Harley Davidson 2008 Touring Models. Electrical Diagnostics Manual — page 33
HOME
RELAY AND FUSE BLOCKS
A.9
FUSE BLOCK REPAIR
NOTE
The wiring diagram indicates when one socket terminal is be
Removing Socket Terminals
crimped to two wire leads.
1. See Figure A-23. To remove secondary locks, insert end
of small flat blade screwdriver (1) under lip of locking
sm00025
wedge (2) and gently pry up secondary lock.
NOTE
1
For best results, start with locking wedge on outboard side of
secondary lock.
2
2. Looking into chamber at top of fuse block, note the tang
next to each socket terminal.
3. Using a thin flat blade, like that on a hobby knife, gently
push tang away from terminal, and then tug on wire to
back terminal out.
Installing Socket Terminals
1. Match the wire lead color to the fuse block terminal cavity.
NOTES
•
Refer to the main harness wiring diagram for wire lead
1. Pry up secondary lock
color codes.
2. Lip of locking wedge
•
See Figure A-24. The main fuse block terminal cavity is
Figure A-23. Fuse Block: Remove Secondary Locks
identified as alpha (1) and numeric (2) coordinates. Refer
to the main harness wiring diagram for fuse block terminal
cavity coordinates.
2. With the open side of the socket terminal facing the tang,
sm00026
push lead into chamber at the wire end of the fuse block.
A click is heard when the terminal is properly engaged.
1
3. Gently tug on the wire to verify that the terminal is locked
in place and will not back out of the chamber.
A
C
E
G
J
2
1
4. Install the secondary locks. With the locking wedges
positioned above the tangs in each chamber, slide flat
2
side of secondary lock into slot (between rows), and push
down until it bottoms.
3
4
Crimping Terminals
B
D
F
H
Terminals are crimped twice; once over the wire core and a
second time over the insulation/seal.
A correctly crimped terminal may require different crimping
dies found on separate crimpers.
1. Alpha
2. Numeric
Figure A-24. Fuse Block: Coordinates (typical)
2008 Touring Diagnostics: Appendix A Connector Repair A-19
HOME
150 METRI-PACK CONNECTORS
A.10
150 METRI-PACK CONNECTOR REPAIR
Inserting Socket Terminal
General
NOTE
For wire location purposes, alpha characters are stamped into
Metri-Pack connectors are embossed with the initials (P.E.D.).
the socket housings.
There are two types of connectors in this series:
1.
See Figure A-25 for pull-to-seat connector or Figure A-26
•
Pull-to-Seat
for push to seat connector. Using a thin flat blade, like that
on a hobby knife, carefully bend the tang outward away
•
Push-to-Seat
from the terminal body.
Separating Pin and Socket Housings
2.
Gently pull or push on the lead to install the terminal back
Bend back the external latch slightly and separate the pin and
into the chamber. A click is heard when the terminal is
socket halves of the connector.
properly seated.
Mating Pin and Socket Housings
3.
Gently pull or push on the lead to verify that the terminal
is locked in place.
Align the wire colors and push the pin and socket halves of the
connector together.
For push-to-seat: See Figure A-26. Seat wires in separate
channels of wire lock and then push channels inside
Removing Socket Terminal
chambers at wire end of socket housing. Fully installed,
slot on each side of wire lock engages ear on socket
1. See Figure A-25 for pull-to-seat connector or Figure A-26
housing.
for push to seat connector. Remove wire lock (1) from wire
end of socket housing on push-to-seat type connectors.
NOTE
For best results, free one side of wire lock first and then release
the other side.
2. Find the locking tang in the mating end of the connector.
NOTE
The tangs are always positioned in the middle of the chamber
and are on the same side as the external latch.
3. Gently insert a safety pin into the chamber about
1/8
in. (3.2 mm).
a. For pull-to-seat: Stay between the terminal and the
chamber wall and pivot the end of the pin toward the
terminal body.
b. For push-to-seat: There is a small opening for the
pin.
4. When a click is heard, remove the pin and repeat the
procedure.
NOTE
The click is the sound of the tang returning to the locked posi-
tion as it slips from the point of the pin.
5. Pick at the tang until the clicking stops and the pin seems
to slide in deeper than it had previously. This is an indica-
tion that the tang has been depressed.
NOTE
On those terminals that have been extracted on multiple
occasions, the click may not be heard, but pivot the pin as if
the click was heard at least 3 times.
6. Remove the pin.
a. For pull-to-seat: Push on the lead to extract the ter-
minal from the mating end of the connector.
b. For push-to-seat: Pull on the lead to draw the ter-
minal out the wire end.
A-20 2008 Touring Diagnostics: Appendix A Connector Repair
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sm00027
sm00028
1
1
2
2
3
3
4
4
1. Remove wire lock
1. Locate tang in chamber
2. Pivot pin to depress tang
2. Pivot pin to depress tang
3. Pull to remove
3. Push to remove
4. Raise tang to install
4. Raise tang to install
Figure A-26. 150 Metri-Pack Connector: Push-to-Seat
Figure A-25. 150 Metri-Pack Connector: Pull-to-Seat
2008 Touring Diagnostics: Appendix A Connector Repair A-21
HOME
280 METRI-PACK CONNECTORS
A.11
280 METRI-PACK CONNECTOR REPAIR
sm00029
General
See Figure A-27. Called Packard connectors, Metri-Pack series
connectors are embossed with the initials (P.E.D.)
Separating Pin and Socket Housings
Depress the wireform and use a rocking motion to detach the
socket connector half.
Mating Pin and Socket Housings
Align the groove in the socket housing with the tab in the pin
housing. Push the pin and socket halves of the connector
together until the latch clicks.
Removing Socket Terminals
1. See Figure A-28. Pry rubber seal from wire end of con-
nector and move seal down wires (1) toward conduit. Hold
the connector so that the wireform is facing down.
2. Looking into the wire end of the connector, insert the point
of a safety pin (2) between the top of the terminal and the
inside chamber wall.
Figure A-27. 280 Metri-Pack Connector (P.E.D.)
3. Push safety pin completely into chamber while watching
terminal on mating end of connector. When terminal is
observed moving forward slightly, tang is depressed.
Remove safety pin.
NOTE
Repeat as necessary until the terminal can be pushed out of
the connector.
4. Push on wire end of the lead to extract the terminal from
the mating end of the connector.
5. If necessary, crimp new terminals on wires. See
A.15 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps.
Installing Socket Terminals
NOTE
Terminal cavities are lettered on the socket housing. To match
the wire lead colors to the terminal cavity, refer to the wiring
diagram.
1. See Figure A-28. Using a thin flat blade, like an X-Acto
knife (4), carefully bend the tang outward away from the
terminal body.
2. Gently pull on the wire lead (5) to draw the terminal back
into the chamber. The tang faces opposite the wireform
as it enters the chamber.
NOTE
A "click" is heard when the terminal is properly seated.
3. Push on lead to verify that terminal is locked in place.
4. Fit rubber wire seal back into wire end of connector.
Crimping Terminals
If necessary, crimp new terminals on the wire leads. Refer to
A.15 METRI-PACK TERMINALS, Metri-Pack Terminal Crimps.
A-22 2008 Touring Diagnostics: Appendix A Connector Repair
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sm00030
1
2
3
4
5
1. Pry rubber seal from connector
2. Insert safety pin to depress tang
3. Push on lead to remove terminal
4. Raise tang with X-Acto knife
5. Pull on lead to draw terminal into chamber
Figure A-28. 280 Metri-Pack Connector: Remove/Install
Socket Terminal
2008 Touring Diagnostics: Appendix A Connector Repair A-23
HOME
480 METRI-PACK CONNECTORS
A.12
4. Rotate the hinged secondary lock inward until latches fully
480 METRI-PACK CONNECTOR REPAIR
engage tabs on both sides of connector housing.
General
NOTE
A 480 Metri-Pack (P.E.D.) connector is frequently used for the
If removed, install new anchored cable strap in O.E. location.
B+ (battery voltage) connector to power P&A accessories.
Tighten cable strap to capture conduit of both accessory con-
Referred to as Packard connectors, Metri-Pack connectors are
nector and B+ connector approximately 1.0 in. (25.4 mm) from
embossed with the initials P.E.D.
housings.
Separating Pin and Socket Housings
sm00031
NOTE
1
Cut any cable strap anchoring the wire conduits of the pin
(accessory connector housing) and the socket (B+) housing.
See Figure A-29. Using small flat blade screwdriver, depress
button (1) on pin housing (red wire) side of the connector and
pull apart the pin and socket housings.
Mating Pin and Socket Housings
2
Orient the latch on the socket housing to the button catch on
the pin housing and press the housings together.
Removing Socket Terminals
1. See Figure A-29. Bend back the latch (2) slightly and free
one side of secondary lock, then repeat to release the
opposite side. Rotate the secondary lock outward on hinge
to access terminal in chamber of connector housing.
2. On the mating end of the connector, note the tang in the
square shaped opening centered next to the terminal.
Gently insert the point of a stick pin or large safety pin into
the opening (3) between the tang and the chamber wall
until it stops.
3. Pivot the end of the pin toward the terminal body to
depress the tang.
4. Remove the pin and then pull terminal out of the wire end
of connector housing.
5. If necessary, crimp new terminals on wires. See
A.15 METRI-PACK TERMINALS.
Installing Socket Terminals
3
1. Carefully bend the tang outward away from the terminal
body.
2. With the tang on the same side as the square shaped
opening in the mating end of the connector housing, feed
1.
Button on pin housing
terminal into wire end of connector housing until it "clicks"
2.
Secondary lock latch
in place.
3.
Opening between tang and chamber wall
3. Verify that terminal will not back out of the chamber. A
Figure A-29. 480 Metri-Pack Connector: Remove Socket
slight tug on the cable will confirm that it is locked.
Terminal
A-24 2008 Touring Diagnostics: Appendix A Connector Repair
HOME
630 METRI-PACK CONNECTORS
A.13
engages a rib in the chamber wall to lock the terminal in
630 METRI-PACK CONNECTOR REPAIR
place.
PART NUMBER
TOOL NAME
3. Moving to the mating end of the connector, take note of
TT600-3
SNAP-ON PICK
the small opening on the chamber wall side of each ter-
minal.
General
4. Insert SNAP-ON PICK (Part No. TT600-3) into opening
Referred to as Packard connectors, Metri-Pack 630 series
until it stops. Pivot the end of the pick toward the terminal
connectors are embossed with the initials P.E.D.
to depress the locking tang.
Separating Pin and Socket Housings
5. Remove the pick and gently tug on the wire to pull the
terminal from the wire end of the connector. Repeat steps
NOTE
if the terminal is still locked in place.
If necessary, remove connector from barbed anchor or other
retaining device.
6. If necessary, crimp new terminals on wires. Refer to
A.15 METRI-PACK TERMINALS.
Bend back the external latch slightly and separate pin and
socket halves of the connector.
Installing Socket Terminal
Mating Pin and Socket Housings
NOTE
Orient the latch to the catch and push the pin and socket halves
Refer to the wiring diagrams to match wire lead colors to alpha
of the connector together until the latch "clicks".
characters molded into the secondary locks of each connector
housing.
NOTE
1. Using a thin flat blade, like that of a hobby knife, carefully
If removed, install connector on barbed anchor or other OE
bend the tang outward away from the terminal body.
retaining device.
2. With the tang facing the chamber wall, push the lead into
Removing Socket Terminal
the chamber at the wire end of the connector. A click is
1. Bend back the latch slightly and free one side of the sec-
heard when the terminal is properly seated.
ondary lock. Repeat the step to unlatch the other side.
3. Gently tug on the wire end to verify that the terminal is
2. Rotate the secondary lock outward on hinge to view the
locked in place and will not back out of the chamber.
terminals in the chambers of the connector housing. The
4. Rotate the hinged secondary lock inward until tabs fully
locking tang is on the side opposite the crimp tails and
engage latches on both sides of connector.
2008 Touring Diagnostics: Appendix A Connector Repair A-25
HOME
800 METRI-PACK CONNECTORS
A.14
DELPHI MAXI-FUSE HOUSING REPAIR
sm00032
General
1
A Delphi Maxi-fuse connector completes the circuit through
the main fuse (Maxi-fuse).
Removing Maxi-Fuse
1. See Figure A-30. Depress latches on Maxi-fuse cover (1)
2
and then slide cover off of connector (2).
2. Holding the connector (fuse holder), pull the Maxi-fuse out
of the connector.
Installing Maxi-Fuse
1. Insert the blade terminals of the Maxi-fuse into the sockets
of the connector and press the Maxi-fuse into the con-
nector.
2. Slide the cover over the fuse until the cover clicks into
place.
1. Maxi-fuse cover
NOTE
2. Delphi Maxi-fuse housing
If removed from an OE attachment such as a grooved fuse
Figure A-30. Delphi Connector Housing: Maxi-Fuse
block cover, engage cover and slide into place.
Removing Socket Terminals
1. See Figure A-31. Gently pull socket housing to disengage
slots (1) on secondary lock (2) from tabs (3) on socket
housing. Free secondary lock from cables and set aside.
2. Take note of the opening on one side of the socket ter-
minal. Gently insert flat blade of pick (Snap-On TT600-5)
or small screwdriver into opening (4) until it stops. Pivot
the pick toward the terminal body and hold in position.
3. Tug on cable to pull socket from wire end of socket
housing. A firm tug is necessary to overcome the resist-
ance of the rubber seal.
4. Repeat to remove remaining socket terminal.
Installing Socket Terminals
1. See Figure A-32. Carefully bend tang outward away from
the terminal body.
2. Feed socket into wire end of socket housing until it clicks
in place. Verify that socket will not back out of chamber.
A slight tug on the cable will confirm that it is locked.
3. Push rubber seal into wire end of socket housing.
4. Repeat to install remaining socket terminal.
5. Install secondary lock onto cables and then push onto wire
end of socket housing until slots engage tabs on sides of
socket housing.
A-26 2008 Touring Diagnostics: Appendix A Connector Repair
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sm00033
sm00034
3
1
2
Figure A-32. Delphi Maxi-Fuse Housing: Bend Tang
4
1. Secondary lock slot
2. Secondary lock
3. Tab
4. Insert flat blade into opening
Figure A-31. Delphi Maxi-Fuse Housing: Remove Socket
Terminals
2008 Touring Diagnostics: Appendix A Connector Repair A-27
HOME
METRI-PACK TERMINALS
A.15
METRI-PACK TERMINAL CRIMPS
sm00035
PART NUMBER
TOOL NAME
HD-38125-6
PACKARD TERMINAL CRIMP TOOL
HD-38125-7
PACKARD TERMINAL CRIMPER
HD-38125-8
PACKARD CRIMPING TOOL
Matching Terminal To Crimper
Metri-Pack connectors embossed with the initials P.E.D. require
Packard crimp tools to crimp terminals to wire leads.
1
Terminals are crimped twice to a wire lead, once over the wire
core and a second time over the insulation/seal.
See Figure A-33. A completed crimp may require two different
crimping dies found on PACKARD TERMINAL CRIMP
TOOL (Part No. HD-38125-6) and/or PACKARD TERMINAL
CRIMPER (Part No. HD-38125-7). The terminal (pin or socket)
and the wire lead gauge will determine the core crimp die and
the insulator/seal die.
NOTE
The PACKARD CRIMPING TOOL (Part No. HD-38125-8) will
also crimp sealed splice connectors in wire gauge sizes 18-20,
2
14-16 and 10-12.
Preparing Wire Lead
Use a wire striper to strip off the insulation and expose
5/32
in. (4.0 mm) of wire core.
Crimping Wire Core
NOTE
Metri-Pack terminal crimps require two steps. Always perform
Crimping Wire Core before Crimping Insulation/Seal.
1. Squeeze and release handles until ratchet automatically
opens.
3
2. Identify the corresponding sized nest for the core crimp.
3. Position the core crimp in the die. Be Sure the core crimp
tails are facing the forming jaws.
4. Gently squeeze the handles until crimpers just secure the
core crimp tails.
5. Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze core
wire strands, while long pair is positioned over the insula-
tion or seal material.
1.
HD-38125-6 sealed terminals
6. Squeeze handles tightly closed. Release grip and the tool
2.
HD-38125-7 non-sealed terminals
will automatically open.
3.
HD-38125-8 non-sealed terminals
Figure A-33. Metri-Pack Terminal Crimp Tools
Crimping Insulation/Seal
NOTE
Always perform Crimping Wire Core before Crimping Insu-
lation/Seal.
A-28 2008 Touring Diagnostics: Appendix A Connector Repair
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1. See Figure A-34. Identify the correct die for the insula-
sm00036
tion/seal crimp (2).
2. Position the insulation/seal crimp in the nest. Be sure the
2
1
insulation/seal crimp tails are facing the forming jaws.
3. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimp is complete.
Inspecting Crimps
1. See Figure A-34. Inspect the wire core crimp (1). The tails
should be folded in on the wire core without any distortion
or excess wire strands.
2. Inspect the insulation (2) or seal (3) crimp. The tails of the
terminal should be wrapped around the insulation without
distortion.
3
1. Wire core crimp
2. Insulation crimp
3. Seal crimp
Figure A-34. Metri-Pack Connector: Inspect Core and
Insulation/Seal Crimps
2008 Touring Diagnostics: Appendix A Connector Repair A-29
HOME
MOLEX CONNECTORS
A.16
5. With all terminals installed, push the secondary lock into
MOLEX CONNECTOR REPAIR
the socket housing to lock the wire terminals into the
PART NUMBER
TOOL NAME
housing.
HD-48114
MOLEX ELECTRICAL CONNECTOR
TERMINAL REMOVER
sm00040
Separating Pin and Socket Housings
See Figure A-35. Depress the latch while pulling the pin and
socket housings apart.
Mating Pin and Socket Housings
1. Orient the latch on the pin housing to the latch pocket on
the socket housing so the rails on the outside of the pin
housings lines up with the tunnels on the socket housing.
2. Press the housings together until the latch clicks.
Removing Terminals
1. Pull the secondary lock up, approximately
3/16 in. (4.8
mm), until it stops.
a. Socket Housing: See Figure A-36. Use a small
screwdriver in the pry slot. The slot next to the
external latch provides a pivot point.
Figure A-35. Molex Connector: Latch
b. Pin Housing: See Figure A-37. Use needle nose
pliers to engage the D-holes in the center of the sec-
ondary lock.
sm00041
NOTE
Do not remove the secondary lock from the connector housing.
2. See Figure A-38. Insert MOLEX ELECTRICAL CON-
NECTOR TERMINAL REMOVER (Part No. HD-48114)
into the pin hole next to the terminal until the tool bottoms.
a. Socket Housing: The pin holes are inside the ter-
minal openings.
b. Pin Housing: The pin holes are outside the pins.
3. Pressing the terminal remover to the bottom of the pin
hole, gently pull on the wire to remove wire terminal from
its cavity.
Installing Terminals
1. See Figure A-39. From the wiring diagram, match the wire
Figure A-36. Molex Connector: Secondary Lock Pry Slot
color to its numbered terminal cavity.
(Socket Housing)
NOTE
Cavity numbers (1) are stamped on the housing at the ends
of the cavity rows. The cavity number can be determined by
counting the cavities up or down along the row from each
stamped number.
2. Orient the terminal so that the tang (2) opposite the open
crimp engages the slot (3) in the cavity.
3. Push the terminal into the cavity.
4. Gently tug on wire to verify that the terminal is captured
by the secondary lock.
A-30 2008 Touring Diagnostics: Appendix A Connector Repair
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sm00042
sm00044
3
1
Figure A-37. Molex Connector: Secondary Lock D-Holes
(Pin Housing)
2
sm00043
1. Cavity number
2. Tang
3. Cavity slot
Figure A-39. Molex Connector: Pin Cavities and Wire
Terminal
Figure A-38. Molex Connector: Terminal Remover
(HD-48114)
2008 Touring Diagnostics: Appendix A Connector Repair A-31
HOME
PACKARD ECM CONNECTOR
A.17
PACKARD 100W CONNECTOR REPAIR
sm00037
General
A Packard 100W connector connects the the electronic control
module (ECM) to the main harness.
3
NOTE
For vehicles with 73-pin connectors, see A.18 PACKARD
MICRO-64 CONNECTORS and A.15 METRI-PACK TER-
MINALS.
Separating Socket Housing From ECM
See Figure A-40. While pressing the connector into the ECM,
1
2
press the thumb lever (1) against the connector until the latch
(2) pops out of the catch (3) on the ECM.
Mating Socket Housing To ECM
Push the connector into the ECM until the latch is captured by
the catch on the ECM.
Removing Socket Terminal
1. See Figure A-41. Gently depress latch (1) on each side
of the clear plastic secondary lock (2) and remove. For
best results, release one side at a time.
1.
Thumb lever
2. Carefully cut cable strap (3) to free strain relief collar (4)
2.
Latch
from conduit (5).
3.
Catch (ECM)
3. See Figure A-42. Using a thin blade, gently pry at seam
Figure A-40. Packard 100W to ECM (Typical)
at back of socket housing to release three plastic pins (1)
from slots in housing. Separate and spread halves of
socket housing.
4. Push on wire lead to free terminal from chamber.
Installing Socket Terminal
1. From inside socket housing, gently pull on wire to draw
terminal into chamber.
2. Exercising caution to avoid pinching wires, press halves
of socket housing together until three plastic pins fully
engage slots in housing.
3. Install new cable strap in groove of strain relief collar
capturing cable conduit.
4. With the two ribs on the secondary lock on the same side
as the external latch, install over terminals until latches
lock in place.
Crimping Terminals
If necessary, crimp new terminals on wire leads. See
A.15 METRI-PACK TERMINALS.
A-32 2008 Touring Diagnostics: Appendix A Connector Repair
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sm00038
sm00039
1
1
1
2
1
3
5
1
4
1. Latch
2. Secondary lock
3. Cable strap
4. Strain relief collar
5. Conduit
2
Figure A-41. Packard 100W Connector
1. Pins
2. Socket terminal
Figure A-42. Packard 100W Connector: Separate Halves
of Socket Housing
2008 Touring Diagnostics: Appendix A Connector Repair A-33
HOME
PACKARD MICRO-64 CONNECTORS
A.18
PACKARD MICRO-64 CONNECTOR REPAIR
sm00046
PART NUMBER
TOOL NAME
HD-45928
PACKARD MICRO-64 TERMINAL
REMOVER
HD-45929
PACKARD MICRO-64 TERMINAL
CRIMPER
General
Packard Micro-64 connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.
For pin 73 of these ECMs, see A.10 150 METRI-PACK CON-
NECTORS.
Separating Pin and Socket Housings
Bend back the external latches slightly and separate the pin
Figure A-43. Packard Micro 64 Terminal Remover
and socket housings.
(HD-45928)
Mating Pin and Socket Housings
Orient the wire lead colors and push the pin and socket hous-
ings of the connector together until the latches click.
sm00048
Removing Terminal
1. See Figure A-45. Locate the head of the secondary lock
(1) on one side of the connector housing.
2. Insert the blade of a small screwdriver between the center
ear of the lock and the connector housing and gently pry
out lock. When partially removed, pull lock from connector
housing.
3. Locate pin hole (2) between terminals on mating end of
connector.
4. See Figure A-46. Obtain the PACKARD MICRO-64 TER-
MINAL REMOVER (Part No. HD-45928).
5. See Figure A-44. Push the adjacent terminals all the way
into the connector housing and then insert tool into hole
until it bottoms.
6. Leaving the tool installed, gently tug on wires to pull either
one or both terminals from wire end of connector. Remove
tool.
Figure A-44. Packard Micro 64 Connector: Insert Tool and
Remove Terminal
A-34 2008 Touring Diagnostics: Appendix A Connector Repair
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Installing Terminal
sm00047
1. Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter-
3
minal is necessary.
2
1
6
NOTE
1
See Figure A-45. For wire location purposes, the corners of
the socket housing are stamped (3) with the numbers 1, 6, 7
and 12, representing terminals 1-6 on one side, and 7-12 on
1
2
3
4
5
6
the other.
7
8
9 10
11 12
2. Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.
NOTE
7
12
Once the terminal is removed it may not lock in place when
first reinstalled. Until the lock engages, move the terminal back
1. Secondary lock
and forth slightly while wiggling the lead.
2. Pin hole
3. Since the terminal remover tool releases two terminals
3. Stamped number
simultaneously, repeat step 2 on the adjacent terminal
Figure A-45. Packard Micro 64 Connector: Housing
even if it was not pulled from the connector housing.
4. With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.
sm00045
Preparing Wire Leads for Crimping
Strip lead removing 1/8 in. (3.0 mm) of insulation.
Crimping Terminals
1. Inspect new socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.
2. See Figure A-47. Squeeze the handles of the PACKARD
MICRO-64 TERMINAL CRIMPER (Part No. HD-45929)
to cycle the tool to the fully open position (1).
3. Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).
4. With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).
Figure A-46. Packard Micro 64 Terminal Crimper (HD-45929)
5. Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails and the closed side of
the terminal rests on the outer nest of the crimp tool.
6. Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that wide
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.
7. Squeeze handle of crimp tool until tightly closed (4). Tool
automatically opens when the crimping sequence is com-
plete.
8. Raise locking bar and barrel holder to remove contact.
Inspecting Crimps
Inspect the quality of the core and insulation crimps. Distortion
should be minimal.
2008 Touring Diagnostics: Appendix A Connector Repair A-35
HOME
sm00049
1
2
3
4
1. Open position
2. Raising locking bar
3. Insert terminal
4. Crimp terminal
Figure A-47. Packard Micro 64 Connector: Terminal in
Crimper
A-36 2008 Touring Diagnostics: Appendix A Connector Repair
HOME
SEALED SPLICE CONNECTORS
A.19
5. Squeeze the handles tightly closed to crimp the lead in
SEALED SPLICE CONNECTOR REPAIR
the insert (2). The tool automatically opens when the
PART NUMBER
TOOL NAME
crimping is complete.
HD-25070
ROBINAIR HEAT GUN
6. Slide the connector to the other half of the metal insert.
Insert the stripped wire lead (1) until it stops, and crimp
HD-38125-8
PACKARD CRIMPING TOOL
the lead in the insert (2).
HD-39969
ULTRA-TORCH UT-100
HD-41183
HEAT SHIELD ATTACHMENT
General
Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Splice connectors and several OE ring terminal connectors
Failure to follow manufacturer's instructions can cause a
use heat shrink covering to seal the connection.
fire, which could result in death or serious injury. (00335a)
Preparing Wire Leads
•
Avoid directing heat toward any fuel system component.
NOTE
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.
If adjacent wires are to be spliced, stagger the splices so that
the sealed splice connectors will not touch each other but are
•
Avoid directing heat toward any electrical system com-
located at different positions along the length of the wires.
ponent other than the connectors on which heat shrink
work is being performed.
1. Using a shop gauge, identify the gauge of the wire.
•
Always keep hands away from tool tip area and heat shrink
2. Match the wire gauge to a sealed splice connector by color
attachment.
and part number. Refer to Table A-4.
7. Use an ULTRA-TORCH UT-100 (Part No. HD-39969), or
3. Using a wire stripper, cut and strip a length of insulation
a ROBINAIR HEAT GUN (Part No. HD-25070) with a
off the wire ends. Refer to Table A-4 for the strip length.
HEAT SHIELD ATTACHMENT (Part No. HD-41183), to
heat the connector from the center of the crimp (3) out to
Table A-4. Sealed Splice Connectors
each end.
WIRE GAUGE
COLOR
PART NO.
STRIP LENGTH
NOTE
18-20
Red
70585-93
3/8 in. (9.5 mm)
It is acceptable for the splice to rest against the heat shrink
(0.5-0.8 mm)
tool attachment.
14-16
Blue
70586-93
3/8 in. (9.5 mm)
Inspecting Seals
(1.0-2.0 mm)
See Figure A-49. Allow the splice to cool and inspect the seal.
10-12
Y
ellow
70587-93
3/8 in. (9.5 mm)
The insulation should appear smooth and cylindrical. Melted
(3.0-5.0 mm)
sealant will have extruded out the ends (4) of the insulation.
NOTE
If any copper wire strands are cut off of the wire core, trim the
end and strip the wire again in a larger gauge stripper.
Splicing Wire Leads
NOTE
See Figure A-49. The connector is crimped twice - one side
and then the other.
1. See Figure A-48. Open the PACKARD CRIMPING
TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.
2. Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.
3. Gently squeeze the handles until the connector is held in
the jaws.
4. See Figure A-49. Feed the stripped end of a wire into the
connector until the wire stops inside the metal insert (1).
2008 Touring Diagnostics: Appendix A Connector Repair A-37
HOME
sm00050
sm00051
1
1
3
2
2
1
2
1. Red connector die
3
2. Blue connector die
3. Yellow connector die
Figure A-48. Packard Crimping Tool (HD-38125-8)
4
4
1. Wire lead in metal insert
2. Crimp metal insert
3. Center of crimp
4. Melted sealant
Figure A-49. Sealed Splice Connector
A-38 2008 Touring Diagnostics: Appendix A Connector Repair
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