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Terminal Replacement Instructions (95-007)

Publication date: 2000-12-18
Reference number: 95-007
Supersedes refnos: 00-039

TERMINAL REPLACEMENT INSTRUCTIONS

TERMINAL REPLACEMENT INSTRUCTIONS

TECHNICAL SERVICE BULLETIN

Reference Number(s): 00-039, Date of Issue:  December 18, 2000
ACURA: All
CATEGORY: Tools
APPLIES TO: All
Superceded Bulletin(s): 95-007, Date of Issue:  May 2, 1995
NOTE: Replaces 95-007, dated May 2, 1995

DESCRIPTION

These terminal replacement instructions apply to these kits and tools:

This bulletin covers these topics:

WARRANTY CLAIM INFORMATION

None; this bulletin is for information only.

PARTS INFORMATION

Terminal Inspection Feeler Tool Set: T/N 07XAJ-001000A

Terminal Pin Kit A: T/N 07JAZ-003000B, which contains Pin Tool Set T/N 07JAZ-002000A, Crimper T/N 07JAZ-001020A, and various terminals.

Terminal Pin Kit B: T/N 07QAZ-003020B, which contains Crimper Tool Set T/N 07NGZ-001010A (used on splice connectors only), Heat Gun T/N 07NGZ001020A, various terminals, and splice connectors.

The following kit has been shipped to dealerships. This kit is to be added to Terminal Pin Kit B, T/N 07QAZ003020B:

  1. Terminal Pin Update Kit, T/N 07XAZ-002000A which includes 25 each of the following terminals:
  2. P/N 07JAZ-001320A
  3. P/N 07JAZ-001330A
  4. P/N 07JAZ-001340A
  5. P/N 07JAZ-001350A
  6. P/N 07JAZ-001360A
  7. P/N 07JAZ-001370A
  8. P/N 07JAZ-001380A
  9. P/N 07JAZ-001400A
  10. P/N 07JAZ-001410A
  11. 1 pc inner and outer label for Terminal Pin Kit B: T/N C7QAZ-003020

Replacement terminals, wire seals, and splice connectors are listed on the inside lid of each terminal pin kit.

Additional information on replacement connectors, terminals, and pigtails is listed in the Acura Electrical Connector Catalog (P/N 13CNNB-3). See Fig 1 .

Fig 1: Acura Electrical Connector Catalog
G94C58034

HOW TO REPLACE CONNECTOR TERMINALS

The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability.

IMPORTANT: On some models, the SRS wires are in a separate harness If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 

Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS  .

REMOVING THE TERMINAL

Use the tools from Pin Tool Set T/N 07JAZ-002000A.

First, check the connector that you are about to repair.

  • If it has a secondary terminal lock, go to CONNECTORS WITH A SECONDARY LOCK  . A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal.
  • If the connector does not have a secondary lock, go to CONNECTORS WITHOUT A SECONDARY LOCK  .

CONNECTORS WITH A SECONDARY LOCK

All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number or terminal cavities.

  1. EXAMPLE A: 
    1. Release the secondary lock. See Fig 2 .
      Fig 2: Connector W/ Secondary Lock - Releasing Secondary Lock
      G94D58035
    2. Remove the terminal. See Fig 3 .
      Fig 3: Connector W/ Secondary Lock (Example A) - Removing Terminal
      G94E58036
    3. Go to HOW TO INSTALL NEW TERMINALS  .
  2. EXAMPLE B: 
    1. Remove the secondary lock from the male terminal half. See Fig 4 .
      Fig 4: Connector W/ Secondary Lock (Example B) - Male Terminal Half
      G94F58037
    2. Remove the secondary lock from the female terminal half. SeeFig 5 .
      Fig 5: Connector W/ Secondary Lock (Example B) - Female Terminal Half
      G94G58038
    3. Remove the terminal (same procedure for male and female). SeeFig 6 .
      Fig 6: Connector W/ Secondary Lock (Example B) - Removing Terminal
      G94H58039
    4. Go to HOW TO INSTALL NEW TERMINALS  .
  3. EXAMPLE C: 
    1. Remove the secondary lock. See (Fig 7 ).
      Fig 7: Connector W/ Secondary Lock (Example C) - Removing Secondary
      G94A58040
    2. Remove the terminal from the female half. See Fig 8 .
      Fig 8: Connector W/ Secondary Lock (Example C) - Female Terminal Half
      G94B58041
    3. Remove the terminal from the male half. See Fig 9 .
      Fig 9: Connector W/ Secondary Lock (Example C) - Male Terminal Half
      G94C58042
    4. Go to HOW TO INSTALL NEW TERMINALS  .
  4. EXAMPLE D: 
    1. Remove the secondary locks. See Fig 10 .
      Fig 10: Connector W/ Secondary Lock (Example D) - Releasing Secondary
      G94D58043
    2. Remove the terminal (same procedure for male and female). See Fig 11 .
      Fig 11: Connector W/ Secondary Lock (Example D) - Removing Terminal
      G94E58044
    3. Go to HOW TO INSTALL NEW TERMINALS  .
  5. EXAMPLE E: 
    1. Remove the secondary locks. See Fig 12 .
      Fig 12: Connector W/ Secondary Lock (Example E) - Releasing Secondary
      G94F58045
    2. Remove the terminal (same procedure for male and female). See Fig 13 .
      Fig 13: Connector W/ Secondary Lock (Example E) - Removing Terminal
      G94G58046
    3. Go to HOW TO INSTALL NEW TERMINALS  .
  6. EXAMPLE F: 
    1. Remove the secondary locks. See Fig 14 .
      Fig 14: Connector W/ Secondary Lock (Example F) - Releasing Secondary
      G94H58047
    2. Remove the terminal from the female half. See Fig 15 .
      Fig 15: Connector W/ Secondary Lock (Example F) - Female Terminal
      G94I58048
    3. Remove the terminal from the male half. See Fig 16 .
      Fig 16: Connector W/ Secondary Lock (Example F) - Male Terminal
      G94J58049
    4. Go to HOW TO INSTALL NEW TERMINALS  .

CONNECTORS WITHOUT A SECONDARY LOCK

All examples are shown with the connector lock facing Up. The illustrations are examples Of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape.

  1. EXAMPLE A: 
    1. Remove the terminal. See Fig 17 .
      Fig 17: Connector W/O Secondary Lock (Example A) - Removing Terminal
      G94D58050
    2. Go to HOW TO INSTALL NEW TERMINALS  .
  2. EXAMPLE B: 
    1. Remove the terminal. See Fig 18 .
      Fig 18: Connector W/O Secondary Lock (Example B) - Removing Terminal
      G94E58051
    2. Go to HOW TO INSTALL NEW TERMINALS  .
  3. EXAMPLE C: 
    1. Remove the terminal. See Fig 19 .
      Fig 19: Connector W/ O Secondary Lock (Example C) - Removing Terminal
      G94F58052
    2. Go to HOW TO INSTALL NEW TERMINALS  .
  4. EXAMPLE D: 
    1. Remove the terminal. See Fig 20 .
      Fig 20: PIN Tool D 07JAZ-002040A
      G94G58053
    2. Go to HOW TO INSTALL NEW TERMINALS  .
  5. EXAMPLE E: 
    1. Remove the terminal. See Fig 21 .
      Fig 21: Connector W/O Secondary Lock (Example E) - Removing Terminal
      G94H58054
    2. Go to HOW TO INSTALL NEW TERMINALS  .
  6. EXAMPLE F: 
    1. Remove the terminal. See Fig 22 .
      Fig 22: Connector W/O Secondary Lock (Example F) - Removing Terminal
      G94I58055
    2. Go to HOW TO INSTALL NEW TERMINALS  .
  7. EXAMPLE G: 
    1. Remove the terminal. See Fig 23 .
      Fig 23: Connector W/O Secondary Lock (Example G) - Removing Terminal
      G94J58056
    2. Go to HOW TO INSTALL NEW TERMINALS  .

HOW TO INSTALL NEW TERMINALS

  1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate.
    NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures.
  2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. See Fig 24 .
    Fig 24: Crimping Tool - 07JAZ-001020A
    G94A58057
  3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. If the wire has a wire seal, replace it with a new one from the kit. See Fig 25 .
    NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again.
    Fig 25: Wire With A Seal / Wire Without A Seal
    G94B58058
  4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. See Fig 26 .
    Fig 26: Position Of The Terminal Before Crimping
    G94C58059
  5. Insert the wire in the terminal to the position shown in Fig 25 .
  6. Squeeze the tool with both hands until the stops make contact. See Fig 27 .
    Fig 27: Squeezing Crimping tool Till It Stops Making Contact
    G94F58060
  7. Crimp the insulation crimp.
    • If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact.
    • If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. See Fig 28 .
    Fig 28: Crimping With / Without A Wire Seal
    G94G58061
  8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. See Fig 29 & Fig 30 .
    Fig 29: Inspection Of Wire Crimp (Examples)
    G94H58062
    Fig 30: Good / No Good Crimped Edges (Examples)
    G94I58063
  9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place.
  10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector.

HOW TO INSTALL PIGTAIL TERMINALS

Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. Refer to the PIGTAIL TERMINAL SELECTION CHART  .

NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals.
NOTE: IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 
  1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set T/N 07JAZ-002000A.
  2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. See Fig 31 .
    NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires.
    Fig 31: Cutting And Stripping Wire
    G94J58064
  3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire).
  4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire.
  5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. See Fig 32 .
    Fig 32: Inserting Pigtail Terminal Into Connector Cavity
    G94A58065
  6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with re-wrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail.
  7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. See Fig 33 .
    NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper.
    Fig 33: Wire Stripped Off A Yellow, Pink Or Blue Connector
    G94B58066
  8. Put the splice connector in the proper size slot in the Crimper Tool, T/N 07NGZ-00101-0A, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open.
    Fig 34: Crimping Tool Identification
    G94C58067
  9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. See Fig 35 .
    Fig 35: Inserting Bare Wires Into Connector End Of Crimper Jaw
    G94D58068
  10. Crimp the other wire in the same way into the other end of the splice connector.
  11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector.
  12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. See Fig 36 .
    Fig 36: Shielding Repaired Wire With Non-Flammable Material
    G94E58069
  13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube.
    NOTE: Be careful when working with the high heat produced by the heat gun.
    Fig 37: Heat Shrinking Splice Connector
    G94H58070

PIGTAIL TERMINAL SELECTION CHART

Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures.

PIGTAIL TERMINAL SELECTION CHART

Replace -ment Terminal P/N Wire SizeBeing Repaired Pigtail Terminal P/N Splice Connector Color Wire Seal Style
07JAZ-001040A 20 AWG 04320-SP0-A00 Yellow ---
07JAZ-001040A 16 AWG 04320-SP0-B00 Pink ---
07JAZ-001090A 20 AWG 04320-SP0-C00 Yellow A
07JAZ-001090A 16 AWG 04320-SP0-D00 Pink A
07JAZ-001090A 20 AWG 04320-SP0-E00 Yellow B
07JAZ-001090A 16 AWG 04320-SP0-F00 Pink B
07JAZ-001030A 20 AWG 04320-SP0-G00 Yellow ---
07JAZ-001080A 20 AWG 04320-SP0-J00 Yellow ---
07JAZ-001080A 16 AWG 04320-SP0-M00 Pink ---
07JAZ-001260A 20 AWG 04320-SP0-A10 Yellow ---
07JAZ-001260A 16 AWG 04320-SP0-N00 Pink ---
07JAZ-001220A 16 AWG 04320-SP0-P00 Pink ---
07JAZ-001280A 16 AWG 04320-SP0-P00 Pink ---
07JAZ-001230A 20 AWG 04320-SP0-S00 Yellow ---
07JAZ-001230A 16 AWG 04320-SP0-T00 Pink ---
07JAZ-001230A 14 AWG 04320-SP0-U00 Blue ---
07JAZ-001240A 20 AWG 04320-SP0-V00 Yellow ---
07JAZ-001240A 16 AWG 04320-SP0-W00 Pink ---
07JAZ-001290A 20 AWG 04320-SP0-Y10 Yellow ---
(1) 20 AWG 04320-SP0-B10 Yellow ---
(1) 20 AWG 04320-SP0-F10 Yellow ---
(1) 20 AWG 04320-SP0-K10 Yellow ---
(1) 20 AWG 04320-SP0-N10 Yellow ---
(1) 20 AWG 04320-SP0-R10 Yellow ---
(1) Replacement terminals are not available. Instead refer to the Acura Electrical Connector Catalog for proper pigtail terminal applications.
Fig 38: Styles A & B Wire Seal
G94I58071

CHECKING FOR POOR FIT OF TERMINALS

Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set T/N 07XAJ-001000A, you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. See Fig 39 .

  1. Find the terminal tool that best matches the male terminal in the mating connector.
  2. Insert the terminal tool into the female terminal, and then remove the terminal tool.
    NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit.
    Fig 39: Terminal Inspection Feeler Tool
    G00183891
  3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit.
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