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File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 3/25
EXPLODED VIEW
CONNECTOR 38-WAY
DELPHI PART-NO. 15498535FORD PART-NO. 6G9T-14A464-VZA
MCP 4,8 Female Terminal
MCP 1,5 or CTS 1,5
Female Terminal
COVER
DELPHI PART-NO. 15498543FORD PART-NO. 6G9T-14N003-VZA
MCP 2,8 Female Terminal
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 4/25
LIST OF COMPONENTS
Attention:
All plastic components must be stored minimum 24 hours, in the temperature of min +18C,
before further assembly steps are taken. This is necessary to avoid breakage of hinge or snap
elements.
Component:
Delphi
PART-NO. amount
Cover 15498543 6G9T-14N003-VZA 1
Connector 38-way 15498535 6G9T-14A464-VZA 1
assembled
MCP 1,5 or CTS 1.5 Female Terminal - max. 34
MCP 2,8 Female Terminal - max. 2
MCP 4,8 Female Terminal - max. 2
FORD
PART-NO.
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REV 02 May 05, 2009
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 6/25
A
SSEMB
LY
Step 1 completed.
Step 1: Insert MCP 1,5 Female Terminals into the Receptacle Housing 38-way
according to the harness drawing and the specified code.
ASSEMBLY
INSERTING MCP 1,5
CONNECTOR 38-WAY
1237
214
24
26
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 7/25
Step 2 completed.
Step 2: Insert MCP 2,8 Female Terminals into the Receptacle Housing 38-way
according to the harness drawing and the specified code.
A
SSEMB
LY
INSERTING MCP 2,8
CONNECTOR 38-WAY
38
25
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 9/25
Step 4 completed.
Step 4: Push the Secondary Lock to the end position using tool PN 10806565 .
Attention! There is no possibility to connect together Male and Female
Connectors without correctly locked Secondary Lock.
A
SSEMB
LY
ACTIVATE SECONDARY LOCK
CONNECTOR 38-WAY
Secondary Lock
(opposite to Lever) Lever
Slots released by final-
positined Secondary
Lock
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 10/25
Step 5 completed.
Step 5: Orient and comb wires in appropriate direction. Hitch one side of the Cover
on the Receptacle Housing 38-way.
A
SSEMB
LY
ASSEMBLE COVER
Hitched point
CONNECTOR 38-WAY
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 11/25
Step 6 completed.
Step 6: Lock the other side of the Cover by rotating it about the hitched point
until four locking arms are correctly closed.
A
SSEMB
LY
LOCKING COVER
Locks on both sides
of the Receptacle Housing 38-way
are correctly closed
CONNECTOR 38-WAY
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 13/25
A
SSEMB
LY
Step 6 Perform electrical test according to Ring Out Board specifications.
ELECTRICAL TEST ON RING OUT BOARD
CONNECTOR 38-WAY
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REV 02 May 05, 2009
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 14/25
A
SSEMB
LY
Holder specifications.
ELECTRICAL TEST ON RING OUT BOARD
CONNECTOR 38-WAY
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 15/25
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 16/25
REMOVING STRAP
D
ISA
SSEMB
LY
Step D-1 completed.
Step D-1: Remove Strap.
DISASSEMBLY CONNECTOR 38-WAY
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REV 02 May 05, 2009
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 17/25
ROTATING LEVER
D
ISA
SSEMB
LY
Step D-2 completed.
Step D-2: Move the Leverto the middle position - about 90 degrees from horizontal
position.
CONNECTOR 38-WAY
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 19/25
REMOVING COVER
D
ISA
SSEMB
LY
Step D-4 completed.
Step D-4: Remove Covercompletely.
CONNECTOR 38-WAY
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REV 02 May 05, 2009
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 20/25
UNLOCK. SECONDARY LOCK
D
ISA
SSEMB
LY
Step D-5 completed.
Step D-5: Push the Secondary Lock to the pre-assembled position using tool PN
10806565 .
CONNECTOR 38-WAY
Secondary Lock
(Lever on the same side)
Lever
Slots blocked by
opened Secondary
Lock
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File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 21/25
REMOVING MCP 4,8
D
ISA
SSEMB
LY
Step D-6 completed.
Step D-6: Locate Terminaltangs at the front of the cavity. Insert (operation 1) the tool
NO. 10714843 straight into the channel of cavity, deflect tangs to unseat
the Terminaland gently pull on the cable to remove (operation 2) MCP 4,8
Female Terminalfrom the Receptacle Housing 38-way.
CONNECTOR 38-WAY
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 22/25
REMOVING MCP 2,8
D
ISA
SSEMB
LY
Step D-7 completed.
Step D-7: Locate Terminaltangs at the front of the cavity. Insert (operation 1) the tool
NO. 10714843 straight into the channel of cavity, deflect tangs to unseat
the Terminaland gently pull on the cable to remove (operation 2) MCP 2,8
Female Terminalfrom the Receptacle Housing 38-way.
CONNECTOR 38-WAY
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REV 02 May 05, 2009
File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 23/25
REMOVING MCP 1,5
D
ISA
SSEMB
LY
Step D-8 completed.
Step D-8: Locate Terminaltangs at the front of the cavity. Insert (operation 1) the tool
NO. 10803860 straight into the channel of cavity, deflect tangs to unseat
the Terminaland gently pull on the cable to remove (operation 2) MCP 1,5
Female Terminalfrom the Receptacle Housing 38-way.
CONNECTOR 38-WAY
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File-Name: adi15498537_2_REV02.pdf
EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
Contact at CTC Wuppertal: Heiko Pantke - 0049 202 291 2317
Andreas Sikora - 0049 202 291 3081 24/25
TOOLS
These tools is available at
Sales & Service
Sylvia Kirberg
phone: +49 202 291 4458
fax: +49 202 291 4567
Item Function Tool PN.
1 Disassembly tool for MCP 1,5 Female Terminals 10803860
2 Disassembly tool for MCP 2,8andMCP 4,8 Female Terminals 10714843
3 Disassembly tool for Secondary Lock 10806565
2
3
1
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EUCD Assembly Manuals
Connector 38-way - assembly at harness plant
REVISIONS
REV 01
Change description Date
May 05, 2009
Revision
Initial Edition