Delphi GT 280 User manual

Issued by
CTC Warren, Ohio
STC Saltillo, Mex.
February 2017
4 Way GT 280 Sealed Connection System
GT 2.8 Female Terminal System (Sealed)
ASSEMBLY MANUALS
PRE - ASSEMBLY
HARNESS ASSEMBLY
CAR ASSEMBLY
ASSEMBLY MANUAL - 33278895

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 2017 DELPHI. All rights reserved.
Developed by : Deniss Guerrero [phone]
Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895
TABLE OF CONTENTS
3
PRE–ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE CONNECTOR
5
List of Components & Exploded View
6
Step 1 –Insert Connector Seal
7
Step 2 –Install PLR to Pre-Stage Position
8
Step 3 –Assemble CPA to Pre-Stage Position (Optional Component)
9
Connector Assembly –Completed
9
HARNESS ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR
10
List of Components & Exploded View
11
Step 1 –Identify Cavities
12
Step 2 –Assemble Cavity Plug (If Required)
12
Step 3 –Align Terminals Female 2.8 and Female Assembly
13
Step 4 –Insert Terminals Female GT 2.8 (Or Equivalent)
14
Step 5 –Lock PLR to Full-Stage Position
15
Harness Assembly –Completed
16

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895
TABLE OF CONTENTS
4
CAR ASSEMBLY SECTION
ASSEMBLY OF THE CONNECTION SYSTEM
17
List of Components & Exploded View
18
3D Model
19
Step 1 –Identify Index Features
20
Step 2 –Align Index Features and Mate Female Assembly and Mating Part Together
20
Step 3 –Lock CPA to Full –Stage Position (Optional Component)
21
Connection System –Completed Assembly
22
DISASSEMBLY SECTION
DISASSEMBLY OF THE CONNECTION SYSTEM
23
Step 1 –Move CPA to Pre-Stage Position (Optional Component)
24
Step 2 –Disconnect
25
Connection System –Completed Disassembly
25
REPAIR / REPLACEMENT SECTION
FEMALE CONNECTOR SUB COMPONENTS:
26
PLR Replacement –Step 1 (Remove PLR)
27
Step 2 (Install PLR)
28
TERMINAL F 2.8 Replacement –Step 1 (Remove Terminal)
28
Step 2 (Insert Terminal)
30
Recommended Repair Tools
31
REVISIONS
32

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895
4 Way GT 280 Sealed Connection System
ASSEMBLY OF THE
FEMALE CONNECTOR
5
CONNECTOR ASSEMBLY
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 6
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 PLR
1 CONNECTOR SEAL
1 FEMALE CONNECTOR
1 CPA *
LIST OF COMPONENTS & EXPLODED VIEW
CONNECTOR
SEAL
CPA *
PLR
*OPTIONAL COMPONENT

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 7
STEP 1a –Insert Connector Seal
STEP 1b –Insert Connector Seal
ASSEMBLY
CONNECTOR SEAL ASSEMBLED
VERIFY THE ORIENTATION OF THE SEAL AND INSERT IT INTO THE CONNECTOR
IMPORTANT! VERIFY THAT CONNECTOR SEAL IS NOT BUNCHED OR ROLLED
DURING THE INSERTION

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 8
STEP 2a –Install PLR to Pre-Stage Position
STEP 2b –Install PLR to Pre-Stage Position
ASSEMBLY
IDENTIFY THE CORRECT ORIENTATION
OF THE PLR
PLR IS NOW
IN PRE-STAGE POSITION
INSERT PLR ONTO THE CONNECTOR
VERIFY AUDIBLE CLICK VERIFY THAT THE LOCKS ON CONNECTOR
ARE FASTENED ON THE PLR SLOTS

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 9
STEP 3 –Assemble CPA to Pre-Stage Position (Optional Component)
FEMALE CONNECTOR ASSEMBLY –COMPLETED
ASSEMBLY
VERIFY AUDIBLE CLICK
CPA IS NOW
IN PRE-STAGE POSITION
IDENTIFY THE CORRECT ORIENTATION OF
CPA AND PUSH IT ONTO THE CONNECTOR

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895
4 Way GT 280 Sealed Connection System
10
FEMALE ASSEMBLY
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY
ASSEMBLY OF THE
FEMALE HARNESS ASSEMBLY

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 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
4 MAX SEALED TERMINAL GT 2.8
AS REQUIRED CAVITY PLUG *
LIST OF COMPONENTS & EXPLODED VIEW
SEALED TERMINAL GT 2.8
*OPTIONAL COMPONENT
CAVITY PLUG *

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 12
STEP 1 –Identify Cavities
STEP 2a –Assemble Cavity Plug (If Required)
ASSEMBLY
CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR
BACK VIEW
PUSH THE PLUG INTO ITS RESPECTIVE CAVITY
UNTIL THE PLUG IS EVEN WITH THE EDGE OF
THE CAVITY
PLUG CAN BE INSERTED WITH THE FINGERS
OR WITH TOOL 10914973 IF NECESSARY

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 13
STEP 2b –Assemble Cavity Plug (If Required)
STEP 3 –Align Terminals Female GT 2.8 (Or Equivalent) and Female Assembly
ASSEMBLY
INSERT FEMALE TERMINALS INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN.
- PROPER ORIENTATION OF TERMINAL REQUIRED -
INDEX FEATURES
TERMINAL FRONT VIEW
CAVITY PLUG INSTALLED
0 mm

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 14
STEP 4a –Insert Terminals Female GT 2.8 (Or Equivalent)
STEP 4b –Insert Terminals Female GT 2.8 (Or Equivalent)
ASSEMBLY
GENTLY PULL ON THE CABLE TO
VERIFY THE LOCK SYSTEM
3 USE THE SAME PROCESS TO INSERT THE
REMAINING TERMINALS NEEDED
TERMINAL FULLY ENGAGED
UNDER THE FLEX LOCK
VERIFY AUDIBLE CLICK
2
PUSH THE TERMINAL STRAIGHT
INTO THE CAVITY
1

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 15
STEP 5a –Lock PLR to Full-Stage Position
STEP 5b –Lock PLR to Full-Stage Position
ASSEMBLY
PLR IS NOW IN
FULL-STAGE POSITION
PUSH THE PLR FORWARD
DO NOT FORCE THE PLR, IF IT CAN’T BE LOCKED REVISE IF TERMINALS ARE PROPERLY SEATED
VERIFY AUDIBLE CLICK VERIFY THAT THE LOCK ON CONNECTOR IS
FASTENED ON THE PLR SLOT

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 16
FEMALE HARNESS ASSEMBLY –COMPLETED
ASSEMBLY
PERFORM TESTS. APPLY COVERINGS AS REQUIRED. INSPECT THE ASSEMBLY.

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895
4 Way GT 280 Sealed Connection System
ASSEMBLY OF THE
CONNECTION SYSTEM
17
FEMALE ASSEMBLY
MATING PART
PRE - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 18
LIST OF COMPONENTS & EXPLODED VIEW
ASSEMBLY
MATING PART
QUANTITY COMPONENTS OF 4 WAY GT 280 SEALED CONNECTION SYSTEM
1 MATING PART
1 FEMALE ASSEMBLY
Pictures used in this Assembly Manual and original parts may differ in some
details. These differences have no influence on the assembly process.
FEMALE ASSEMBLY

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 19
3D MODEL VIEW
CLICK IMAGE TO START
3D VISUALIZATION
ASSEMBLY

Assembly Manual
4 Way GT 280 Sealed Connection System
GT 2.8 Terminal System (Sealed)
© Delphi Corporation. All Rights Reserved
www.delphi.com
Assembly Manual - 33278895 20
STEP 1 –Identify Index Features
STEP 2a –Align Index Features and Mate Female Assembly and Mating Part Together
ASSEMBLY
IMPORTANT! IF THE INDEXES DON'T LINE UP, DO NOT CONTINUE.