411-78084 Instruction Sheet 05NOV07 Rev. F4 Sealed EFI ECU 0.64/2.3 0.64/2.3 I/O Connector 1. Part Names and Part Numbers 1.1 Housings CLIP WIRE COVER LEVER FEMALE CONNECTOR MALE CONNECTOR Part Number Part Name 1612272 Sealed 0.64/2.3I/O Conn.186Pos. Cap Housing Assembly STD Type 1747536 Sealed 0.64/2.3I/O Conn.186Pos. Cap Housing Assembly Flange Type 1827028 Sealed 0.64/2.3I/O Conn.186Pos. Cap Housing Assembly THS type 1717313 Sealed 0.64/2.3I/O Conn.149Pos. Cap Housing Assembly STD Type 1612275-1 Sealed 0.64/2.3I/O Conn.126Pos. Plug Housing Assembly STD Type(Clip non-conformable) 1612275-3 1747137-1 1747137-3 1827021 1827022 1612275-2 1612275-4 1747137-2 1747137-4 1827015 1612283 1747140 Sealed 0.64/2.3I/O Conn.126Pos. Plug Housing Assembly STD Type(Clip conformable) Sealed 0.64/2.3I/O Conn.126Pos. Plug Housing Assembly Reverse Type(Clip non-conformable) Sealed 0.64/2.3I/O Conn.126Pos. Plug Housing Assembly Reverse Type(Clip conformable) Sealed 0.64/2.3I/O Conn.112Pos. Plug Housing Assembly THS STD Type Sealed 0.64/2.3I/O Conn.112Pos. Plug Housing Assembly THS Reverse Type Sealed 0.64/2.3I/O Conn. 89Pos. Plug Housing Assembly STD Type(Clip non-conformable) Sealed 0.64/2.3I/O Conn. 89Pos. Plug Housing Assembly STD Type(Clip conformable) Sealed 0.64/2.3I/O Conn. 89Pos. Plug Housing Assembly Reverse Type(Clip non-conformable) Sealed 0.64/2.3I/O Conn. 89Pos. Plug Housing Assembly Reverse Type(Clip conformable) Sealed 0.64/2.3I/O Conn. 74Pos. Plug Housing Assembly THS Reverse Type Sealed 0.64/2.3I/O Conn. 60Pos. Plug Housing Assembly STD Type Sealed 0.64/2.3I/O Conn. 60Pos. Plug Housing Assembly Reverse Type 1612281 Sealed 0.64/2.3I/O Conn. 126Pos. Lever STD Type 1747139 Sealed 0.64/2.3I/O Conn. 126Pos. Lever Reverse Type 1612288 Sealed 0.64/2.3I/O Conn. 60Pos. Lever STD Type 1747142 Sealed 0.64/2.3I/O Conn. 60Pos. Lever Reverse Type 1746941 Sealed 0.64/2.3I/O Conn. 126Pos. Wire Cover TypeRight and Left Lock 1746816 Sealed 0.64/2.3I/O Conn. 126Pos. Wire Cover TypeOne Side Lock 1871551 Sealed 0.64/2.3I/O Conn. 126Pos. Wire Cover TypeRight and Left Lock 1903751 Sealed 0.64/2.3I/O Conn. 89Pos. Wire Cover TypeRight and Left Lock 1981831 Sealed 0.64/2.3I/O Conn. 126Pos. Wire Cover Type One Side Lock 1981984 Sealed 0.64/2.3I/O Conn. 126Pos. Wire Cover Type Right and Left Lock 1871550 Sealed 0.64/2.3I/O Conn. 74Pos. Wire Cover TypeRight and Left Lock 1746817 Sealed 0.64/2.3I/O Conn. 60Pos. Wire Cover TypeOne Side Lock 1827114 Sealed 0.64/2.3I/O Conn. 60Pos. Wire Cover TypeRight and Left Lock 1939393 Sealed 0.64/2.3I/O Conn. 89/126Pos. Clip Fig.1 Note: Part number is consisted from listed base number and 1 digit numeric prefix and suffix with dash. Refer to catalog or customer drawing for specific part numbers for each base number. When prefix zero, zero and dash are omitted. 213-8535 3-5-8 1 Tyco Electronics AMP K.K. (3-5-8 Hisamoto Takatsu-ku Kawasaki, 213-8535) This document is subject to change. Call local AMP for the latest revision. (c) Copyright 2005 by Tyco Electronics AMP K.K. All rights reserved. * : Trademark of 38 Instruction Sheet 411-78084 1.2 Terminals <0.64 Terminals> Part Number 1612290-1 1612290-2 Wire Type Part Name 2 Type Size(mm ) CAN CHFUS 0.64 Receptacle (Female Terminal) 0.22 0.35, 0.5 AVSS/AVSSH/AVSSX 0.3 AESSX 0.3 AVSS/AVSSH/AVSSX/AESSX 0.5 <2.3II Terminals> TE Part Part Name Number 2.3II Receptacle (S) (Female Terminal) 2.3II Receptacle (M) (Female Terminal) Wire Type Type AVSS/CAVS 0.3, 0.5 AVSSX/AVSSH/AESSX 0.3, 0.5 AVS/AVSS 0.5, 0.85 AVSS 0.5, 0.85 AVSS/CAVS 0.5, 0.85 AVSS/AVSSH/AESSX 0.5, 0.75 AVSS/AVSSX/AESSX/AVSSH/CAVS 2.3II Receptacle (L) (Female Terminal) 2 Size(mm ) AVSS/AVSSX/AESSX/HFSS/CAVS 1.25 2 Fig.2 1.3 Others <Terminal extraction jig> 0.64 Terminals : 3070000(SUMITOMO No.) 2.3II Terminals : Precision screwdriver(1.2mm1.6mm) <PC Board Installation for Cap Housing Assembly> 186Pos Jig : 1762875-2(TE Part Number) 149Pos Jig : 1762875-1(TE Part Number) THS Jig : Rev. F4 2 of 38 Instruction Sheet 149/186P Cap Housing Assembly STD Type 1.4 Components View 89/126P Plug Housing Assembly STD Type 411-78084 89/126P Clip 2.3Receptacle Contact 0.64 Receptacle Contact 126Pos Wire Cover TypeRight and Left Lock 126Pos Lever STD Type 60Pos Plug Assembly Reverse Type 2.3 Dummy Wire Seal 60Pos Lever Reverse Type 0.64Dummy Wire Seal 60Pos Wire Cover TypeOne Side Lock Fig.3 Rev. F4 3 of 38 Instruction Sheet 411-78084 186Pos STD Type 186Pos Flange Type 186Pos THS Type 126Pos STD Type 126Pos Reverse Type 126Pos Type 126Pos STD Type (Clip non-conformable) 126Pos STD Type (Clip conformable) 126Pos Reverse Type (Clip non-conformable) 126Pos Reverse Type (Clip conformable) 112Pos THS STD Type 112Pos THS Reverse Type 89Pos STD Type (Clip non-conformable) 89Pos STD Type (Clip conformable) 89Pos Reverse Type (Clip non-conformable) 89Pos Reverse Type (Clip conformable) 74Pos THS Reverse Type 60Pos STD Type 60Pos Reverse Type Male Connector Lever Wire Cover 89/126Pos Clip THS Jig 74Pos Type 60Pos Type 60Pos Type I 126Pos Type 126Pos Type 186Pos Jig 89Pos Type 126Pos Type 126Pos Type 60Pos Reverse Type 60Pos STD Type 149Pos Jig 149Pos STD Type Female Connector Installation Jig 1.5 Acceptable table of housing(:Acceptable :Not acceptable) Clip Fig.4 Rev. F4 4 of 38 Instruction Sheet 411-78084 2. Customer Receiving Inspection We conduct inspections according to our quality control regulations to maintain an over all lot control. In addition, the customers should conduct receiving inspections based on the specific customer drawings. 3. Storage and Carrying 3.1 Terminal (1) Avoid leaving or carrying the terminal reel in an open area without wrapping it in proper material. (2) Do not lift up and carry the terminal reel by gripping one the side of reel, this may result in damage to the reel, and terminals before use. (See Fig.4) Do not lift up laterally Acceptable Fig.5 (3) Avoid storing the terminal reel in a moist or dusty place. Stock the reel in a comparatively dry and clean place (5354585%RH) away from direct sunlight. (4) When removing the terminal reel from the machine, fasten the end of terminal strip onto the edge of the reel with use of proper string or wire. (See Fig.5) Tie strip end with a wire neatly Fig.6 3.2 Housing (1) Avoid storing the terminal reel in a moist or dusty place. Stock the reel in a comparatively dry and clean place (5354585%RH) away from direct sunlight. (2) Avoid leaving or carrying the terminal reel in an open area without wrapping it in proper material. (3)Do not drop or shock the housing when carrying it. Rev. F4 5 of 38 Instruction Sheet 411-78084 4. Fixing Housing and PC Board 4.1 Male Connector and PC Board Installation Jig 149/186Pos Cap Housing Assembly STD Type 186Pos Cap Housing Assembly Flange Type 149Pos PC Board Installation Jig 186Pos Cap Housing Assembly THS Type 186 Pos PC Board Installation Jig Fig.7 4.2 Fixing Housing and PC Board in state with Tine Plate Insert the terminal of the male connector into the holes of PC Board. Then after fixing the housing and the board with temporary snap fixing, solder the terminals. Terminals (P. C. Board side) Temporary fixing snaps NOTE NOTE Fig. 8 Do not deform the terminal (PC Board side); otherwise the male connector can not be fixed on the PC Board. In all the processes, both sides (mating side and solder side) of the terminal and the housing must not be damaged or deformed by the operation. No foreign substance NOTE NOTE Rev. F4 is permissible in the mating area and case seal area. See the customer drawing for the PC Board dimension. Please note that it is not of transform and damage of the temporary fixing snap when you temporarily stop the substrate to the snap for a temporary fixing. 6 of 38 Instruction Sheet NOTE 411-78084 No discoloration or deformation should be caused by the heat of soldering. 4.3 Installation work to PC Board as removed Tine Plate (1) Please make Tine Plate upward like fig.9, and install the Male Connector in substrate made of Tyco installation Jig. Male Connector Tine Plate PC Board Installation Jig Fig. 9 NOTE Do not deform the terminal when Tine Plate is removed. (2) Detach Tine Plate after installing Male Connector on Jig. Tine Plate In condition of installation Male Connector NOTE Rev. F4 In condition of detaching Tine Plate Fig. 10 Do not deform the terminal when Tine Plate is removed. 7 of 38 Instruction Sheet 411-78084 (3)Confirm the insertion the Terminal of the Male Connector into the holes of PC Board after detaching Tine Plate. PC Board Temporary fixing snaps NOTE NOTE NOTE Fig. 11 Please note that it is not of transform and damage of the temporary fixing snap when you temporarily stop the substrate to the snap for a temporary fixing. See the customer drawing for the PC Board dimension. Please confirm the thing that the Terminal the hole of PC Board when PC Board is installed. (4)Please remove from Jig, and soldering the Male Connector after installing the PC Board in the Male Connector. Male Connector PC Board Installation Jig NOTE NOTE NOTE Rev. F4 Fig. 12 Be careful not to catch the Terminal on Jig when Tine Plate is removed. Moreover, the Terminal must not come off from the PC Board's hole. No discoloration or deformation should be caused by the heat of soldering. In all the processes, both sides (mating side and solder side) of the terminal and the housing must not be damaged or deformed by the operation. No foreign substance is permissible in the mating area and case seal area. 8 of 38 Instruction Sheet 411-78084 5. Crimping Operation Any crimping of terminals must be performed by using appropriate AMP tools according to the applicable Instruction Sheet and Specification. 5.1 Wires 5.1.1 Applicable Wires See Fig.2 . 5.1.2 Notes for Stripping of Wire End Wire end must be stripped without nick, cutoff, or damage of wire strands. Nick Defective Cut off Defective Damaged Defective Fig.13 Intact and Normal 5.2 Operation of Crimping Machine See the following instruction sheet for automatic terminating machine. 0.64Receptacle 114-5336 2.3Receptacle 5.3 Storage and Handling of Crimped Products (1) Store the products in a clean, dry area, cover with proper sheet or paper when placed in an open area until the next day. (2) Crimped leads should be processed in bundles of less than 100 pieces. Take care of the tangle and damage on the products. (3) Avoid stacking and piling up the in-process products in large volume. Terminal failure and fall of retention force occur by deformation of the terminal. 6. Harness Making 6.1 Female Connector, Wire Cover and Lever, Clip 89/126Pos Plug Housing Assembly Reverse Type 89/126Pos Plug Housing Assembly STD Type 60Pos Plug Housing 74Pos Plug Housing Assembly 112Pos Plug Housing Assembly Assembly Reverse Type THS Reverse Type THS Reverse Type 60Pos Plug Housing Assembly STD Type 112Pos Plug Housing Assembly THS STD Type Fig.14 (To be continued) Rev. F4 9 of 38 Instruction Sheet 411-78084 126Pos Wire Cover Type 126Pos Wire Cover Type 126Pos Wire Cover Type 89Pos Wire Cover Type V 126Pos Wire Cover Type 126Pos Wire Cover Type 70Pos Wire Cover THS Type 126Pos Lever STD Type 60Pos Wire Cover Type 126Pos Lever Reverse Type 60Pos Wire Cover Type 60Pos Lever STD Type 60Pos Lever Reverse Type 89/126Pos Clip Fig.14 (End) Rev. F4 10 of 38 Instruction Sheet 411-78084 6.2 Procedure for Female Terminal Insertion into Housing (1) Confirm the retainer is in pre-assembled condition. See para.6.3. The terminal can not be inserted in final lock condition. (1.4) (0) Pre-locked Condition final-locked Condition Fig.15 (2)Confirm type of plating on the terminal. It must be the same type of plating on the female terminal and on the male terminal. The type of plating can be seen on the customer drawing. NOTE Should not connect the terminals between different types. (3)Confirm the terminal size (0.64, 2.3II). The cavity size of housing can be identified by the shape of cavities. See the customer drawings to know the construction of cavities. Rev. F4 11 of 38 Instruction Sheet 411-78084 Plug Housing Assembly Cavities for 2.3II Receptacle Cavities for 0.64 Terminal 2.3Receptacle 0.64 Receptacle Fig.16 (4) 79/89/126 pos turn the lever bearing to left as shown in Fig.17, and 60 pos insert the crimping side of 0.64/2.3II Receptacle terminal with the lever bearing turned to right and insert terminal into the housing. The insertion is finished when housing lance is locked and the terminal can not be more inserted. If harness has any blanked cavities, dummy rubber plugs must be inserted. Plug Housing Assembly Lever bearing Dummy Wire Seal for 2.3 Cavity Dummy Wire Seal for 0.64 Cavity 2.3II Receptacle 89/126Pos Contact 60Pos Lever bearing 0.64 Receptacle Contact Lever bearing Lever bearing 74Pos Rev. F4 112Pos 12 of 38 Instruction Sheet Crimping side Crimping side 0.64 Receptacle Contact 2.3II Receptacle Contact NOTE 411-78084 Fig.17 Hold the wire so as not to generate the compression buckling of the transformation as you insert the terminal into the plug housing cavity. (5) By pulling the terminal by 20N MAX, check to make sure that the terminal can not be withdrawn. Please lightly push the terminal again after confirming the terminal pull, and make the clearance position into the terminal and housing lance. (6) Please insert Dummy Wire Seal in the position in which 01mm goes out of the upper surface of the cavity. Cavity Dummy Wire Seal 01mm Fig.18 NOTE Please use 1 piece cavity when you use Dummy Wire Seal. The retainer might not close when two or more pieces are put. Rev. F4 13 of 38 Instruction Sheet 411-78084 6.3 Retainer (Final Lock) Operation (1) After insertion of all of the terminals, press the retainer for final lock condition. The final lock operation is finished by confirmation that the retainer is kept in the final condition by the 2 projections. Press retainer through the hole on Plug housing (1.4) (0) Pre-locked Condition Final-locked condition Fig.19 (2) The double lock operation can not be completed if there are any half inserted terminals. When the retainer can not be pressed to the final condition, do not press by force, find the half inserted terminal, and insert it to proper position. See para.6.1. 6.4 The notice regarding semi- installing inspection 6.4.1 The female terminal semi- installing inspection with appearance 1Semi- installing inspection of the female terminal is possible with the fact that floating occurs at the time of retainer installing job. Verifying the floating of the retainer Counter installing inspection state Fig.20 Final-locked condition 6.4.2 The female terminal semi- installing inspection with the increase of the retainer operation load 1The retainer operation load at the time of female terminal semi- installing it is the load above approximately 2 times the normal time vis-a-vis the retainer operation load, semi- installing inspection is possible. 6.4.3 Prevention of semi- installing with female terminal arrangement state 1The peripheral terminal is less crowded terminal not yet installing (and when the cavity) it is state, please verify that primary person in charge stopping catches. NOTE Semi-installing inspection cannot be detected by the fact that draft and float generating when there are some gaps around the peripheral terminal. Please verify that primary person in charge stopping catches. NOTE Rev. F4 When abnormality is discovered, please be sure to exchange with the new item. 14 of 38 Instruction Sheet 411-78084 6.5 Wire cover installation and removal operations 6.5.1 126Pos Type/Type/Type, 89Pos Type, 74Pos Type,60Pos TYPE-Wire CoverRight and Left Lock 1 Set of wire cover When harness installed operations and installation of the retainerfinal lock condition is completed, the wire cover like the below figure, from above is installed to the female housing. Until non- displacement lock section 2 places and lock section 2 places are fixed to the female housing, please install to the direction of the arrow. When installing in order not to catch the wire to the cover, please note. Lock Non- displacement lock Installation Female housing 126Pos Wire Cover Fig.21 Lock Non- displacement lock Installation Female housing 60Pos TYPE- Wire Cover Fig.22 It is work similar as for 74Pos Typeand 126Pos Type/Type . 89Pos Type Rev. F4 15 of 38 Instruction Sheet 411-78084 (2)If the lock of the wire cover like of the below figure the lock on left and right , and the non- displacement lock of the cover is fitted to the female housing, installing the wire cover is completion. Please verify that the left and right lock has mated. Left and right lock position Installing imperfection Completion of installing The lock of the wire cover it is not fixed Left and right nondisplacement lock The lock section of the wire cover has hidden Completion of installing Installing imperfection The non- displacement lock is hitting on the housing. Installing imperfection Completion of installing The non- displacement lock is hitting on the housing. Completion of installing Fig.23 Rev. F4 Installing imperfection 16 of 38 Instruction Sheet 411-78084 3 The removal of the wire cover, while pushing the lock on left and right of the cover to direction of the arrow, to pull up the lock section to on, please unlock the lock. It pulls up to on Lock While pushing the lock, it pulls up to on Fig.24 When it unlocks the lock of the wire cover and passes through from the female housing please pull out to direction of the arrow. The wire cover is pulled out Fig.25 Rev. F4 17 of 38 Instruction Sheet 411-78084 6.5.2 60Pos Type,126Pos TYPE /TYPE Wire CoverOne Side Lock 1 Set of wire cover When harness installed operations and installation of the retainerfinal lock condition is completed, the wire cover like the below figure, the hook is inserted to the installation holes of the female housing. Lock Hook insert to the installation hole Female housing installation holes Hook 60Pos Wire Cover Type Fig.26 Hook Lock Lock insert to the installation hole Hook insert to the installation hole 126Pos Wire Cover Type 126Pos Wire Cover Type Fig.27 Rev. F4 18 of 38 Instruction Sheet 411-78084 (2) While hooking the hook of the wire cover to the installation holes, please install the lock to direction of the arrow. When installing in order not to catch the wire to the cover, please note. Installing the lock Installing the lock Fig.28 (3) If the lock of the wire cover like of the below figure the lock of the cover is fitted to the female housing, installing the wire cover is completion. Please verify that the left and right lock has mated. Installing imperfection Completion of installing The lock section of the cover it is not fixed Installing imperfection Completion of installing Left and right lock Portion of the lock has hidden Fig.29 Rev. F4 19 of 38 Instruction Sheet 411-78084 (4) The removal of the wire cover, while pushing the lock on left and right of the cover to direction of the arrow, to pull up the lock to on, please unlock the lock. It pulls up to on Left and right lock It pulls up to on While pushing the top of the lock, it pulls up to upward direction Lock While pushing the lock, it pulls up to on 126Pos Wire Cover Type 126Pos Wire Cover Type Fig.30 (5) When it unlocks the lock of the wire cover and passes through from the female housing in order for the hook not to be caught, please pull out to direction of the arrow. Female housing In order for the hook not to be caught to the female housing, please pull out 126Pos Wire Cover Type 126Pos Wire Cover Type Fig.31 Rev. F4 20 of 38 Instruction Sheet 411-78084 6.6 Lever Fitting Operation (1) Confirming Slider Position The slider rough sketch position (when the slider lock has caught) please verify that it is. NOTE When the lever is installed when the slider has sprung out there is a possibility of breaking the connector. NOTE Being to be play in the slider, until it hits to stopper, when you push securely, there is a feel. NOTE Reference you ask the point of caution when installing the EFI ECU CONNECTOR PLUG ASSY LEVER. Slider Plug housing Fig.32 (2) Align of Plug Housing Assembly and Lever Confirm the direction of Plug Housing Assembly and Lever as the following figure. Fit the shafts on lever into bearing on Plug housing. And then assemble the lever temporarily parallel to Plug Housing. Rev. F4 21 of 38 Instruction Sheet Lock on Lever 411-78084 Plug Housing Assembly Lever Lever lock position Sliding bearing Plug Housing bearing Lever frame Please make the plug housing and the lever parallel Fig.33 Rev. F4 22 of 38 Instruction Sheet 411-78084 (3) Installation of lever While supporting the bearing subordinate of the plug housing with the index finger of the both hands, with the thumb of the both hands (you hold the lever with the both hands and until in order to be packed) sound does the lever, please push in. Please hold down the plug housing bearing subordinate with one pointing finger of the both hands Lever pushing direction Lever installation state Assembling the lever temporarily Fig.34 NOTE NOTE Please verify that the lever bearing is placed parallel on the bearing of the plug housing. As for installation job of the lever we request the job under normal temperature. 6.7 Installation of clip (1) Please confirm the lever installation work is completed, and the lever is being locked. NOTE NOTE In the state at the previous state of the lever installation, there is a possibility that the installation of the clip becomes hard. Reference you ask the point of caution when installing the EFI ECU CONNECTOR PLUG ASSY CLIP. Lever on lock state Fig.35 (2) Plug housing Assembly is set to the position of the clip. Please match the guide hole of plug housing Assembly and the position of the guide pin of the clip, and unite the clip temporarily. Plug Housing Assembly Guide hole Lock hole 5 REF Guide Lock Clip It fits position, and unites the clip temporarily. Fig.36 NOTE Rev. F4 When abnormality is discovered, please be sure to exchange with the new item. 23 of 38 Instruction Sheet 411-78084 (3) Installation of clip Please push the clip below of plug housing Assembly vertically by the thumb of both hands (you hold the clip with the both hands and until in order to be packed). 1.95 REF Assembling the clip temporarily Press Clip Clip installation state Fig.37 NOTE Please do not add an excessive load when you install the clip. There is a possibility that the connector is damaged. (4) Installation completion of clip Please confirm the lock pin of the clip in the lock hole of plug housing Assembly. Space None space Clip Installing imperfection It doesn't lock It is confirmed to lock. (Two places) Lock section(state of lock) Under such a condition, please do not use it. Lock section Installing imperfection Fig.38 NOTE As for installation job of the clip we request the job under normal temperature. 6.8 Removal operations of clip (1) Release of lever lock Please release the lever lock according to para.6.9, and rotate the lever to the place that becomes vertical for the engagement side. Release of lever lock Fig.39 Rev. F4 24 of 38 Instruction Sheet 411-78084 (2) Removal of clip Please push the hanging part in the point of the lock pin of the clip in the direction of the center of the connector, release the lock, and remove the clip. The lock point is pushed Removal Clip Fig.40 (3) Release removal of clip Please return it to the state of the lever lock after confirming the clip came off from the bearing. The lever is rotated to the state of the lock NOTE Rev. F4 Fig.41 Please the clip recycling cannot not be done, and do not use the clip used once. There is a possibility of not functioning originally when using it again. 25 of 38 Instruction Sheet 411-78084 6.9 Lever removal job (1)Release of lever The back of the lever is lightly pushed While the lever lock is pushed in cancellation direction Please turn the lever to pulling up direction Lever on lock Lever lock release direction Lever pulling up direction The back of Lever NOTE Rev. F4 Fig.42 When the lever was pulled up when the lever lock is not cancelled, there is a possibility the lever lock making break. 26 of 38 Instruction Sheet 411-78084 (2) Release completion of lever The lever it becomes completion of lever cancellation at the place where it becomes vertical mating the surface Fig.43 (3) Removal of lever While turning the lever point to lever axial cancellation direction from cancellation state of the lever, until sound does the lever, please push. Also please verify the lever frame comes off from the bearing of the lever. Lever release direction The bearing of the lever The lever frame Lever release direction Fig.44 Please operate lightly in a direction opposite to cancellation direction after verifying that the lever frame comes off from the bearing of the plug housing, please remove the lever in lever removal direction. Opposite direction cancellation Lever removal Lever removal Opposite direction cancellation NOTE NOTE NOTE Rev. F4 Fig.45 At the time of the lever removal when catching is felt, please verify the lever frame and that the bearing of the plug housing has come off. Please reset the slider after the lever removing to initial position. Please do not let the lever be locked, when you return the lever in a direction opposite to cancellation direction. 27 of 38 Instruction Sheet 411-78084 6.10 How to Extract Retainer Confirm the retainer in pre-locked condition at extracting female terminals. If the retainer is in final-locked condition, the terminal can't be inserted or extracted. Draw out the retainer from final-locked condition to pre-locked condition as the following matters. (1)Insert 1mm precision screwdriver into hole on retainer. (2)Draw out the retainer about 1.4mm, Please verify that stuffing the person in charge stopping section is cancelled. Draw out the retainer Insertion hole for jig After releasing the retainer Before releasing the retainer NOTE NOTE Fig.46 Please do not pull out the retainer above necessity. It becomes cause of damage. Please do not insert the driver other than the jig insertion section. It becomes terminal deformation and cause of rubber damage for sealed. 6.11 How to extract the female terminal (1) Confirm the retainer in pre-locked condition. If the retainer is in final-locked condition, retainer must be changed in pre-locked condition; See para.6.10. The female terminal can not be extracted in final assembled condition. For 0.64 terminal Insert the special extraction tool into the proper hole. Remove the loaded terminal from housing with the crimped wire. Hole for extraction jig Released lance Straight Insertion Fig.47 NOTE Rev. F4 If terminal can't be drawn, pull out the special extraction tool, put back it again by wire and then insert the tool again. Become cause of deformed the tool or housing lance damaged forcedly. Don't repeat this operation more than 10 times, otherwise retention force has fallen. Don't use the tool for retainer extraction. 28 of 38 Instruction Sheet 411-78084 (3) For 2.3Terminal Insert the 1.21.6mm blade precision screwdriver into the proper hole. While referring to Fig.48, canceling the housing lance to pull the electric wire, please pull out the terminal. Driver insertion area Depression housing lance Fig.48 (4) If the female terminal can't be extracted, don't pull the wire by force. Confirm the housing lance is unlocked. Fig.49 NOTE Do not insert the precision screwdriver or extraction jig into the female contact. If you insert this, the contact should be exchanged, not used. 6.12 Control of Harness 6.12.1 Control of Harness Don't apply excess force or shock to the connector and wire. 6.12.2 Taping up wires Tape up the wire at intervals of more than 30mm from the end of housing, not apply excess force to the wires. 30mm MIN. Fig.50 6.12.3 Harness Check (1)Applicable mating half or equivalent product should be used at harness checking. (2)Never insert probe pin into female terminal. The pin must be probed on wire side. NOTE If the probe pin should be inserted, the female terminal must be renewed. 6.12.4 Storage Avoid storing the connector in a moist or dusty place. Stock the connector away from direct sunlight. 6.12.5 Shipping and Carrying The connector should be used with the proper packaging to prevent the ingress of dust, moisture, etc. Rev. F4 29 of 38 Instruction Sheet 411-78084 7. Lever cancellation job before the connector mating (1)The back of the lever is lightly pushed While the lever lock is pushed in cancellation direction Please turn the lever to pulling up direction Lever on lock Lever lock release direction Lever pulling up direction The back of Lever Fig.51 (2) It becomes completion of lever cancellation at the place where it becomes vertical the lever the mating face. NOTE NOTE NOTE NOTE Fig.52 Please do not push the lever lock forcibly. When abnormality is discovered, please be sure to exchange with the new item. When the lever was pulled up when the lever lock is not cancelled, there is a possibility the lever lock making break. Structure that the lever comes off when the lever is turned by 90 degree or more for connector damage prevention. Rotation prohibition of 90 degree or more Rev. F4 30 of 38 Instruction Sheet 411-78084 8. Mating and Extraction of Connector 8.1 Mating connector (1) Check the terminal fitting condition in housing, the position of taping up wire, and retainer final-locked condition. If the retainer is in pre-locked condition, press the retainer to final lock condition as Para.6 (2) Check the defects, deformation, discoloration, damage, rust, crack, deficit, etc. of housing and contact. NOTE Exchange the connector if any defects are found. (3)Insert the proper female connector straightly into the male housing with the direction shown on Fig.53. (4)Rotate the lever as arrow direction, If the operation is finished, you can hear the click sound and can't insert further. Don't apply excess force, if you can't insert into the male housing, and check the items of (1), (2). NOTE Don't apply excess force without the insertion direction at inserting. NOTE Don't nip the wires with lever at lever rotating. NOTE After verifying the male connector boss and that the slider has fallen, please operate the lever in mating. NOTE When at the time of lever operation abnormality is felt, without making fit unreasonably, after resetting one time lever, please do re-operation. push in into the direction of the arrow. Male Connector Boss Slider Fig.53 Rotate the lever as shown Mating direction Mating direction Lever Fig.54 Finish Fig.55 (5)In addition, plug housing is lightly pulled, check that the connector doesn't come off. Rev. F4 31 of 38 Instruction Sheet 411-78084 8.2 Pulling out the connector (1) Please cancel the lever lock of the female connector. In order not to push the lever lock unreasonably, please note. (2) When it can cancel the lever lock, please turn to the point of you open the lever to direction of the arrow, becoming vertical mating the fit aspect. (3) The female housing, the wire cover and the wire - the clamp, please pull out straightly. When it cannot pull out, without pulling unreasonably, please verify that it becomes vertical the lever mating fit direction. NOTE When pulling out, the slider, please do not grasp the lever. NOTE When the wire cover is not with only the electric wire is grasped, please pull out the connector not to give the damage to the electric wire and the seal section. Lever lock cancellation Slider Lever open Lever lock cancellation Lever open Lever Fig.56 Lever cancellation Fig.57 Connector extraction Slider Lever Fig.58 Rev. F4 32 of 38 Instruction Sheet 411-78084 NOTE Don't apply excess force without the insertion direction at unmating Don't pull the wire only Fig.59 8.3 General Attention Matters (1) Don't mate and unmate the connector unnecessarily. (2) Don't insert any objects except the proper connector. (3) Don't apply unnecessary force or shock to the wire and connector at mating and unmating operation. Rev. F4 33 of 38 Instruction Sheet Point of caution when installing the SEALED EFI ECU CONNECTOR PLUG ASSY LEVER 411-78084 Attachment data1 1/3 Lever installation and removal job is recommend to execute in the environment of 10 degrees or more. Please note that the resin might be damaged about work at 0 degree or less. Resets two sliders until hitting to stopper. There is a feeling when securely pushing until it hits the stopper because of idle. The lever is placed in the support section and the lock section naturally. Please verify that the lever of support section is placed parallel on the receiving side of the substance housing. While receiving with the index finger of the both hands, you push it right under with the both hands thumb. At this time, pushes naturally so that the pushed direction should not push outside. Both hands of the thumb are preferable as like left photograph. Rev. F4 34 of 38 Instruction Sheet When removing the lever, note 411-78084 Attachment data1 2/3 4Pushing the button of the lock, you remove the lock. At the time, do not pull on unreasonably before coming off. 5The lever is pulled up gradually. 6There is one time moderation impression at position of 90 degrees and stops. 7Furthermore when it pushes down, power collects all at once until sound does, it falls in additionally and it stops. At this time, it does not keep pushing with force. 8To grip the lever lightly by the hand without connector, pull it forward, you remove from the support section. Rev. F4 35 of 38 Instruction Sheet 411-78084 Attachment data1 3/3 9At this time, removes for the feeling lightly pulled without power. When movement such as caught is not smooth during work, does again without forcibly pulling. 10The lever comes off lightly. Rev. F4 36 of 38 Instruction Sheet Point of caution when installing the SEALED EFI ECU CONNECTOR PLUG ASSY CLIP 411-78084 Attachment data2 1/2 Lever installation and removal job is recommend to execute in the environment of 10 degrees or more. Please note that the resin might be damaged about work at 0 degree or less. Please confirm doing to the installation of the lever by the harness manufacturing work. The clip is naturally put on the installation position of plug assembly. It pushes it the right under by the both hands thumb while receiving it by person finger of both hands. It pushes naturally so that there is no direction pushed at this time for outside. Both hands of the pushed thumb are as preferable as that of a left photograph. Rev. F4 37 of 38 Instruction Sheet 411-78084 Attachment data2 2/2 When removing the Clip, note The lever is released according to the Instruction sheet. The lock point of the clip is pushed internally With a tool etc. At this time, please note that the lock point is pushed so as not to damage the main body of the connector. Lock section The clip comes off lightly. The clip cannot be used again when the connector is used again, and exchange it for the new item, please. After the clip removing, the lever is locked. Rev. F4 38 of 38