Delphi 1.5 OCS Series User manual

Issued by
CTC Warren, Ohio
STC Saltillo, Mex.
February 2016
1.5 OCS Sealed Connection System
1.5 Terminal System
ASSEMBLY MANUALS
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY MANUAL - 13987928

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 2012 DELPHI. All rights reserved.
Developed by : Deniss Guerrero & Javier Esquivel [phone]
Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928
TABLE OF CONTENTS
3
PRE–ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE CONNECTOR
6
View of Versions
7
List of Components & Exploded View
9
Step 1 - Insert Connector Seal
10
Step 2 - Align and Insert PLR (to Pre-Stage Position)
11
Step 3 - Lock CPA (to Pre-Stage Position)
12
Step 4 -Install Cable Seal
14
Step 5 - Insert Retainer
15
Female Connector –Completed Assembly
16
ASSEMBLY OF THE MALE CONNECTOR
17
View of Versions
18
List of Components & Exploded View
20
Step 1 - Align and Insert PLR (to Pre-Stage Position)
21
Step 2 - Install Cable Seal
22
Step 3 - Insert Retainer
23
Male Connector –Completed Assembly
24
HARNESS ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR
25

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928
TABLE OF CONTENTS
4
List of Components & Exploded View
26
Step 1 - Identify Cavities
27
Step 2 - Align Cavity Plug (Optional)/Terminals Female 1.5 and Female Assembly
27
Step 3 - Insert Cavity Plug (Optional)/Terminals OCS Female 1.5
28
Step 4 - Close PLR to Full-Stage
30
Female Assembly - Completed
30
ASSEMBLY OF THE MALE HARNESS ASSEMBLY CONNECTOR
31
List of Components & Exploded View
32
Step 1 - Identify Cavities
33
Step 2 - Align Cavity Plug (Optional)/Terminals Male 1.5 and Male Assembly
33
Step 3 - Insert Cavity Plug (Optional)/Terminals OCS Male 1.5
34
Step 4 - Close PLR to Full-Stage
36
Male Assembly - Completed
36
CAR ASSEMBLY SECTION
ASSEMBLY OF THE CONNECTION SYSTEM
37
3D Model
38
Step 1 - Identify and Align Index Features
39
Step 2 - Mate Female Assembly and Male Assembly Together Axially
39
Step 3 - Close CPA to Full-Stage
40
Connection System - Completed Assembly
40
DISASSEMBLY SECTION
DISASSEMBLY OF THE CONNECTION SYSTEM
41
Step 1 - Move CPA to Pre-Stage Position
42
Step 2 - Release the Connector Lock
43
Step 3 - Disconnect
43
Connection System - Completed Disassembly
44

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928
TABLE OF CONTENTS
5
REPAIR / REPLACEMENT SECTION
FEMALE CONNECTOR SUB COMPONENTS:
45
PLR Replacement –Step 1 (Remove)
46
Step 2 (Install)
48
TERMINAL F OCS 1.5/CAVITY PLUG Replacement –Step 1 (Remove)
48
Step 2 (Insert)
50
RETAINER Replacement –Step 1 (Remove)
50
Step 2 (Install)
51
CABLE SEAL Replacement –Step 1 (Remove)
52
Step 2 (Install)
53
CPA Replacement –Step 1 (Remove)
53
Step 2 (Insert)
54
CONNECTOR SEAL Replacement –Step 1 (Remove)
55
Step 2 (Install)
56
MALE CONNECTOR SUB COMPONENTS:
57
TERMINAL M OCS 1.5/CAVITY PLUG Replacement –Step 1 (Move PLR to Pre-Stage)
58
Step 2 (Remove)
59
Step 3 (Insert)
61
RETAINER Replacement –Step 1 (Remove)
61
Step 2 (Install)
62
CABLE SEAL Replacement –Step 1 (Remove)
63
Step 2 (Insert)
64
PLR Replacement –Step 1 (Remove)
64
Step 2 (Install)
66
Recommended Repair Tools
67
REVISIONS
68

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928
1.5 OCS Sealed Connection System
ASSEMBLY OF THE
FEMALE CONNECTOR
6
FEMALE ASSEMBLY
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 7
VIEW OF VERSIONS
ASSEMBLY
2 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
3 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
4 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
6 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES, WHICH DIFFER IN THE INDEXING AND COLOR,
REFER TO LATEST DRAWINGS FOR DETAILS

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 8
VIEW OF VERSIONS
ASSEMBLY
8 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
10 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
12 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
16 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES, WHICH DIFFER IN THE INDEXING AND COLOR,
REFER TO LATEST DRAWINGS FOR DETAILS

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 9
Pictures used in this Assembly Manual and original parts may differ in some
details, these differences have no influence on the assembly process.
ASSEMBLY
PLR
CONNECTOR SEAL
QUANTITY COMPONENTS OF 1.5 OCS FEMALE CONNECTOR
1 PLR
1 CONNECTOR SEAL
1 FEMALE CONNECTOR
1 CABLE SEAL
1 RETAINER
1 CPA
LIST OF COMPONENTS & EXPLODED VIEW
FEMALE CONNECTOR
RETAINER
CPA
CABLE SEAL

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928
IMPORTANT! VERIFY THAT CONNECTOR SEAL IS NOT OVER SEATED,
BUNCHED OR ROLLED DURING THE INSERTION
10
STEP 1a –Insert Connector Seal
STEP 1b –Insert Connector Seal
SECTION VIEW
ASSEMBLY
CONNECTOR WALL
SEALING
SURFACE AREA
CONNECTOR WALL
SEALING SURFACE AREA
IDENTIFY THE SEALING SURFACE AREA TO
INSERT THE CONNECTOR SEAL THEN, PUSH THE CONNECTOR SEAL INTO THE CONNECTOR
CONNECTOR SEAL INSERTED

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 11
STEP 2a –Align and Insert PLR (to Pre-Stage Position)
STEP 2b –Align and Insert PLR (to Pre-Stage Position)
ASSEMBLY
PLR IS NOW IN
PRE-STAGE POSITION
VERIFY AUDIBLE CLICK
ON BOTH SIDES

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 12
STEP 3a –Lock CPA (to Pre-Stage Position)
STEP 3b –Lock CPA (to Pre-Stage Position)
ASSEMBLY
ALIGN CPA WITH THE CONNECTOR LOCK
BACK VIEW
PRESS DOWN THE CPA UNTIL MATING FEATURES LINE UP
AND THE CONNECTOR LOCK DEFLECTS
TOP VIEW
THEN, PUSH DOWN THE CPA
MATING
FEATURES

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 13
STEP 3c –Lock CPA (to Pre-Stage Position)
STEP 3d –Lock CPA (to Pre-Stage Position)
ASSEMBLY
WITH THE FEATURES ALIGNED,
MOVE THE CPA TO FRONT
TOP VIEW
VERIFY AUDIBLE CLICK
THE CONNECTOR LOCK RETURNS TO ITS ORIGINAL POSITION
CPA IS NOW IN
PRE-STAGE POSITION

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 14
STEP 4 –Install Cable Seal
ASSEMBLY
PROCESS FOR:
3W & 4W CONNECTORS PROCESS FOR: 2W, 6W, 8W, 10W, 12W & 16W CONNECTORS
IDENTIFY THE CORRECT ORIENTATION
OF THE SEAL
1
PUSH CABLE SEAL INTO THE CONNECTOR
2
INSERTION COMPLETED
3
LOCATE AND ALIGN MATING FEATURES
1
PUSH CABLE SEAL INTO THE RETAINER
2
INSERTION COMPLETED
3

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 15
STEP 5 –Insert Retainer
ASSEMBLY
RETAINER LOCKED
VERIFY AUDIBLE CLICK
ON BOTH SIDES
THE INSERTION PROCESS OF THE RETAINER IS THE SAME
REGARDLESS THE INSERTION PROCESS OF THE CABLE SEAL
PRESS RETAINER ONTO CONNECTOR
1
2
INSERTION COMPLETED
3
PRESS RETAINER ONTO CONNECTOR
1
2
INSERTION COMPLETED
3
VERIFY AUDIBLE CLICK
ON BOTH SIDES

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 16
FEMALE CONNECTOR –COMPLETED ASSEMBLY
ASSEMBLY

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928
1.5 OCS Sealed Connection System
ASSEMBLY OF THE
MALE CONNECTOR
17
MALE ASSEMBLY
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 18
VIEW OF VERSIONS
ASSEMBLY
2 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
3 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
4 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
6 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES, WHICH DIFFER IN THE INDEXING AND COLOR,
REFER TO LATEST DRAWINGS FOR DETAILS

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 19
VIEW OF VERSIONS
ASSEMBLY
8 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
10 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
12 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
16 WAY CONNECTOR
TYPE 101 TYPE 102 TYPE 103 TYPE 104 TYPE 105 TYPE 106
EACH CONNECTION SYSTEM HAVE 6 DIFFERENT TYPES, WHICH DIFFER IN THE INDEXING AND COLOR,
REFER TO LATEST DRAWINGS FOR DETAILS

Assembly Manual
1.5 OCS Sealed Connection System
Female/Male 1.5 Terminal System
Contact at STC Saltillo: David Torres [phone]
Assembly Manual - 13987928 20
Pictures used in this Assembly Manual and original parts may differ in some
details, these differences have no influence on the assembly process.
ASSEMBLY
PLR
QUANTITY COMPONENTS OF 1.5 OCS MALE CONNECTOR
1 PLR
1 MALE CONNECTOR
1 CABLE SEAL
1 RETAINER
LIST OF COMPONENTS & EXPLODED VIEW
MALE CONNECTOR
RETAINER
CABLE SEAL
LIST OF COMPONENTS & EXPLODED VIEW