Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 22

3. XM Audio Output Continuity Test

Turn radio off.

Disconnect XM radio [185].

Disconnect radio [28A] from breakout box.

Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), test for continuity between the following:

Breakout box [28B] terminal 18 and XM [185B] ter-
minal 8

Breakout box [28B] terminal 7 and XM [185B] terminal
7

Breakout box [28B] terminal 30 and XM [185B] ter-
minal 6

Is continuity present?

Yes. Connect XM module.

No. Repair open on (R), (BK) or (W) wire between
radio harness [28B] and XM [185B]. (5041)

4. XM Audio Output Short to Ground Test

Test for continuity between the following:

Breakout box [28B] terminal 18 and XM [185B] ter-
minal 8

Breakout box [28B] terminal 7 and XM [185B] terminal
7

Breakout box [28B] terminal 30 and XM [185B] ter-
minal 6

Is continuity present?

Yes. Repair short to ground on (R), (BK) or (W) wire
in radio harness to XM [185B]. Installed modules may
also be shorted to ground internally. Disconnect XM
module while observing multimeter. If disconnecting
any module causes multimeter to indicate infinity,
replace XM module. (6157)

No.

5. XM Audio Output Wires Shorted Together
Test

Disconnect breakout box from radio [28A].

Test for continuity between the following:

Breakout box [28] terminals 18 and 7

Breakout box [28] terminal 7 and 30

Breakout box [28] terminal 30 and 18

Is continuity present?

Yes. Repair short between (R), (BK) or (W) wires in
radio harness. Installed modules may also be shorted
internally. Disconnect XM module while observing
multimeter. If disconnecting any module causes mul-
timeter to indicate infinity, replace XM module. (5041)

No.

Go to Test 6.

6. XM Audio Output Shorted to Voltage Test

Connect breakout box to radio [28A].

Test for voltage between the following:

Breakout box [28] terminal 18 and ground.

Breakout box [28] terminal 7 and ground.

Breakout box [28] terminal 30 and ground.

Is voltage greater than 8V?

Yes. Repair short to voltage on (R), (BK) or (W) wires.
Installed modules may also be shorted internally.
Disconnect XM module while observing multimeter.
If disconnecting any module causes multimeter to
indicate normal voltage, replace XM module. (5041)

No. Replace XM module. (6128)

7. XM Module Power Test

Install BREAKOUT BOX (Part No. HD-42682) and
JUMPER HARNESS (Part No. HD-45325) to XM [185B].

With IGN ON, measure voltage between XM breakout box
(black) terminals 9 and 10.

Is battery voltage present?

Yes.

Go to Test 8.

No. Inspect [185] for damaged, pushed back or cor-
roded terminals. Repair as required, then continue
testing.

Go to Test 10.

8. XM Module CAN Voltage Test

Measure voltage between XM breakout box (black) ter-
minals 11 and 12.

Is voltage between 4-6V?

Yes. Inspect [185] for damaged, pushed back or cor-
roded terminals. Repair as required. If connections
are okay, replace XM module. (6126)

No.

Go to Test 9.

9. XM Module CAN Continuity Test

Connect ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) between radio [28A] and radio
harness [28B].

8-48 2011 Touring Diagnostics: Audio System

Test for continuity between the following:

Radio breakout box [28] terminal 13 and XM breakout
box (black) terminal 11.

Radio breakout box [28] terminal 14 and XM breakout
box (black) terminal 12.

Is continuity present?

Yes. Replace radio. See the service manual. (6103)

No. Repair open on (Y/O) or (Y/V) wires. (6128)

10. XM Module Power/Ground Bus
Continuity Test

Connect ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) between radio [27A] and har-
ness [27B].

With radio on, test for voltage between breakout box ter-
minal 10 and ground.

Is battery voltage present?

Yes. Repair open (R/O) wire between XM [185B] and
radio memory fuse. (6129)

No. Repair open (BK/GN) wire between XM [185B]
and ground. (6129)

SYMPTOM 13: NO OR INTERMITTENT
RECEPTION ON XM MODULE

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

Before proceeding with this test, verify the vehicle is located
in an open area with line of sight to the southern sky and all
metal objects obstructing a properly installed antenna are
removed.

Table 8-52. Symptom 13: No or Intermittent Reception on

XM Module Diagnostic Faults

POSSIBLE CAUSES

XM module malfunction

Antenna malfunction

Satellite unavailable

1. XM Antenna Power Test

Disconnect XM antenna from XM module and turn IGN
ON.

Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), measure the voltage at XM antenna connector
on back of XM module between center conductor and
radio case.

Is voltage 4.25-4.75V?

Yes.

No. Replace XM module. (6126)

2. XM Antenna Resistance Test

Turn IGN OFF.

Measure the resistance between XM antenna cable con-
nector center conductor and antenna cable shield.

Is resistance between 35-55 Ohms?

Yes. Replace XM module. (6126)

No. Replace antenna. (6146)

SYMPTOM 14: NAVIGATION INOPERATIVE

Table 8-53. Symptom 14: Navigation Inoperative

Diagnostic Faults

POSSIBLE CAUSES

Nav module malfunction

Antenna malfunction

Satellite unavailable

Before performing these tests, verify the following:

•

Navigation CD is in good condition.

•

Navigation module is properly installed in radio including
screws.

•

Vehicle is located in an open area with line of sight to the
southern sky.

•

Navigation antenna is properly installed and connected to
navigation module.

•

Any metal objects obstructing a properly installed antenna
are removed.

1. Navigation Module Activation Test

Turn radio ON and press the NAV button.

Is the navigation screen displayed on the radio?

Yes. "GPS Antenna Error" is displayed.

Go to Test

Yes. "GPS Module Error" is displayed. Substitute
module with known good unit. If problem persists,
continue testing.

No. If "Navigation is Not Installed" is displayed, swap
module with known good unit and retest. If problem
persists replace radio. (6103)

2. GPS Antenna Error Test

Disconnect GPS antenna from navigation module.

Measure the voltage at the module from the center con-
ductor to radio case.

Is voltage between 4.5-5.3V?

Yes.

No. Replace navigation module. (6182)

3. GPS Antenna Resistance Test

Measure resistance at the GPS antenna connector
between the center conductor and cable shield.

Is resistance between 105,000-122,000 Ohms?

Yes. Replace navigation module. (6182)

No. Replace antenna. (6183)

2011 Touring Diagnostics: Audio System 8-49

4. GPS Module Error Test

Activate the FM radio band and enter radio test menu
(softkey 1, softkey 3 and OK pressed simultaneously).

Press down arrow to select diagnostic speed type (J1850
for model years 2006 and later).

Is speed type correct?

Yes.

AUDIO SYSTEM SYMPTOMS, Symptom 15: AVC
Inoperative

No. Press CHANGE at softkey 4 until the correct
speed type is displayed. Press EXIT at softkey 6 to
store setting. Cycle ignition switch and repeat
symptom tests.

5. Screen Speed Test

Press down arrow until diagnostic speed input appears.
Should read "O" if the vehicle is stationary.

Ride motorcycle with the speed screen displayed while
monitoring both the screen and the speedometer.

Does the number on the screen increment?

Yes.

Go to Test 6.

No. If the speedometer showed a speed value, repair
the speed input to the radio. See

8.5 ADVANCED

, and repeat Test 4.

6. Navigation CD Operation Test

Insert navigation CD and allow it to load.

Press OKAY when prompted and press softkey 5 to save
the data.

Press softkey 4 (GPS).

Observe the number of satellites and latitude/longitude
information.

Are there any satellites available (may take 5-10 minutes
to acquire)?

Yes. Replace navigation module. (6182)

No. Replace navigation antenna. (6183)

SYMPTOM 15: AVC INOPERATIVE

Table 8-54. Symptom 15: AVC Inoperative Diagnostic

Faults

POSSIBLE CAUSES

VSS malfunction

Loss of communication with ECM

1. AVC Speed Test

Activate the FM radio band and enter radio test menu
(softkey 1, softkey 3 and OK pressed simultaneously).

Press down arrow to select diagnostic speed type (J1850
for model years 2006 and later).

Is speed type correct?

Yes.

8.4 SERIAL DATA BUS DIAGNOSTICS,

No. Press CHANGE at softkey 4 until the correct
speed type is displayed. Press EXIT at softkey 6 to
store setting. Cycle ignition switch and repeat
symptom test.

2. Screen Speed Test

Press down arrow until diagnostic speed input appears.
Should read "O" if the vehicle is stationary.

Ride motorcycle with the speed screen displayed while
monitoring both the screen and the speedometer.

Does the number on the screen increment?

Yes. Adjust AVC by pressing AUDIO + until one or
more bars are present.

No. See

DTC U1016 J1850 Loss of Communication with ECM

SYMPTOM 16: HANDLEBAR, PASSENGER
OR SIDECAR SWITCHES INOPERATIVE

8.2 DTC B2006-B2015, RADIO SWITCH DIAGNOSTICS

SYMPTOM 17: CD SKIPPING

TOOL NAME

PART NUMBER

ADVANCED AUDIO SYSTEM
BREAKOUT BOX

HD-47918

Before proceeding with the following tests, verify the following:

•

CD is in good condition and properly formatted.

•

Radio is installed properly. (6171)

•

Handlebar risers do not contact bottom of radio chassis.

Table 8-55. Symptom 17: CD Skipping Diagnostic Faults

POSSIBLE CAUSES

CD not formatted properly

Exhaust system not mounted correctly

Radio malfunction

1. CD Player to CB/Intercom Interactivity
Test

If the vehicle is equipped with a CB/Intercom, turn it OFF.

Does the CD still skip?

Yes.

No. Possible audio interruptions caused by incoming
CB or intercom signals.

2. Radio Input (Power) Positive Voltage Drop
Test

Install ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) to radio [27A] and radio harness
[27B].

8-50 2011 Touring Diagnostics: Audio System

With IGN and radio ON, measure voltage drop between
battery positive (+) and breakout box terminals 10 and 20.

Is voltage drop greater than 0.5V?

Yes. Repair source of voltage drop between battery
positive and breakout box [27] terminals 10 and 20.
(6172)

No.

3. Radio Input (Power) Negative Voltage
Drop Test

With IGN and radio ON, measure voltage drop between
battery negative (-) and breakout box terminals 11 and
19.

Is voltage drop greater than 0.5V?

Yes. Repair source of voltage drop between battery
negative and breakout box [27] terminals 11 and 19.
(6172)

No.

4. Front Motor Mount Inspection Test

Inspect front motor mount.

Is front motor mount damaged, loose or misaligned?

Yes. Align or replace front motor mount. See the
service manual. (6173)

No.

5. Exhaust System Mounts Inspection Test

Inspect exhaust system mounts.

Do mounts allow muffler isolation so that vibration cannot
reverberate through frame?

Yes. Replace radio. See the service manual. (6101)

No. Correct exhaust mount alignment. See the ser-
vice manual.

SYMPTOM 18: HANDS-FREE PHONE
MODULE INITIAL DIAGNOSTICS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

ADVANCED AUDIO SYSTEM
BREAKOUT BOX

HD-47918

Table 8-56. Symptom 18: Hands-free Phone Module Initial

Diagnostics Diagnostic Faults

POSSIBLE CAUSES

Phone incompatible with system

Phone won't pair

Phone malfunction

1. Phone Mode Enable Test

Can phone mode be enabled?

Yes.

GNOSTICS, DTC U1306 Infotainment Bus Lost
Communication with Hands-Free Phone Module

No. Phone icon appears on radio display.

Go to

Test 6.

No. Phone mode inoperative with no phone icon
on display. See

8.4 SERIAL DATA BUS DIA-

2. Phone Pairing Test

Is phone able to pair with module?

Yes.

No. Phone may not be compatible. See phone com-
patibility list on H-D Net or contact cellular provider
for technical service and source compatible phone.

3. Phone Communication Test

Can caller be heard by rider and the rider be heard by
caller?

Yes.

No.

Go to Test 6.

4. Phonebook Download Test

Does phonebook download completely?

Yes. If the name of the phone service provider is
displayed, then continue with tests.

No. Some phones or sim cards do not support all
features. Contact cellular provider technical service
or obtain compatible phone.

5. Signal Strength Test

Observe signal strength on display.

Is signal strength displayed in upper right hand corner of
display?

Yes. System okay.

No.

Go to Test 16.

2011 Touring Diagnostics: Audio System 8-51

Hands

Free

Module

Bluetooth

Antenna

Differential Mic Out (+)
Differential Mic Out (-)

Battery
Ground

Audio Out (+)
Audio Out (-)

CAN (+)
CAN (-)

8
9

17
18

45
46

(Beige)

6
7
8
9

10
11
12

1
2

1
2
3
4

10
11
12

Future

ACC

1
2

4
5

10
11
12

C.B.

P&A ULTRA

Overlay Harness

For FL/HTCU/HTK/TRU

Only

1 2

5 6 7 8

1 2

5 6 7 8

R/O

Y/O

Y/V

Y/O

Y/V

BK/GN

R/O

Y/O

Y/V

BK/GN

R/O

BK/GN

R/O

Y/O

Y/V

BK/GN

++R

++BK

Y/O

Y/V

++R

++BK

++R

++BK

R/O

Y/O

Y/V

BK/GN

++R

++BK

[186B]

[185B]

Future

ACC

[175B]

[184D]

[194B]

[187B]

[187A]

(BK)

Left XM

HFM Audio (+)

CB/GRMS

Audio (+)

CAN (+)

CAN (-)

XM (-)

MIC Sum Out (-)

HFM Audio (-)

MIC Sum Out (+)

13
14

CB/GRMS

Audio (-) 26

13
14

Right XM (-) 30 30

Ultra Radio

[28B]

[28A]

Battery

Ground

[6B]

[6A]

1
2

4
5
6
7
8
9

10
11
12

1
2

4
5
6
7
8
9

10
11
12

(If Equipped)

C.B.

[184C]

[184B]

R/O

Y/O

Y/V

Y/O

Y/V

Y/O
R/O

R/O

Y/V

Y/O

Y/V

BK
BK

BK/GN

++BK

++R

R/O

BK/GN

(BK)

Radio

Memory Fuse

15A

GND 2

[15B]

[15A]

Main

Harness

[27B]

[27A]

1
2
3
4

20
21

[149B]

Y/V

Y/O

To High

Output

Amplifier

BK/GN

Ground

Stud

(Right)

Battery +

R
R

[149A]

(BK)

em00863

Figure 8-20. Audio, Microphone, Power and CAN Circuits

8-52 2011 Touring Diagnostics: Audio System

6. Phone Module Power Test

Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), measure voltage between hands-free module
[194B] terminals 1 and 2 (ground).

Is battery voltage present?

Yes.

Go to Test 7.

No.

Go to Test 9.

7. CAN Communication Test

Measure voltage between [194B] terminals 17 and 18.

Is measured voltage between 4.0-6.0V?

Yes.

Go to Test 10.

No.

Go to Test 8.

8. Phone Module Continuity Test

Connect ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) between radio [28A] and radio
harness [28B], leaving radio [28A] disconnected.

Test for continuity between [194B] terminal 17 and
breakout box [28] terminal 13 and then between [194B]
terminal 18 and breakout box [28] terminal 14.

Is continuity present?

Yes. Inspect [194] for damaged, pushed back or cor-
roded terminals. Repair as required. If connector ter-
minals are okay, replace radio.

No. Repair open on (Y/O) or (Y/V) wires. (5041)

9. Phone Module Open Ground Test

Test for continuity between [194B] terminal 2 to ground.

Is continuity present?

Yes. Repair open on (R/O) wire between [194B] and
radio memory fuse. (5041)

No. Repair open on (BK/GN) wire between [194B]
and ground. (5041)

10. Phone Mode Entry Test

Does radio enter phone mode when mode switch is
pressed?

Yes.

Go to Test 11.

No. Replace hands-free phone module.

11. Phone Module Output Test

Measure voltage between breakout box [28] terminals 4
and 27.

Is voltage between 0-5VAC while voice prompt is
responding?

Yes. Replace radio. See the service manual. (6101)

No.

Go to Test 15.

12. Phone Module Continuity Test

Test for continuity between breakout box [28] terminal 4
and [194B] terminal 8 and then between breakout box [28]
terminal 27 and [194B] terminal 9.

Is continuity present?

Yes.

Go to Test 13.

No. Repair open (R) or (BK) wire between [194B] and
[28B]. (5041)

13. Phone Module Audio Short to Low Test

Test for continuity between breakout box [28] terminals 4
and 27.

Is continuity present?

Yes.

Go to Test 14.

No. Repair short to low on (R) and (BK) wires. (5041)

14. Phone Module Audio Short to Ground
Test

Test for continuity between breakout box [28] 4 and 27 to
ground.

Is continuity present?

Yes. Repair short to ground on (R) or (BK) wire.
(5041)

No.

Go to Test 15.

15. Phone Module Audio Short to Voltage
Test

With IGN and radio ON, measure voltage between
breakout box [28] 4 and 27 to ground.

Is voltage greater than 9V?

Yes. Repair short to voltage on (R) or (BK) wire.
(5041)

No. Replace hands-free module.

16. Phone Module Antenna Test

Inspect the hands-free module antenna.

Is the hands-free module antenna good?

Yes. Contact cellular provider technical service and
verify phone is compatible. If phone is correct replace
the hands-free phone module.

No. Replace the hands-free module antenna.

2011 Touring Diagnostics: Audio System 8-53

A.1

AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS

AUTOFUSE UNSEALED CONNECTOR
REPAIR

TOOL NAME

PART NUMBER

SNAP-ON TERMINAL PICK

GA500A

General

Autofuse Unsealed connector terminals are found in ignition
switches and some fuse blocks.

Disassembly

Obtain SNAP-ON TERMINAL PICK (Part No. GA500A).

Figure A-1

Figure A-2

. Insert smallest pair of pins

into chamber on mating end of socket housing to press
tangs on each side of terminal simultaneously.

Gently pull on wire to remove terminal from wire end of
socket housing.

If necessary, crimp new terminals on wires.

Assembly

Using a thin flat blade, like that on a hobby knife, carefully
bend tang on each side of terminal outward away from
terminal body.

With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it locks
in place.

sm02849

Figure A-1. Removing Autofuse Unsealed Terminal from

Ignition Switch

sm03480

Figure A-2. Removing Autofuse Unsealed Terminal from

Fuse Block

2011 Touring Diagnostics: Appendix A Connector Repair A-1

A.2

DELPHI 100W MICRO-PACK SEALED
CONNECTOR

DELPHI 100W MICRO-PACK SEALED
CONNECTOR REPAIR

General

A Delphi 100W Micro-Pack Sealed connector connects the
electronic control module (ECM) to the main harness.

NOTE

For vehicles with 73-pin connectors, see

A.9 DELPHI MICRO

64 SEALED CONNECTORS

and

A.8 DELPHI METRI-PACK

TERMINAL REPAIR

Separating Socket Housing From ECM

Figure A-3

. While pressing the connector into the ECM,

press the thumb lever (1) against the connector until the latch
(2) pops out of the catch (3) on the ECM.

Mating Socket Housing To ECM

Push the connector into the ECM until the latch is captured by
the catch on the ECM.

Removing Socket Terminal

See

Figure A-4

. Gently press latch (1) on each side of the

clear plastic secondary lock (2) and remove. For best
results, release one side at a time.

Carefully cut cable strap (3) to free strain relief collar (4)
from conduit (5).

A.8 DELPHI METRI-PACK TERMINAL REPAIR

Figure A-5

. Using a thin blade, gently pry at seam at

back of socket housing to release three plastic pins (1)
from slots in housing. Separate and spread halves of
socket housing.

Push on wire lead to free terminal from chamber.

Installing Socket Terminal

From inside socket housing, gently pull on wire to draw
terminal into chamber.

Exercising caution to avoid pinching wires, press halves
of socket housing together until three plastic pins fully
engage slots in housing.

Install new cable strap in groove of strain relief collar
capturing cable conduit.

With the two ribs on the secondary lock on the same side
as the external latch, install over terminals until latches
lock in place.

Crimping Terminals

If necessary, crimp new terminals on wire leads. See

sm00037

Thumb lever

Latch

Catch (ECM)

Figure A-3. Delphi 100W Micro-Pack Sealed Connector to

ECM (typical)

A-2 2011 Touring Diagnostics: Appendix A Connector Repair

A.3

DELPHI 150 METRI-PACK SEALED
CONNECTORS

DELPHI 150 METRI-PACK SEALED
CONNECTOR REPAIR

General

Delphi 150 Metri-Pack Sealed connectors are embossed with
the initials (P.E.D.).

There are two types of connectors in this series:

•

Pull-to-Seat

•

Push-to-Seat

Separating Pin and Socket Housings

Bend back the external latch slightly and separate the pin and
socket halves of the connector.

Mating Pin and Socket Housings

Align the wire colors and push the pin and socket halves of the
connector together.

Removing Socket Terminal

See

Figure A-6

for pull-to-seat connector or

Figure A-7

for push to seat connector. Remove wire lock (1) from wire
end of socket housing on push-to-seat type connectors.

NOTE

For best results, free one side of wire lock first and then release
the other side.

Find the locking tang in the mating end of the connector.

NOTE

The tangs are always positioned in the middle of the chamber
and are on the same side as the external latch.

Gently insert a safety pin into the chamber about 1/8 in.
(3.2 mm).

For pull-to-seat: Stay between the terminal and the
chamber wall and pivot the end of the pin toward the
terminal body.

For push-to-seat: There is a small opening for the
pin.

When a click is heard, remove the pin and repeat the
procedure.

NOTE

The click is the sound of the tang returning to the locked posi-
tion as it slips from the point of the pin.

Pick at the tang until the clicking stops and the pin seems
to slide in deeper than it had previously. This is an indica-
tion that the tang has been depressed.

NOTE

On those terminals that have been extracted on multiple
occasions, the click may not be heard, but pivot the pin as if
the click was heard at least 3 times.

Remove the pin.

For pull-to-seat: Push on the lead to extract the ter-
minal from the mating end of the connector.

For push-to-seat: Pull on the lead to draw the ter-
minal out the wire end.

Inserting Socket Terminal

NOTE

For wire location purposes, alpha characters are stamped into
the socket housings.

for pull-to-seat connector or

Figure A-6

Figure A-7

for push to seat connector. Using a thin flat blade, like that
on a hobby knife, carefully bend the tang outward away
from the terminal body.

Gently pull or push on the lead to install the terminal back
into the chamber. A click is heard when the terminal is
properly seated.

Gently pull or push on the lead to verify that the terminal
is locked in place.

For push-to-seat: See

Figure A-7

. Seat wires in separate

channels of wire lock and then push channels inside
chambers at wire end of socket housing. Fully installed,
slot on each side of wire lock engages ear on socket
housing.

A-4 2011 Touring Diagnostics: Appendix A Connector Repair

A.4

DELPHI 280 METRI-PACK UNSEALED
CONNECTORS

FUSE BLOCK REPAIR

Removing Socket Terminals

See

Figure A-8

. To remove secondary locks, insert end

of small flat blade screwdriver (1) under lip of locking
wedge (2) and gently pry up secondary lock.

NOTE

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

Looking into chamber at top of fuse block, note the tang
next to each socket terminal.

Using a thin flat blade, like that on a hobby knife, gently
push tang away from terminal, and then tug on wire to
back terminal out.

Installing Socket Terminals

Match the wire lead color to the fuse block terminal cavity.

NOTES

•

Refer to the main harness wiring diagram for wire lead
color codes.

•

See

Figure A-9

. The main fuse block terminal cavity is

identified as alpha (1) and numeric (2) coordinates. Refer
to the main harness wiring diagram for fuse block terminal
cavity coordinates.

With the open side of the socket terminal facing the tang,
push lead into chamber at the wire end of the fuse block.
A click is heard when the terminal is properly engaged.

Gently tug on the wire to verify that the terminal is locked
in place and will not back out of the chamber.

Install the secondary locks. With the locking wedges
positioned above the tangs in each chamber, slide flat
side of secondary lock into slot (between rows), and push
down until it bottoms.

Crimping Terminals

Terminals are crimped twice; once over the wire core and a
second time over the insulation/seal.

A correctly crimped terminal may require different crimping
dies found on separate crimpers.

NOTE

The wiring diagram indicates when one socket terminal is be
crimped to two wire leads.

sm00025

Pry up secondary lock

Lip of locking wedge

Figure A-8. Fuse Block: Remove Secondary Locks

sm00026

Alpha

Numeric

Figure A-9. Fuse Block: Coordinates (typical)

A-6 2011 Touring Diagnostics: Appendix A Connector Repair

A.5

DELPHI 480 METRI-PACK UNSEALED
CONNECTORS

DELPHI 480 METRI-PACK UNSEALED
CONNECTOR REPAIR

General

A 480 Metri-Pack connector is frequently used for the B+
(battery voltage) connector to power P&A accessories.

A.8 DELPHI METRI-PACK TERMINAL REPAIR

Figure A-10

. An AFL housing (5) is used on many igni-

tion/light switches. The secondary lock (4) must be opened
before removing the terminal from the housing.

Separating Pin and Socket Housings

NOTE

Cut any cable strap anchoring the wire conduits of the pin
(accessory connector housing) and the socket (B+) housing.

See

Figure A-10

. Using small flat blade screwdriver, press

button (1) on pin housing (red wire) side of the connector and
pull apart the pin and socket housings.

Mating Pin and Socket Housings

Orient the latch on the socket housing to the button catch on
the pin housing and press the housings together.

Removing Socket Terminals

See

Figure A-10

. Bend back the latch (2) slightly and free

one side of secondary lock, then repeat to release the
opposite side. Rotate the secondary lock outward on hinge
to access terminal in chamber of connector housing.

On the mating end of the connector, note the tang in the
square shaped opening centered next to the terminal.
Gently insert the point of a stick pin or large safety pin into
the opening (3) between the tang and the chamber wall
until it stops.

Pivot the end of the pin toward the terminal body to press
the tang.

Remove the pin and then pull terminal out of the wire end
of connector housing.

If necessary, crimp new terminals on wires. See

Installing Socket Terminals

Carefully bend the tang outward away from the terminal
body.

With the tang on the same side as the square shaped
opening in the mating end of the connector housing, feed
terminal into wire end of connector housing until it "clicks"
in place.

Verify that terminal will not back out of the chamber. A
slight tug on the cable will confirm that it is locked.

Rotate the hinged secondary lock inward until latches fully
engage tabs on both sides of connector housing.

NOTE

If removed, install new anchored cable strap in O.E. location.
Tighten cable strap to capture conduit of both accessory con-
nector and B+ connector approximately 1.0 in. (25.4 mm) from
housings.

sm00031a

Button on pin housing

Secondary lock latch

Opening between tang and chamber wall

Secondary Lock (shown open)

AFL housing

Figure A-10. Delphi 480 Metri-Pack Unsealed Connector:

Remove Socket Terminal

A.8 DELPHI METRI-PACK TERMINAL REPAIR

2011 Touring Diagnostics: Appendix A Connector Repair A-7

A.6

DELPHI 630 METRI-PACK UNSEALED
CONNECTORS

DELPHI 630 METRI-PACK UNSEALED
CONNECTOR REPAIR

TOOL NAME

PART NUMBER

SNAP-ON PICK

SNAP-ON TT600-3

Separating Pin and Socket Housings

NOTE

If necessary, remove connector from barbed anchor or other
retaining device.

Bend back the external latch slightly and separate pin and
socket halves of the connector.

Mating Pin and Socket Housings

Orient the latch to the catch and push the pin and socket halves
of the connector together until the latch "clicks".

NOTE

If removed, install connector on barbed anchor or other OE
retaining device.

Removing Socket Terminal

Bend back the latch slightly and free one side of the sec-
ondary lock. Repeat the step to unlatch the other side.

Rotate the secondary lock outward on hinge to view the
terminals in the chambers of the connector housing. The
locking tang is on the side opposite the crimp tails and
engages a rib in the chamber wall to lock the terminal in
place.

Moving to the mating end of the connector, take note of
the small opening on the chamber wall side of each ter-
minal.

Insert SNAP-ON PICK (Part No. SNAP-ON TT600-3) into
opening until it stops. Pivot the end of the pick toward the
terminal to press the locking tang.

Remove the pick and gently tug on the wire to pull the
terminal from the wire end of the connector. Repeat steps
if the terminal is still locked in place.

If necessary, crimp new terminals on wires. Refer to

Installing Socket Terminal

NOTE

Refer to the wiring diagrams to match wire lead colors to alpha
characters molded into the secondary locks of each connector
housing.

Using a thin flat blade, like that of a hobby knife, carefully
bend the tang outward away from the terminal body.

With the tang facing the chamber wall, push the lead into
the chamber at the wire end of the connector. A click is
heard when the terminal is properly seated.

Gently tug on the wire end to verify that the terminal is
locked in place and will not back out of the chamber.

Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.

A-8 2011 Touring Diagnostics: Appendix A Connector Repair

A.7

DELPHI 800 METRI-PACK SEALED MAIN FUSE
HOUSING

DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING REPAIR

Removing Socket Terminals

Disconnect battery.

See

Figure A-11

. Disengage slots (1) on secondary lock

(2) from tabs (3) and remove secondary lock.

Insert flat blade of pick or small screwdriver into opening
(4) until it stops.

Tug on cable to pull socket from connector housing. Pivot
the pick toward the terminal body to release the latch if
necessary.

Repeat to remove remaining socket terminal.

NOTE

The battery positive cable and power wire for the main fuse
are crimped together at the starter ring terminal. Both must be
replaced as an assembly if either requires replacement.

Installing Socket Terminals

Figure A-12

. Carefully bend tang outward away from

the terminal body.

Properly orient terminal to the cavity in the housing and
push terminal into connector housing until it clicks in place.
Verify that socket will not back out of chamber.

Push rubber seal into connector housing.

Repeat to install remaining socket terminal.

Install secondary lock onto connector housing. be sure
slots engage tabs on sides of connector housing.

Connect battery cables.

sm00033

Secondary lock slot

Secondary lock

Tab

Insert flat blade into opening

Figure A-11. Delphi 800 Metri-Pack Sealed Main Fuse

Housing: Remove Socket Terminals