMP TOOL cont.

J-38125-6 (W) P/N (W) 12125080 J-38125-64 (M) P/N (M) 15397700

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

TERMINAL CRIMP TOOL cont.

J-38125-641 (6-8) J-38125-642 (H-K)

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

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Terminals and Connectors

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

2. The Bosch symbol may be located on the connector

3. The letters BSK may be visible on the connector

25

.64 Connector
Lock Tang Core Wings

Connector w/.64 round terminal

Entry Canals

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.

Terminal release tool inserted into connector

26

Bosch Sensor Connector (BSK)

Core Wings Cable Seal

Lock Tang

Insulation Wings

280 BSK Sealed

Entry Canals

J-38125-7

J-38125-6

Lock Tangs

Lock Tangs

27

Junior Power Timer (JPT)

Insulation Wings

Lock Tang (2)

Core Wings

280 JPT Sealed

J-38125-7

J-38125-6

Entry Canals

28

Delphi Automotive Systems

Delphi Connector Identification
Delphi connectors can be identified by the letters PED (Packard Electric Division) or DELPHI molded into the connector body.

29

Weather Pack

Insulation Wings

Seal

Core Wings

Weatherpack Sleeve Female Sealed

12085271 / J-38125-7 and 12085270 / J-381256

30

280 Metri-Pack

Seal

Core Wings

Insulation Wings

Metri-pack 280 Series Female Sealed

12085270 / J-38125-6

31

280 Metri-Pack (Tangless)

Insulation Wings

Core Wings

Metri-pack 280 Series Tangless

Entry Canal

TPA Terminal Lock

12085271 / J-38125-7

32

480 Metri-Pack

Core Wings

Lock Tang

Insulation Wings

Metri-pack 480 Series

TPA

Entry Canal

12085271 / J-38125-7

33

630 Metri-Pack (Pull to Seat)

Core Wings

Insulation Wings Entry Canal

Metri-pack 630 Series Female (pull to seat)

12085271 / J-38125-7

34

Edgeboard

Entry Canal

Edgeboard Female

12085271 / J-38125-7

35

Metri-Pack 150 Series

Seal

Insulation Wings

Entry Canal

Core Wings

M/P 150 Series Female

12085271 / J-38125-7

36

Micro-Pack 100
Entry Canal

M/P 100W Female

12125080 / J-38125-101

37

Tangless 100W

Insulation Wings

Core Wings TPA

Tangless 100W Female Sealed

12125080 / J-38125-101

38

Tangless 100W (2.54mm Center Line [CL])

CPA

Core Wings

Insulation Wings

100W Series Female

TPA/Cover

J-38125-101(W)

39

100W Tangless Connectors/Terminals Compared

(3.0CL)

(2.54CL)

Grey TPA from 2.54mm CL Connector

Terminals are of different lengths

40

Micro .64

Insulation Wings

Core Wings Entry Canal

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

280 YESC Unsealed Female

TPA

Entry Canal

12085271 / J-38125-7

43

Type 1 Connectors (continued)

This style of Yazaki connector utilizes a seal at the rear of the connector body. Remember to apply the seal to the wire prior to crimping a new terminal on. Be sure that the seal is not damaged when crimping the insulation wings and be sure it has a good fit into the back of the connector body.

Entry Canal Seal Core Wings

Insulation Wings

090-II Sealed Female

TPA

12085271 / J-38125-7 and 12085270 / J-38125-6

44

Type 1 Connectors (continued)

The TPA on this style of Yazaki connector has a series of stops molded into the body of the connector along the side. The TPA should be removed completely to allow the release tool access to the terminal lock tang. As with all TPAs, always reposition the locking device when completing a repair.

Insulation Wings

Core Wings

280 YESC Unsealed Male

TPA

12085271 / J-38125-7

45

Type 1 Connectors (continued)

Entry Canal

Core Wings

Insulation Wings

150 YESC Sealed Female

TPA

12085271 / J-38125-7 and 12085270 / J-38125-6

46

Type 1 Connectors (continued)

630 150 280

26 p 150+280+630 YESC Unsealed Female

TPA

Entry Canal

12085271 / J-38125-7

47

Type 1 Connectors (continued)

Core Wings

Seal

Insulation Wings

10 p 150 YESC Sealed Male

TPA

12085271 / J-38125-7

48

Type 1 Connectors (continued)

Seal Core Wings

Insulation Wings

12p 150 YESC Sealed Female

TPA Entry Canal

12085271 / J-38125-7

49

Type 1 Connectors (continued)

280 280 150

Core Wings

150

Insulation Wings

14p 150 +280 YESC Unsealed Female

TPA

Entry Canal

12085271 / J-38125-7

50

Type 2 Connectors

Entry Canal Insulation Wings

Core Wings

090-II Unsealed Male

TPA

12085271 / J-38125-7

51

Type 3 Connectors

Core Wings

Insulation Wings

7114-3250

L-Type Unsealed Male

Rear Holder

12085271 / J-38125-7

52

Glossary of Terms

53

54

Conduit Connector Connector (Mold-On)

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

Connector Entry Canal

Connector Position Assurance (CPA) Core (Wire or Cable) Core Wings

Fusible Link

Grommet

Insulation Insulation Wings Lead Pigtail Sleeve

Splice Splice Clip Splice (Mold-On) Terminal

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.

Terminal Lock Tang

Terminal Position Assurance (TPA)

56

Continuin g

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General Motors 2004

Printed in USA