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Harley Davidson 2004 Touring Models. Service Manual - page 22

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FLTR WIRE HARNESS CONNECTORS (Continued)

No.

Description

Type

Location

Fig.

[75]

Cruise Roll-Off Switch

Spade Contacts

Right Side of Steering Head

[77]

Voltage Regulator

1 - Place Deutsch

Right Lower Frame Tube (Below Transmission Bracket)

[78]

Electronic Control Module (ECM) ***

36 - Place Packard

Under Right Side Cover

[79]

Crankshaft Position (CKP) Sensor

2 - Place Mini-Deutsch

Bottom of Voltage Regulator

[80]

Manifold Absolute Pressure (MAP) Sensor

3 - Place Packard

Top of Intake Manifold/Induction Module

[83]

Ignition Coil

4 - Place Packard

Below Fuel Tank (Left Side)

[84]

Front Injector ***

2 - Place Packard

Below Fuel Tank (Left Side)

[85]

Rear Injector ***

2 - Place Packard

Below Fuel Tank (Left Side)

[87]

Idle Air Control (IAC) ***

4 - Place Packard

Below Fuel Tank (Right Side)

[88]

Throttle Position Sensor (TP Sensor) ***

3 - Place Packard

Below Fuel Tank (Right Side)

[89]

Intake Air Temperature Sensor (IAT Sensor) ***

2 - Place Packard

Below Fuel Tank (Right Side)

[90]

Engine Temperature Sensor (ET Sensor) ***

2 - Place Packard

Back of Front Cylinder (Left Side)

Continued ...

Right Handlebar

Left Handlebar

Radio Antenna

Switch Controls [22]

Switch Controls [24]

Cable [51]

Radio [27]

Radio

Ground

Main to Interconnect

Harness [1]

Main to Interconnect

Harness [156]

Right Turn

Signal [31R]

Ignition

Left Turn

Signal [31L]

Switch [33]

Headlamp [38]

Main to Interconnect

Harness [15]

Main to Interconnect

Harness [2]

f2230x2x

Figure 8-16. Inner Fairing Connectors (FLTR)

8-10

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FLTR WIRE HARNESS CONNECTORS (Continued)

No.

Description

Type

Location

Fig.

[91]

Data Link

4 - Place Deutsch

Under Right Side Cover

[93]

Tail Lamp

4 - Place Multilock

Circuit Board Under Tail Lamp Assembly

[94]

Rear Fender Lights Harness to Circuit Board

6 - Place Multilock

Circuit Board Under Tail Lamp Assembly

Instrument Nacelle Switches

[105]

[105A, 105B]

Interconnect to Nacelle Switch Harness

12 - Place Multilock

Inside Instrument Nacelle (Under Bezel)

[105C, 105D]

Nacelle Switch Harness to Speaker Switch

4 - Place Multilock

Inside Instrument Nacelle (Under Bezel)

[107]

Ambient Air Temperature Sensor

3 - Place Multilock

Inside Instrument Nacelle (Under Bezel)

[108]

Tachometer

12 - Place Packard

Inside Instrument Nacelle (Back of Tachometer)

[110]

Voltmeter Lamp

Spade Connector

Inner Fairing

[111]

Voltmeter

Spade Connector

Inner Fairing

[112]

Oil Pressure Gauge Lamp

Spade Connector

Inner Fairing

[113]

Oil Pressure Gauge

Spade Connector

Inner Fairing

[114]

Air Temperature Gauge Lamp

Spade Connector

Inner Fairing

[115]

Air Temperature Gauge

Spade Connector

Inner Fairing

[116]

Fuel Gauge Lamp

Spade Connector

Inner Fairing

[117]

Fuel Gauge

Spade Connector

Inner Fairing

[119]

EFI Fuses ***

Fuse Terminals

Fuse Block (Under Right Side Cover)

[121]

Rear Brake Light Switch

Spade Terminals

Beneath Transmission (Right Side)

[122]

Horn

Spade Terminals

Between Cylinders (Left Side)

[123]

Starter Relay

Relay Connector

Rear of Battery Box (Under Seat) - Left Side

[124]

Brake Light Relay

Relay Connector

Fuse Block (Under Left Side Cover)

[126]

Ignition Keyswitch Relay

Relay Connector

Rear of Battery Box (Under Seat) - Left Side

[128]

Starter Solenoid

Spade Terminals

Top of Starter

[129]

Harness Grounds

Ring Terminals

Upper Frame Cross Member (Under Seat)

[131]

Neutral Switch

Post Terminals

Transmission Top Cover

[132]

Cigarette Lighter

Spade Terminals

Inner Fairing

[135]

EFI System Relay ***

Relay Connector

Fuse Block (Under Right Side Cover)

[139]

Oil Pressure Sender

4 - Place Packard

Front Right Crankcase

[141]

Fuel Level Sender (and Fuel Pump on EFI models)

3 - Place Mini-Deutsch

Top of Canopy (Under Console)

[142]

Security Siren (Optional)

3 - Place Packard

Under Right Side Cover (Behind Electrical Bracket)

[156]

Main to Interconnect Harness

6 - Place Deutsch

Inner Fairing - Front of Right Fairing Bracket

[160]

B+

1 - Place Packard

Upper Frame Cross Member (Under Seat)

*** Fuel Injected Models

**** Carbureted Models

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NOTES

8-12

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DEUTSCH ELECTRICAL CONNECTORS

8.2

GENERAL

f1049a8x

Attachment clips are attached to the pin housings of some

connectors. The clips are then attached to T-studs on the

motorcycle frame. T-studs give positive location to electrical

connectors and wire harnesses. Consistent location reduces

electrical problems and improves serviceability.

To become familiar with the Deutsch connector, read the

parts description below while referencing the 12-place con-

nector illustrated in Figure 8-19.

Socket housing: alignment tabs and/or external latch, sec-

ondary locking wedge, internal seal, wire seal, seal pin.

NOTE

Figure 8-18. Depress Terminal Latches/Back Out Pins

Seal pins or plugs are installed in the wire seals of unused

chambers. If removed, seal pins must be replaced to main-

NOTE

tain the integrity of the environmental seal.

With few exceptions, the socket housing can always be found

Pin housing: alignment grooves and/or external latch cover,

on the accessory side, while the pin side of the connector is

secondary locking wedge, wire seal, seal pin.

plumbed to the wiring harness.

REMOVING/DISASSEMBLING

REMOVING/INSTALLING SOCKETS

Push the connector to disengage small end of slot on

attachment clip fromT-stud. Lift connector off T-stud.

1. See Figure 8-17. Remove the secondary locking wedge.

Depress the external latch(es) on the socket housing

Insert the blade of a small screwdriver between the

side and use a rocking motion to separate the pin and

socket housing and locking wedge inline with the groove

socket halves. Two-, three-, four- and six-place Deutsch

(inline with the pin holes if the groove is absent). Turn the

connectors have one external latch, while eight- and

screwdriver 90 degrees to pop the wedge up.

twelve-place connectors have two, both of which must

be pressed simultaneously to separate the connector

2. Gently depress terminal latches inside socket housing

halves.

and back out sockets through holes in rear wire seal.

See Figure 8-18.

NOTE

4566

If new terminals must be installed, see CRIMPING

INSTRUCTIONS in this section.

3. Fit rear wire seal into back of socket housing, if removed.

Grasp socket approximately 1 inch (25.4 mm) behind the

contact barrel. Gently push sockets through holes in wire

seal into their respective chambers. Feed socket into

chamber until it “clicks” in place. Verify that socket will

not back out of chamber; a slight tug on the wire will con-

firm that it is properly locked in place.

4. Install internal seal on lip of socket housing, if removed.

Insert tapered end of secondary locking wedge into

socket housing and press down until it snaps in place.

The wedge fits into the center groove within the socket

housing and holds the terminal latches tightly closed.

Figure 8-17. Remove Secondary Locking Wedge

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f1915x8x

Wire Seal

Housing

Terminal

Locking Wedge

(Pin Side)

Locking Wedge

(Socket Side)

Internal

Seal

Latch Cover

Socket

Housing

Alignment

Grooves

Wire

Seal

Alignment

Tabs

Seal

NOTE

For exploded views of 2-place,

3-place and

4-place Deutsch

connectors, see Figure 8-21.

External

Latch

Socket

Terminal

Figure 8-19. 12-Place Deutsch Connector (Exploded View)

NOTE

While rectangular wedges do not require a special orienta-

tion, the conical secondary locking wedge of the 3-place con-

nector must be installed with the arrow pointing toward the

Housing

external latch. See Figure 8-20.

NOTE

If the secondary locking wedge does not slide into the

Arrow Points to

installed position easily, verify that all terminals are fully

External Latch

installed in the socket housing. The lock indicates when ter-

minals are not properly installed by not entering its fully

installed position.

Socket

Housing

REMOVING/INSTALLING PINS

1. Remove the secondary locking wedge. Use the hooked

f1515x8x

end of a stiff piece of mechanics wire, a needle nose pli-

ers or a suitable pick tool (HD-41475-100). See Figure

Figure 8-20. 3-Place Locking Wedge Orientation

8-22.

8-14

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f1510x8x

2-Place Connector

3-Place Connector

4-Place Connector

Socket Side

Pin Side

12. Socket Terminal

18. Locking Wedge

13. Wire Seal

19. Latch Cover

14. Socket Housing

20. Pin Housing

15. External Latch

21. Wire Seal

16. Internal Seal

22. Pin Terminal

17. Locking Wedge

Figure 8-21. 2-Place, 3-Place and 4-Place Deutsch Connectors

2004 Touring: Wiring

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click (latch), press on one side of the connector until that

latch engages, then press on the opposite side to

engage the other latch.

NOTES

●

Deutsch connectors are colored coded for location pur-

poses. Those connectors associated with left side

accessories, such as the front and rear left turn signals,

Figure 8-22. Deutsch Connector Pick Tool

are gray. All other connectors, including those associ-

(Part No. HD-41475-100)

ated with right side accessories, are black.

●

If it should become necessary to replace a plug or

Gently depress terminal latches inside pin housing and

receptacle, please note that the 8-place and 12-place

back out pins through holes in wire seal.

gray and black connectors are not interchangeable.

Since location of the alignment tabs differ between the

NOTE

black and gray connectors, plugs or receptacles must be

If new terminals must be installed, see CRIMPING

replaced by those of the same color. If replacing both the

INSTRUCTIONS on this page.

socket and pin halves, then the black may be substituted

for the gray, and vice versa. The socket and pin halves of

Fit wire seal into back of pin housing. Grasp crimped pin

all other connectors are interchangeable, that is, the

approximately 1 inch (25.4 mm) behind the contact bar-

black may be mated with the gray, since the alignment

rel. Gently push pins through holes in wire seal into their

tabs are absent and the orientation of the external latch

respective numbered locations. Feed pin into chamber

is the same.

until it “clicks” in place. Verify that pin will not back out of

chamber; a slight tug on the wire will confirm that it is

Fit the attachment clip to the pin housing, if removed.

properly locked in place.

Place large end of slot on attachment clip over T-stud on

Insert tapered end of secondary locking wedge into pin

frame. Push assembly forward to engage small end of

housing and press down until it snaps in place. The

slot.

wedge fits in the center groove within the pin housing

and holds the terminal latches tightly closed.

NOTE

CRIMPING INSTRUCTIONS

While rectangular wedges do not require a special orienta-

tion, the conical secondary locking wedge of the 3-place con-

Use the Deutsch Terminal Crimp Tool (HD-39965) to install

nector must be installed with the arrow pointing toward the

standard size terminals with crimp tails, as described under

external latch. See Figure 8-20.

STANDARD TERMINALS below. To install the mini-Deutsch

NOTE

terminals with crimp tails, see MINI TERMINALS, which fol-

lows. To install those terminals without crimp tails, both stan-

If the secondary locking wedge does not slide into the

dard and mini-Deutsch, use the Deutsch Solid Barrel Contact

installed position easily, verify that all terminals are fully

Crimp Tool (HD-42879) as described under SOLID BARREL

installed in the pin housing. The lock indicates when termi-

CONTACTS.

nals are not properly installed by not entering its fully

installed position.

NOTE

A Deutsch Connector Service Kit (HD-41475) contains a

selection of wire seals, internal seals, seal plugs, secondary

ASSEMBLING/INSTALLING

locking wedges, attachment clips and socket/pin terminals.

Also included is a compartmented storage box, carrying case

1. Insert socket housing into pin housing until it snaps in

and pick tool (HD-41475-100) used for the removal of all

place. Two-, three-, four- and six-place Deutsch connec-

types of locking wedges.

tors have one external latch on the socket half of the

connector. To fit the halves of the connector together, the

latch on the socket side must be aligned with the latch

Standard Terminals

cover on the pin side.

For those connectors with two external latches (8-place

1. Obtain the DEUTSCH TERMINAL CRIMP TOOL (HD-

and 12-place), a different system is used to prevent

39965).

improper assembly. Align the tabs on the socket housing

2. Squeeze the handles to cycle the crimp tool to the fully

with the grooves on the pin housing. Push the connector

open position. See Figure 8-23.

halves together until the latches “click.” If latches do not

8-16

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f1516x8x

Gauge

Nest of

Wire

Crimp Tool

Front

16-18

Middle

Locking

Bar

1. Insert contact through hole of locking bar

2. Insert stripped lead until it contacts

so that barrel rests on nest of crimp tool.

locking bar.

3. Close and squeeze crimp tool.

4. Raise locking bar and remove contact.

Insulation crimp

Core crimp

5. Inspect quality of core and insulation crimps.

f1558x8x

Figure 8-23. Deutsch Crimping Procedure

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Raise the locking bar by pushing up on bottom flange.

Solid Barrel Contacts

With the crimp tails facing upward, insert contact

(socket/pin) through hole of locking bar, so that the

For Size 20, 16 and 12 Contacts

rounded side of the contact barrel rests on the nest (con-

Wire Range 26-12 AWG

cave split level area) of the crimp tool. Use the middle

hole in the locking bar for 16-18 gauge wire, the front

Obtain the DEUTSCH SOLID BARREL CONTACT

hole for 20 gauge wire.

CRIMP TOOL (HD-42879).

Release locking bar to lock position of contact. If the

Squeeze the handles to cycle the crimp tool to the fully

crimp tails are slightly out of vertical alignment, the crimp

open position.

tool automatically rotates the contact so that the tails

face straight upward. When correctly positioned, the

Remove locking pin from selector knob. See Figure 8-

locking bar fits snugly in the space between the contact

24.

band and the core crimp tails.

Raise selector knob and rotate until selected wire size

Strip lead removing 5/32 inch (4.0 mm) of insulation.

stamped on wheel is aligned with “SEL. NO.” arrow. See

Insert wires between crimp tails until ends make contact

upper frame of Figure 8-25.

with locking bar. Verify that wire is positioned so that

Loosen knurled locknut and turn adjusting screw clock-

short pair of crimp tails squeeze bare wire strands, while

wise (in) until it stops.

long pair folds over insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

Turn tool over and drop contact into indentor cover hole

automatically opens when the crimping sequence is

with the wire end out.

complete. Raise up locking bar and remove contact.

Turn adjusting screw counterclockwise (out) until contact

Inspect the quality of the core and insulation crimps. Dis-

is flush with bottom of depression in indentor cover.

tortion should be minimal.

Tighten knurled locknut.

Slowly squeeze handles of crimp tool until contact is

centered between indentor points. See middle frame of

Figure 8-25.

Mini Terminals

Strip wire lead removing 1/4 inch (6.4 mm) of insulation.

Obtain the PACKARD TERMINAL CRIMP TOOL (HD-

10.

Insert bare wire strands into contact barrel. See lower

38125-7).

frame of Figure 8-25.

Strip wire lead removing 5/32 inch (4.0 mm) of insula-

tion.

11.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

Compress handles until ratchet automatically opens.

complete.

NOTE

12.

Remove crimped contact from indentor.

Always perform core crimp before insulation crimp.

13.

Inspect the quality of the crimp. Verify that all wire

Position the core crimp on nest E of the crimping tool. Be

strands are in crimp barrel.

sure the core crimp tails are facing the forming jaws.

Gently apply pressure to handles of tool until crimpers

just secure the core crimp tails.

Insert stripped wire between crimp tails. Verify that wire

Adjusting

is positioned so that short pair of crimp tails squeeze

Locking

Screw

bare wire strands, while long pair is positioned over the

insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete.

Position the insulation crimp on nest C of the crimping

tool. Be sure the insulation crimp tails are facing the

forming jaws.

Selector

Squeeze handle of crimp tool until tightly closed. Tool

Locknut

Knob

f1535x8x

automatically opens when the crimping sequence is

complete.

Figure 8-24. Deutsch Solid Barrel Contact Crimp Tool

10.

Inspect the quality of the core and insulation crimps. Dis-

(Part No. HD-42879)

tortion should be minimal.

8-18

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NOTE

Rotate selector knob to align wire size on wheel

with arrow stamped in tool.

Tool must be readjusted when changing contact size/type.

14. Install pin to lock position of selector knob.

Selector

Knob

f1534x8x

Turn adjusting screw as described in text. When

contact is flush with bottom of depression in

indentor cover, squeeze handles to center contact

between indentor points.

Indentor

Cover

Contact

Indentor

Points

f1532x8x

Insert bare wire strands into contact barrel.

Squeeze handle of crimp tool until tightly closed.

f1533x8x

Figure 8-25. Deutsch Solid Barrel Contact

Crimping Procedure

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8-19

HOME

1-PLACE CABLE CONNECTOR

General

Use the following instructions to service the voltage regulator

cable connector.

Removal

1. Depress external latch and separate pin and socket

halves of connector.

7786

2. Pull rear wire seal from back of housing and slide down

voltage regulator cable to move out of the way.

3. Obtain terminal pick tool (Deutsch® 114008) like that

shown in A of Figure 8-26.

CAUTION

Rough handling or careless storage can result in tool

damage. Exercise care to avoid cracking or breaking the

thin plastic construction.

Install terminal pick tool onto voltage regulator cable so

that the tapered end is in the wire end of the housing.

See B of Figure 8-26.

7787

Push tool into wire end of housing until it bottoms. Gen-

tly tug on housing to pull from terminal. See C of Figure

8-26.

Remove tool from voltage regulator cable.

Installation

Insert terminal into wire end of housing until it “clicks” in

place. Verify that terminal will not back out of housing. A

slight tug on the voltage regulator cable will confirm that

it is properly locked in place.

Fit rear wire seal into back of housing.

Mate pin and socket halves of connector.

7788

Figure 8-26. Remove Socket/Pin Housing

8-20

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AMP MULTILOCK ELECTRICAL CONNECTORS

8.3

is engaged but then inadvertently released. Repeat the

REMOVING SOCKET/PIN

step without releasing the tang.

TERMINALS

NOTE

1. Remove connector from the retaining device, either

An Electrical Terminal Crimp Tool (Part No. HD-41609) is

attachment or rosebud clip.

used to install Amp Multilock pin and socket terminals on

wires. If new terminals must be installed, see CRIMPING

2. Depress the button on the socket terminal side of the

INSTRUCTIONS in this section.

connector

(plug) and pull apart the pin and socket

halves. See Figure 8-27.

3. Bend back the latch slightly and free one side of second-

INSTALLING SOCKET/PIN

ary lock, then repeat the step to release the other side.

Rotate the secondary lock outward on hinge to access

TERMINALS

terminals in chambers of connector housing.

4. Looking in the terminal side of the connector (opposite

NOTE

the secondary lock), take note of the cavity next to each

For wire location purposes, numbers are stamped into the

terminal.

secondary locks of both the socket and pin housings. See

5. See Figure 8-28. With the flat edge against the terminal,

Figure 8-30.

insert the pick (Snap-On TT600-3) into the cavity until it

stops. Pivot the end of the pick away from the terminal

From the secondary lock side of the connector, insert the

and gently tug on wire to pull terminal from chamber. Do

terminal into its respective numbered chamber until it

not tug on the wire until the tang is released or the termi-

snaps in place. For proper fit, the slot in the terminal

nal will be difficult to remove. A “click” is heard if the tang

must face the tang in the chamber.

Secondary Lock

NOTE

Open

For exploded views of 3-place

and

6-place Amp Multilock

connectors, see Figure 8-31.

Pin Terminal

Button

Secondary Lock

Latch

Open

Latch

Pin Housing

Socket Housing

Socket Terminal

Latch

Secondary Lock

f1292x2x

Open

Figure 8-27. 10-Place Amp Multilock Connector (Exploded View)

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HOME

Secondary Lock

Open

f1289x2x

Socket Terminal

Socket Housing

Pick Tool

Pin Terminal

Secondary Lock

Open

Pick Tool

Pin Housing

1. Open Secondary Lock.

2. Insert Pick into Cavity on Mating End of Connector.

3. Pivot End of Pick to Release Tang.

4. Gently Tug on Wire to Remove Terminal from Housing.

Figure 8-28. Release Tang and Back Out Terminals

NOTE

The tang in the chamber engages the slot to lock the terminal

Pin Housing

Tang

Button

in position. On the pin side of the connector, tangs are posi-

tioned at the bottom of each chamber, so the slot in the pin

terminal (on the side opposite the crimp tails) must face

downward. On the socket side, tangs are at the top of each

chamber, so the socket terminal slot (on the same side as the

crimp tails) must face upward. Up and down can be deter-

mined by the position of the release button (used to separate

the pin and socket halves), the button always being the top of

the connector. See Figure 8-29.

2. Gently tug on wire end to verify that the terminal is

Tang

Socket Housing

f1428x8x

locked in place and will not back out of chamber.

Figure 8-29. Tang Location (Cross Sectional View)

8-22

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f1287x2x

Secondary Locks Open

- AMP

3-Place Connector

6-Place Connector

10-Place Connector

Figure 8-30. Numbers Stamped on Secondary Locks for Wire Color Locations (Socket Housings Shown)

f1291x2x

3-Place Connector

6-Place Connector

Socket Side

23. Socket Terminal

24. Secondary Lock (Open)

25. Latch

26. Socket Housing

27. Button

Pin Side

28. Pin housing

29. Latch

30. Secondary Lock (Open)

31. Pin Terminal

f1288x2x

Figure 8-31. 3-Place and 6-Place Amp Multilock Connectors

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Locking Bar

f1286x2x

Insulation

Core

Groove

Crimp Tail

Insulation

Crimp Tail

Core

Locking Bar

Crimp Tail

Groove

Tang Slot

PIN TERMINAL

Tang Slot

SOCKET TERMINAL

f1290a2x

Locking

Bar

1. Raise locking bar and seat contact on nest

2. Insert stripped lead until it contacts

of crimp tool. Release locking bar.

locking bar.

Gauge

Nest of

Wire

Crimp Tool

Front

Middle

Rear

3. Close and squeeze crimp tool.

4. Raise locking bar and remove contact.

Figure 8-32. Amp Multilock Crimping Procedure

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Rotate the hinged secondary lock inward until tabs fully

CRIMPING INSTRUCTIONS

engage latches on both sides of connector.

Insert the socket housing (plug) into the pin housing

Squeeze the handles to cycle the crimp tool (Part No.

(receptacle) until it snaps in place.

HD-41609) to the fully open position.

Install connector on retaining device, either attachment

Raise locking bar by pushing up on bottom flange. With

or rosebud clip.

the crimp tails facing upward, insert contact (socket/pin)

through locking bar, so that the closed side of the con-

tact rests on the nest (concave split level area) of the

crimp tool). Use the front nest for 20 gauge wire, the

middle for 16 gauge and the rear for 18 gauge. See Fig-

ure 8-32.

Release locking bar to lock position of contact. When

correctly positioned, the locking bar fits snugly in the

space at the front of the core crimp tails.

Strip lead removing 5/32 inch (4.0 mm) of insulation.

Insert wires between crimp tails until ends make contact

with locking bar. Verify that wire is positioned so that

short pair of crimp tails squeeze bare wire strands, while

long pair folds over insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete. Raise up locking bar and remove contact.

Inspect the quality of the core and insulation crimps. Dis-

tortion should be minimal.

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8-25

HOME

PACKARD ELECTRICAL CONNECTORS

8.4

150 METRI-PACK SERIES

General

2-Place

Use these instructions to service the following connectors:

● MAP Sensor [80B]

● Ignition Coil [83B/130B]

IAT Sensor Connector [89B]

● IAC Actuator [87B]

● TP Sensor [88B]

● ET Sensor [90B]

2-Place

● IAT Sensor [89B]

Disassembly

Remove the connector from the retaining device, if

ET Sensor Connector [90B]

present.

Bend back the external latch(es) slightly and separate

the pin and socket halves of the connector.

To free a pull-to-seat terminal from the connector hous-

ing, first look into the mating end of the connector to find

3-Place

the locking tang. See A in Figure 8-34. The tangs are

always positioned in the middle of the chamber and are

on the same side as the external latch. On those con-

nectors with locking ears, the tang is on the side oppo-

site the ear. See Figure 8-35.

TP Sensor Connector [88B]

At a slight angle, gently insert the point of a one inch

safety pin down the middle of the chamber about 1/8

inch (3.2 mm), and pivot the end of the pin toward the

terminal body. When a click is heard, remove the pin and

repeat the procedure. See B in Figure 8-34. The click is

the sound of the tang returning to the locked position as

4-Place

it slips from the point of the pin. Pick at the tang in this

manner until the clicking stops and the pin seems to

slide in at a slightly greater depth than it had previously.

This is an indication that the tang has been depressed.

NOTE

IAC Connector [87B]

On those terminals that have been extracted on a previous

occasion, no clicking sound may be heard when the pin is

pivoted to depress the tang, but proceed as if the clicking is

Figure 8-33. Packard External Latch Type Connectors

audible and then push on the wire end of the lead to check if

(Socket Sides)

the terminal is free.

NOTE

Remove the pin and push on the wire end of the lead to

When picking multiple terminals, the end of the pin may

extract the terminal from the mating end of the connec-

become malleable. For best results, continue the procedure

tor. See C in Figure 8-34. If necessary, pull back the con-

with a new safety pin.

duit and remove the wire seal at the back of the

connector to introduce some slack in the wires.

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f1360x8x

Locate tang on latch side of chamber.

Push on wire end of lead to remove terminal.

Pivot end of pin to depress tang.

Raise tang and re-install terminal.

Figure 8-34. Depress Tang and Extract Terminal From Mating End of Connector

6. If necessary, crimp new terminals on wires. See Crimp-

2. Gently pull on the lead at the wire end of the connector

ing Instructions at the end of this section.

to draw the terminal back into the chamber. A click is

heard when the terminal is properly seated.

3. Push on the lead to verify that the terminal is locked in

Assembly

place.

NOTE

4. Push the pin and socket halves of the connector

For wire location purposes, alpha characters are stamped

together until the latches “click.”

into the socket housings.

1. Using a thin flat blade, like that on an X-Acto knife, care-

fully bend the tang outward away from the terminal body.

280 METRI-PACK SERIES

See D in Figure 8-34.

General

Use these instructions to service the following:

● Front/Rear Fuel Injectors [84B/85B]

● System Fuse Block [64B]

Fuel Injectors

Disassembly

1. Depress the wireform and use a rocking motion to

detach the electrical connector.

Figure 8-35. Packard Pull-to-Seat Terminal Connector

With Locking Ear

2. Pry rubber seal from wire end of connector and move

seal down wires toward conduit.

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f2012x9x

A. Insert safety pin at wire end of

C. Raise tang with blade of X-Acto

connector to depress tang.

knife.

B. Push on wire end of lead to

D. Pull on wire end of lead to draw

remove terminal.

terminal back into chamber.

Figure 8-36. Extract/Install Socket Terminal at Mating End of Connector

Hold the connector so that the wireform is facing down,

Gently pull on the lead at the wire end of the connector

and looking into the wire end of the connector, insert the

to draw the terminal back into the chamber. Be sure that

point of a safety pin between the top of the terminal and

the tang faces opposite the wireform as it enters the

the inside chamber wall.

chamber. A “click” is heard when the terminal is properly

Push safety pin completely into chamber while watching

seated. See D in Figure 8-36.

terminal on mating end of connector. When terminal is

Push on lead to verify that terminal is locked in place.

observed moving forward slightly, then tang is

depressed. See A in Figure 8-36. Remove safety pin.

Fit rubber wire seal back into wire end of connector.

NOTE

Push the pin and socket halves of the connector

Repeat steps 3 and 4 as necessary until the desired result is

together until the latch “clicks.” The groove in the socket

achieved.

housing must be aligned with the tab in the pin housing.

Push on wire end of the lead to extract the terminal from

the mating end of the connector. See B in Figure 8-36.

If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

NOTE

For wire color locations, see Section

8.8 WIRING DIA-

GRAMS and then refer to Figure 8-37.

1. Using a thin flat blade, like that on an X-Acto knife, care-

fully bend the tang outward away from the terminal body.

Figure 8-37. Fuel Injector Connector [84B/85B]

See C in Figure 8-36.

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System Fuse Block

Disassembly

1. Remove system fuses and relay(s) from fuse block.

2. Remove secondary locks as follows:

a. Insert end of small flat blade screwdriver under lip of

locking wedge and gently pry up secondary lock.

NOTE

For best results, start with locking wedge on outboard side of

secondary lock. See Figure 8-38.

Lip of

Locking Wedge

f2205x8x

3. Remove socket terminals as follows:

a. Looking into chamber at top of fuse block, note the

Figure 8-38. Remove Secondary Locks From Fuse Block

tang next to each socket terminal.

b. Using a thin flat blade, like that on an X-Acto knife,

gently push tang away from terminal, and then tug

on wire to back terminal out wire end of chamber.

4. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

Install socket terminals as follows:

NOTE

See Section 8.8 WIRING DIAGRAMS, MAIN HARNESS, for

f2204x8x

wire colors and locations.

a. With the open side of the socket terminal facing the

1. Headlamp

Radio Power

tang, push lead into chamber at the wire end of the

2. Ignition

Accessory

fuse block. A click is heard when the terminal is

3. Lighting

Battery

properly engaged.

4. Instruments

10. Brake Light Relay

5. Brakes/Cruise

11. P&A

b. Gently tug on the wire to verify that the terminal is

6. Radio Memory

locked in place and will not back out of the chamber.

Figure 8-39. Fuse Block (FLTR, FLHTC/U)

Install secondary locks as follows:

a. With the locking wedges positioned above the tangs

in each chamber, slide flat side of secondary lock

Disassembly

into slot (between rows), and push down until it bot-

toms. See Figure 8-38.

Remove seat.

Install system fuses and relay(s) in fuse block.

1WARNING

Always disconnect the negative battery cable first. If the

480 METRI-PACK SERIES

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

explosion, which could result in death or serious injury.

General

Unthread bolt and remove battery negative cable (black)

Use the following instructions to service the B+ connector.

from battery negative (-) terminal.

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