Delphi HV-2000 User manual

Issued by
CTC Warren, Ohio
STC Saltillo, Mex.
September 2016
HV-2000 Right Angle Bolted Connector
Female Power Pack 2000 Terminal System (Sealed)
ASSEMBLY MANUALS
CONNECTOR - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY MANUAL - 33366036

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 2016 DELPHI. All rights reserved.
Developed by : Deniss Guerrero [phone]
Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
TABLE OF CONTENTS
3
CONNECTOR–ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE CONNECTOR
5
List of Components & Exploded View
6
Step 1 –Assembly O-Ring Seal onto Bolt
7
Step 2 –Retain Bolt to Housing with Bolt Retainer
7
Step 3 –Insert Face Seal into Housing Shroud
9
Step 4 –Press Shunt into the Inner Connector
10
Step 5 –Assembly Inner Connector
11
Connector Assembly –Completed
12
HARNESS ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR
13
List of Components & Exploded View
14
Step 1 –Insert Retainer and Cable Seal onto Coaxial Cable
15
Step 2 –Partially Strip the Cables and Remove Stripped Insulation
16
Step 3 –Insert and Crimp Ferrules
17
Step 4 –Sonic Weld Female Terminal
19
Step 1 –Identify Cavities
20
Step 2 –Align and Insert Terminals Female Power Pack 2000
20
Step 3 –Assemble Lock TPA/Clip
22
Step 4 –Insert Cable Seal into the Housing
23
Step 5 –Install Seal Retainers
23
Harness Assembly –Completed
24

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
TABLE OF CONTENTS
4
CAR ASSEMBLY SECTION
ASSEMBLY OF THE CONNECTION SYSTEM
25
List of Components & Exploded View
26
Step 1 –Identify Index Features in both the Mating Interface and Bolted Connector
27
Step 2 –Assembly Bolted Connector onto Mating Interface
27
Connection System –Completed Assembly
29
DISASSEMBLY SECTION
DISASSEMBLY OF THE CONNECTION SYSTEM
30
Step 1 –Disconnect
31
Connection System –Completed Disassembly
31
REPAIR SECTION
FEMALE CONNECTOR SUB COMPONENTS:
32
LOCK TPA/CLIP Replacement –Step 1 (Remove)
33
Step 2 (Insert)
33
FEMALE TERMINAL Replacement –Step 1 (Release Seal Retainer)
34
Step 2 (Remove Terminal)
35
Step 3 (Insert Terminals)
36
INNER CONNECTOR Replacement –Step 1 (Remove)
36
Step 2 (Insert)
37
BOLT Replacement –Step 1 (Remove)
37
Step 2 (Insert)
38
Recommended Repair Tools
39
REVISIONS
40

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
HV-2000 Right Angle Bolted Connector
ASSEMBLY OF THE
FEMALE CONNECTOR
5
FEMALE CONNECTOR
ASSEMBLY
CONNECTOR - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 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
QUANTITY COMPONENTS
1 BOLT RETAINER
1 FACE SEAL
1 INNER CONNECTOR
1 SHUNT
1 HOUSING
1 O-RING SEAL
1 BOLT
LIST OF COMPONENTS & EXPLODED VIEW
O-RING SEAL
FACE SEAL
BOLT
RETAINER
INNER CONNECTOR
HOUSING
BOLT
REFER TO LATEST DRAWING 33352038 FOR PART NUMBERS AND DETAILS
SHUNT

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 7
STEP 1 –Assembly O-Ring Seal onto Bolt
STEP 2a –Retain Bolt to Housing with Bolt Retainer
ASSEMBLY
INSERT O-RING SEAL ONTO BOLT AND PLACE IT
UNDERNEATH THE BOLT HEAD IMPORTANT! VERIFY THAT O-RING SEAL IS NOT
ROLLED OR DAMAGED DURING THE INSERTION
O-RING SEAL INSERTED
IMPORTANT! USE OF PROPER LUBRICANT IS
REQUIRED FOR O-RING SEAL ASSEMBLY
INSERT THE BOLT ASSEMBLY INTO THE
HOUSING HOLE ONCE THE BOLT HAS BEEN INSERTED, PLACE THE HOUSING ONTO THE ASSEMBLY FIXTURE

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 8
STEP 2b –Retain Bolt to Housing with Bolt Retainer
STEP 2c –Retain Bolt to Housing with Bolt Retainer
ASSEMBLY
BOLT RETAINER INSERTED
PLACE BOLT RETAINER ONTO THE BOLT AS SHOWN BELOW,
BOLT RETAINER FLAT FACE MUST BE FACING TOWARD THE HOUSING
IMPORTANT! BOLT RETAINER ORIENTATION IS CRITICAL TO ACHIEVE THE CORRECT FUNCTION OF THE BOLT
PRESS THE BOLT RETAINER DOWN UNTIL IT SURPASSES THE BOLT NOTCH,
VISIBLE CRACKS ARE NOT PERMITTED AFTER BEING ASSEMBLED

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 9
STEP 3a –Insert Face Seal into Housing Shroud
STEP 3b –Insert Face Seal into Housing Shroud
ASSEMBLY
FACE SEAL INSERTED
IMPORTANT! VERIFY THAT FACE SEAL IS EVENLY
ASSEMBLED AND NOT BUNCHED OR ROLLED DURING
THE INSERTION
INSERT FACE SEAL ONTO ASSEMBLY FIXTURE MAKE SURE THE SEAL MUST IS NOT BUNCHED
OR ROLLED
PRESS THE SEAL INTO THE HOUSING SHROUD
SEAL IS ORIENTED WITH THE SEAL RETENTION BUMPS
AS SHOWN

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 10
STEP 4a –Press Shunt into the Inner Connector
STEP 4b –Press Shunt into the Inner Connector
ASSEMBLY
LOCATE THE SLOT TO INSERT THE SHUNT AND PRESS IT INTO THE INNER CONNECTOR
PUSH INNER CONNECTOR INTO THE HOUSING SHROUD
SHUNT INSERTED