Savana 3500 V8-4.8L (2009)
Terminal Replacement Procedure
After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector.
2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock.
2. Disconnect the connector from the component or separate the connectors for in-line connectors.
3. Remove the terminal position assurance (TPA) device.
4. Insert the proper pick or removal tool into the front of the connector body.
Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the
terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old
terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Crimp a new terminal to the wire.
