Delphi 101 User manual

Issuedby
CTC Warren,Ohio
STC Saltillo,Mex.
October 2015
2 Way Unsealed OCS 1.2 Inline
Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
ASSEMBLY MANUALS
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY MANUAL - 33286031

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 2015 DELPHI. All rights reserved.
Developed by : Deniss Guerrero [phone]
Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031
TABLE OF CONTENTS
3
PRE–ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE CONNECTOR 5
View of Versions 6
List of Components & Exploded View 7
ASSEMBLY SEQUENCE:
Step 1 –Assemble CPA to Pre-Stage Position 8
Connector Assembly –Completed 9
HARNESS ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR 10
List of Components & Exploded View 11
ASSEMBLY SEQUENCE:
Step 1 –Identify Cavities for Terminals OCS 1.2 (or Equivalent) 12
Step 2 –Align Terminals Female 1.2 and Female Assembly 12
Step 3 –Insert Terminals Female OCS 1.2 (or Equivalent) 13
Step 4 –Lock Connector Hinge to Closed Position 14
Harness Assembly –Completed 15
ASSEMBLY OF THE MALE HARNESS ASSEMBLY CONNECTOR 16
View of Versions 17
List of Components & Exploded View 18
ASSEMBLY SEQUENCE:
Step 1 –Identify Cavities for Terminals OCS (or Equivalent) 19
Step 2 –Align Terminals Male 1.2 and Male Assembly 19

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031
TABLE OF CONTENTS
4
Step 3 –Insert Terminals Male OCS 1.2 (or Equivalent) 20
Step 4 –Lock Connector Hinge to Closed Position 21
Harness Assembly –Completed 22
CAR ASSEMBLY SECTION
ASSEMBLY OF THE CONNECTION SYSTEM 23
List of Components & Exploded View 24
3D Model 25
Step 1 –Identify Index Features 26
Step 2 –Align Index Features and Mate Female Assembly and Male Assembly Together 26
Step 3 –Lock CPA to Full –Stage Position 27
Connection System –Completed Assembly 28
DISASSEMBLY SECTION
DISASSEMBLY OF THE CONNECTION SYSTEM 29
Step 1 –Move CPA to Pre-Stage Position 30
Step 2 –Disconnect 31
Connection System –Completed Disassembly 31
REPAIR / REPLACEMENT SECTION
FEMALE CONNECTOR SUB COMPONENTS: 32
TERMINAL F OCS 1.2 Replacement –Step 1 (Release Connector Hinge) 33
Step 2 (Remove Terminal) 34
Step 3 (Insert Terminal) 35
MALE CONNECTOR SUB COMPONENTS: 36
TERMINAL M OCS 1.2 Replacement –Step 1 (Release Connector Hinge) 37
Step 2 (Remove Terminal) 38
Step 3 (Insert Terminal) 29
Recommended Repair Tools 40
REVISIONS 41

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031
2 Way Unsealed OCS 1.2 Inline
Connection System
ASSEMBLY OF THE
FEMALE CONNECTOR
5
FEMALE CONNECTOR
ASSEMBLY
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 6
VIEW OF VERSIONS
ASSEMBLY
THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS, WHICH DIFFER IN THE INDEXING AND COLOR.
THE METHOD OF ASSEMBLY IS THE SAME FOR ALL CONNECTORS REGARDLESS OF THEIR DIFFERENCES.
REFER TO LATEST TAXI ASSEMBLY DRAWING FOR DETAILS.
Type 101 Type 102
Type 103 Type 104

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 7
Pictures used in this Assembly Manual and original parts may differ in some
details. These differences have no influence on the assembly process.
ASSEMBLY
FEMALE CONNECTOR
QUANTITY COMPONENTS
1 FEMALE CONNECTOR
1 CPA
LIST OF COMPONENTS
LIST OF COMPONENTS & EXPLODED VIEW
CPA

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 8
STEP 1a –Assemble CPA to Pre-Stage Position
STEP 1b –Assemble CPA to Pre-Stage Position
ASSEMBLY
IDENTIFYTHECORRECT ORIENTATIONOF THECPAAND INSERT IT ONTOTHECONNECTOR
VERIFYAUDIBLE CLICK ON
BOTH LOCKS
CPAIS NOW
IN PRE-STAGE POSITION
SECTION VIEW

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 9
FEMALE CONNECTOR ASSEMBLY –COMPLETED ASSEMBLY
ASSEMBLY

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031
2 Way Unsealed OCS 1.2 Inline
Connection System
10
FEMALE ASSEMBLY
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY
ASSEMBLY OF THE
FEMALE HARNESSASSEMBLY

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 11
Pictures used in this Assembly Manual and original parts may differ in some
details, these differences have no influence on the assembly process.
ASSEMBLY
FEMALE CONNECTOR
ASSEMBLY
QUANTITY COMPONENTS
1 FEMALE CONNECTOR ASSEMBLY
2 TERMINAL OCS 1.2
LIST OF COMPONENTS & EXPLODED VIEW
TERMINAL
LIST OF COMPONENTS & EXPLODED VIEW

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 12
STEP 1 –Identify Cavities for Terminals OCS 1.2 (or Equivalent)
STEP 2 –Align Terminals Female 1.2 and Female Assembly
ASSEMBLY
CAVITY ID NUMBERS LOCATEDAT THE BACK OF THE CONNECTOR.
BACK VIEW
INSERT FEMALETERMINALSINTORECEPTACLEHOUSING ACCORDING TOINSERTIONPLAN.
- PROPER ORIENTATIONOF TERMINALREQUIRED -
INDEX FEATURE
BACK VIEWS

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 13
STEP 3a –Insert Terminals Female OCS 1.2 (or Equivalent)
STEP 3b –Insert Terminals Female OCS 1.2 (or Equivalent)
ASSEMBLY
TERMINAL FULLYENGAGED UNDER
THE FLEX LOCK
VERIFYAUDIBLE CLICK
1 2
PUSH THE TERMINALSTRAIGHT
INTOTHE CAVITY
GENTLYPULLONTHE CABLETO
VERIFYTHE LOCKSYSTEM
3 USE THESAMEPROCESSTOINSERT THE
REST OF THETERMINALSNEEDED

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 14
STEP 4a –Lock Connector Hinge to Closed Position
STEP 4b –Lock Connector Hinge to Closed Position
ASSEMBLY
CAREFULLYPUSH THE HINGE FORWARD
VERIFYAUDIBLE CLICK
DO NOT FORCE THE HINGE, IF IT CAN’T BE CLOSED REVIEW IF TERMINALS ARE PROPERLY LOCKED
LOCKED HINGE

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 15
FEMALE ASSEMBLY –COMPLETED HARNESS ASSEMBLY
ASSEMBLY
PERFORM TESTS, APPLY COVERINGS AS REQUIRED. INSPECT THE ASSEMBLY.
CONNECTORHINGE MUST BE COMPLETELYCLOSED
BEFORETAPINGOR DRESSING WIRES/HARNESS

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031
2 Way Unsealed OCS 1.2 Inline
Connection System
16
MALE ASSEMBLY
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY
ASSEMBLY OF THE
MALE HARNESSASSEMBLY

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 17
VIEW OF VERSIONS
ASSEMBLY
THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS, WHICH DIFFER IN THE INDEXING AND COLOR.
THE METHOD OF ASSEMBLY IS THE SAME FOR ALL CONNECTORS REGARDLESS OF THEIR DIFFERENCES.
REFER TO LATEST TAXI DRAWING FOR DETAILS.
Type 101 Type 102
Type 103 Type 104

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 18
Pictures used in this Assembly Manual and original parts may differ in some
details, these differences have no influence on the assembly process.
ASSEMBLY
MALE CONNECTOR
QUANTITY COMPONENTS
1 MALE CONNECTOR
2 TERMINAL OCS 1.2
LIST OF COMPONENTS & EXPLODED VIEW
LIST OF COMPONENTS & EXPLODED VIEW
TERMINAL

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 19
STEP 1 –Identify Cavities for Terminals OCS (or Equivalent)
STEP 2 –Align Terminals Male 1.2 and Male Assembly
ASSEMBLY
CAVITY ID NUMBERS LOCATEDAT THE BACK OF THE CONNECTOR
BACK VIEW
INSERT MALETERMINALSINTORECEPTACLEHOUSING ACCORDING TOINSERTIONPLAN.
- PROPER ORIENTATIONOF TERMINALREQUIRED -
INDEX FEATURES
BACK VIEWS

Assembly Manual
2 Way Unsealed OCS 1.2 Inline Connection System
Female/Male OCS 1.2 Terminal System (Unsealed)
Contactat CTCWarren:Michelle Smith+1 [phone]
Assembly Manual - 33286031 20
STEP 3a –Insert Terminals Male OCS 1.2 (or Equivalent)
STEP 3b –Insert Terminals Male OCS 1.2 (or Equivalent)
ASSEMBLY
TERMINALFULLYENGAGED
UNDER THEFLEXLOCK
VERIFYAUDIBLE CLICK
1 2
PUSH THE TERMINALSTRAIGHT
INTOTHE CAVITY
GENTLYPULLONTHE CABLETO
VERIFYTHE LOCKSYSTEM
3 USE THESAMEPROCESSTOINSERT THE
REST OF THETERMINALSNEEDED