MX123 Connection System
MX123 Connection System
User Manual
User Manual
Revision B
Revision B –
–October 22, 2009
October 22, 2009
MX123 Connection System User Manual - AS-34566-001 Rev B 2
Table of Contents
Section 1: Product Introduction
Section 2: Product Summary
Section 3: Harness Assembly Instructions
Section 4: Connector Mating Instructions
Section 5: Service Instructions
Section 6: Electrical Continuity Checking
Section 7: Tool Ordering Information
Section 8: Revision History
Section 9: Files
Section 10: Appendix A - Document Change History
Section 11: Appendix B - Cleaning Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 3
The Molex MX123 Connection System is a sealed system consisting of a
header/controller, mating connectors, and terminals with the following
configuration options:
A. 80-Ckt ~ (80) 0.64mm terminals
B. 73-Ckt ~ (72) 0.64mm and (1) 2.8mm terminals
C. 56-Ckt ~ (56) 0.64mm terminals
D. 49-Ckt ~ (48) 0.64mm and (1) 2.8mm terminals
HIGHLIGHTS:
This system has multiple keying options.
Ground blade engages before signal pins contact.
Connector is friendly to “blind-mate” conditions.
Connector provides temporary retention to the header before the cam assist
lever arm is activated.
Cam assist lever arm remains in pre-lock position until the harness
connector is in pre-lock position on the header/controller.
CPA remains in pre-lock position until cam assist lever arm is locked closed.
Available with molded-in grommet seal plugs for harness customization.
Section 1: Product Introduction
MX123 Connection System User Manual - AS-34566-001 Rev B 4
Lever
Slides
Dress Cover
(Shipped Separately)
Grommet Seal
Connector Position
Assurance (CPA)
Connector Housing
Terminal Position
Assurance (TPA) Perimeter Seal
Grommet Cap
Section 2: Product Summary: 73/80-Ckt
MX123 Connection System User Manual - AS-34566-001 Rev B 5
Section 2: Product Summary: 49/56-Ckt
49/56
49/56-
-Ckt Exploded View
Ckt Exploded View
Lever
Slides
Dress Cover
(Shipped Separately)
Connector Position
Assurance (CPA)
Grommet Seal
Grommet Cap
Perimeter Seal
Terminal Position
Assurance (TPA)
Connector Housing
MX123 Connection System User Manual - AS-34566-001 Rev B 6
Section 2: Product Summary
MX64 Receptacle Terminal
Correct Orientation 90° Misorientation
Lock-out
180° Misorientation
Lock-out
Orientation Tab
Orientation of receptacle terminal during insertion to grommet cap
MX123 Connection System User Manual - AS-34566-001 Rev B 7
Section 2: Product Summary
MX64 Receptacle Terminal
Terminal Grip Code “A”:
22 GA. Wire
Terminal Grip Code “B”:
18/20 GA. Wire
Grip Codes
Visibly Bigger!
MX123 Connection System User Manual - AS-34566-001 Rev B 8
Section 2: Product Summary
2.80mm Receptacle Terminal
(Yazaki Terminal and Cable Seal)
7116-4152-02 Yazaki 2.8mm RCPT TERM Tin 14 Cable Seal
Correct Orientation 180°Misorientation
Lock-out
90°Misorientation
Lock-out
Orientation Tabs
Orientation of receptacle terminal during insertion to grommet cap
MX123 Connection System User Manual - AS-34566-001 Rev B 9
Rectangular cross-section to
prevent mis-orientation into
the grommet seal cover.
Shoulder area provides
forward stop.
Sealing surface
Lock tabs to provide seal
plug retention to
grommet seal cover
.
Rectangular head for ease of
removal from grommet seal
cover.
Section 2: Product Summary
Grommet Seal Plug – Features
Molex Part 34586-0001
MX123 Connection System User Manual - AS-34566-001 Rev B 10
Section 2: Product Summary
73/80-Ckt “As Shipped” 49/56-Ckt “As Shipped”
Harness connector
assembly shipped with TPA
& lever in pre-lock position.
Lever will remain in pre-lock
until mated with
header/controller, or a force
over 190N is achieved.
If lever moves freely from
pre-lock position without
being mated to
Header/Controller:
Do Not Use Connector!
Dress Cover Shipped
Separately.
MX123 Connection System User Manual - AS-34566-001 Rev B 11
Section 3: Harness Assembly Instructions
A. TPA shown in “As Shipped” position
TPA to remain in pre-lock position (as shipped) until all terminals are loaded
(Figs. 3-1 and 3-2). TPA is not to be removed from connector!
Views of TPA in “Pre-Lock” Position
Fig. 3-1
Section View
Fig. 3-2
5.0mm
5.0mm
TYP.
TYP.
MX123 Connection System User Manual - AS-34566-001 Rev B 12
80 way Molex
Wire tie area
Section 3: Harness Assembly Instructions
73 way Molex
Wire tie area
56 way Molex
Wire tie area
WIRE BUNDLE SIDE
20 40 60 80
19 39 59 79
18 38 58 78
17 37 57 77
16 36 56 76
15 35 55 75
14 34 54 74
13 33 53 73
12 32 52 72
11 31 51 71
10 30 50 70
9 29 49 69
8 28 48 68
7 27 47 67
6 26 46 66
5 25 45 65
4 24 44 64
3 23 43 63
2 22 42 62
1 21 41 61
WIRE BUNDLE SIDE
52 72
51 71
50 70
49 69
16 32 48 68
15 31 47 67
14 30 46 66
13 29 45 65
12 28 44 64
11 27 43 63
10 26 42 62
9 25 41 61
8 24 40 60
7 23 39 59
6 22 38 58
5 21 37 57
4 20 36 56
3 19 35 55
2 18 34 54
1 17 33 53
73
WIRE BUNDLE SIDE
14 28 42 56
13 27 41 55
12 26 40 54
11 25 39 53
10 24 38 52
9 23 37 5
8 22 36 50
7 21 35 49
6 20 34 48
5 19 33 47
4 18 32 46
3 17 31 45
2 16 30 44
1 15 29 43
80-Ckt 73-Ckt
56-Ckt
B. Connector Circuit Locations
WIRE BUNDLE
SIDE SHOWN
MX123 Connection System User Manual - AS-34566-001 Rev B 13
C. Terminal Installation
For ease of assembly, it is recommended that when populating the
connector, wires be populated in the following manner (see Fig 3-3): 1) Fully
populate down Column 1 and then 2) continue on to Column 2 and so forth
until the entire connector is populated. Refer to Fig 3-4 for proper terminal
orientation.
0.64mm Orientation
Orientation Tab
Section 3: Harness Assembly Instructions
Align terminal orientation tab
with slot in grommet cap
opening to install the terminal
Fig. 3-3
Column1
Column1
Column2
Column2
Fig. 3-4
MX123 Connection System User Manual - AS-34566-001 Rev B 14
C. Terminal Installation (continued)
With TPA still in pre-lock position, orient terminal to rear of connector.
Grip the wire (Fig. 3-5) and insert terminal through appropriate circuit
opening (Fig. 3-6). If resistance is encountered, retract the terminal and
adjust the angle of insertion. Continue inserting the terminal until it stops
and locks up on the lock finger with an audible click. Tug slightly on wire to
ensure terminal is locked.
Section 3: Harness Assembly Instructions
Fig. 3
Fig. 3-
-5
5Fig. 3
Fig. 3-
-6
6
MX123 Connection System User Manual - AS-34566-001 Rev B 15
D. Wire Dressing Method
After inserting a terminal, bend the wire as close to the grommet cap as
possible and position as shown below. Continue populating terminals as
necessary.
Section 3: Harness Assembly Instructions
1
12
23
3
4
45
56
6
MX123 Connection System User Manual - AS-34566-001 Rev B 16
* Molded-in or single grommet seal plugs are used to seal unused circuit locations.
NOTE! Molded-in grommet seal plug knockout patterns will vary based on
application specific circuit locations. Single grommet seal plugs may still need to
be used to seal circuits without molded-in seal plugs.
Section 3: Harness Assembly Instructions
E. Grommet Seal Cover - Knockout Patterns
Cavities Open For Circuits Molded-in grommet seal plugs
MX123 Connection System User Manual - AS-34566-001 Rev B 17
Section 3: Harness Assembly Instructions
F. Grommet Seal Plug Installation
Step 1: Orient seal plug to the
opening in the grommet cap. Plug
should not be installed when
rotated 90 degrees from proper
orientation.
Step 2: Hold head of seal plug
securely to prevent rotation
during assembly.
Step 3: Push seal plug until it
locks into position into the
grommet cap.
Step 4: Verify that seal plug
shoulder is flush with grommet
cap as shown in cavities 33 and
53.
MX123 Connection System User Manual - AS-34566-001 Rev B 18
G. TPA - Seating
With the terminals fully installed, the TPA can be seated into its final lock
position by applying an even force to both ends (Fig. 3-7) until it comes to a
stop (Fig. 3-8). If the TPA resists, it may be detecting a partially installed
terminal. Pull the TPA back into its pre-lock position and make sure all
terminals are fully seated. Upon completion, the TPA can be seated.
Section 3: Harness Assembly Instructions
Fig. 3-7 Fig. 3-8
MX123 Connection System User Manual - AS-34566-001 Rev B 19
H. Wire Bundle Dressing
After seating the TPA, insert a tie-wrap around the connector (Fig. 3-9) and
around the wire bundle as shown (Fig. 3-10).
While clasping the wire bundle and connector firmly, tighten the tie-wrap
securely around the bundle using an appropriate tie-wrap gun to meet the
specifications listed in Table 1 (next page) and shown in Fig. 3-11 and Fig. 3-
12 (next page).
Fig. 3-9 Fig. 3-10
Section 3: Harness Assembly Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 20
H. Wire Bundle Dressing (continued)
Wire Bundle Height and Width Specifications
GM Part No. Molex Part No. Description Height (H) Width (W)
73/80 Ckt ≤44 mm ≤24 mm
49/56 Ckt ≤43 mm ≤24 mm
12582676
12582679 34575-0003
34565-0003
Section 3: Harness Assembly Instructions
Fig. 3-11 Fig. 3-12
H
HW
W
Table 1: Dress Cover part numbers
MX123 Connection System User Manual - AS-34566-001 Rev B 21
I. Dress Cover Installation
After tie-wrapping the wire bundle, install dress cover by inserting the front
of the dress cover into the connector housing (Fig. 3-13) and pushing the
opposite end (Fig. 3-14) until it snaps into position. Fully seated dress cover
and TPA can be verified by ensuring MAX. height dimension (Fig. 3-14).
Step 1: Insert front end into housing. Step 2: Press down to lock position.
Fig. 3-13 Fig. 3-14
Section 3: Harness Assembly Instructions
47.8mm
MAX.
Top of dress cover to bottom
of fully seated TPA
MX123 Connection System User Manual - AS-34566-001 Rev B 22
Section 4: Connector Mating Instructions
A. Harness Connector To Header/Controller Color Identification
The harness connector TPA will be color-coded to match the appropriate
controller header (Fig. 4-1).
TPA
Header/Controller
Fig. 4-1
MX123 Connection System User Manual - AS-34566-001 Rev B 23
B. Harness Connector to Header/Controller Installation Into Pre-Lock
Correctly orient the harness connector (align keying features) onto the
controller connector (Fig. 4-2). Grip the top of the harness connector and
evenly push the connector downward until the lever moves slightly forward
(Fig. 4-3).
Align
Keying
Features
Align Keying Features
Fig. 4-2 Fig. 4-3
Section 4: Connector Mating Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 24
Caution!
Installing the harness
connector at an extreme
angle (see fig 4- 4 ) may
result in seal “scooping”
creating an environment
for fluid ingress.
Damage to the header, or
connector is possible if
excessive force is used.
Section 4: Connector Mating Instructions
Fig. 4- 4
MX123 Connection System User Manual - AS-34566-001 Rev B 25
C. Harness Connector to Header/Controller Mating To Final Lock
To begin mating the harness connector to the header/controller, place the
palm of your hand on the face of the lever. Push back the connector lever
towards the wire bundle to engage the harness connector to the controller
header (Fig. 4- 5). Mating force should be smooth and continuous. If not,
remove the connector and repeat step B.
Continue to rotate the lever arm (Fig. 4- 6).
Fig. 4-6Fig. 4-5
Section 4: Connector Mating Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 26
C. Harness Connector to Header/Controller Mating To Final Lock (continued)
Continue to rotate the lever until you hear the primary latch click into final lock
over dress cover primary latch (Fig. 4-7a and 4-7b).
Primary Latch Engaged
Dress Cover Primary Latch
Fig. 4-7a Fig. 4-7b
Section 4: Connector Mating Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 27
D. Connector Position Assurance (CPA)
With the harness connector lever arm in its latched position, the CPA can
now be engaged. Push the CPA toward the wire bundle (Fig. 4- 8) until it
clicks into its final locked position (Fig. 4-9).
Fig. 4-8 Fig. 4- 9
Section 4: Connector Mating Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 28
Section 5: Service Instructions
A. Harness Connector Removal From Module
To un-mate the harness connector from the header/controller, push the CPA
away from the wire bundle. Depress the primary latch on the top of the
harness connector so the lever arm releases from the harness connector
(Fig. 5-1).
Fig. 5-1
Primary Latch
NOTE: For soiled or in-service ECM’s, please refer to Section 11 (Appendix B):
Cleaning Instructions prior to commencing the following procedures.
MX123 Connection System User Manual - AS-34566-001 Rev B 29
Section 5: Service Instructions
A. Harness Connector Removal From Module (continued)
Push the top of the mate lever arm away from wire bundle using the palm of
your hand (Fig. 5-2).
Continue to rotate the lever until the connector lifts into pre-lock (Fig. 5-3).
The lever MUST be in the pre-lock position or the connector can not be easily
removed from the module. The lever must be fully forward for the harness
connector to be in pre-lock position.
Fig. 5-2 Fig. 5-3
MX123 Connection System User Manual - AS-34566-001 Rev B 30
Section 5: Service Instructions
A. Harness Connector Removal From Module (continued)
While pushing forward on the lever, grip the back of the harness and evenly
pull straight upwards and away from the module (Fig. 5-4).
Fig. 5-4
2
1
MX123 Connection System User Manual - AS-34566-001 Rev B 31
Section 5: Service Instructions
B. Dress Cover Removal
With the harness connector removed from header/controller (Fig. 5-5),
unlatch the dress cover latch features on each side of the dress cover guide
(Fig. 5-6). A small screwdriver or similar tool can be used to release the
latches.
Latch Feature
on each side
Fig. 5-5 Fig. 5-6
MX123 Connection System User Manual - AS-34566-001 Rev B 32
Section 5: Service Instructions
B. Dress Cover Removal (continued)
With the dress cover latch features unlatched, insert your finger into dress
cover (Fig. 5-7) and pull up and away from the wire bundle. The dress cover
can be completely removed at this point (Fig. 5-8).
Fig. 5-7 Fig. 5-8
MX123 Connection System User Manual - AS-34566-001 Rev B 33
Section 5: Service Instructions
C. Tie-Wrap Removal
The tie-wrap can now be removed from the wire bundle (Fig. 5-9) for easier
access to the wire to be serviced. The tie-wrap MUST be cut under the wire
dress tab to prevent damage to the wires!
Do not cut near wires!
Fig. 5-9
MX123 Connection System User Manual - AS-34566-001 Rev B 34
Section 5: Service Instructions
D. TPA Servicing
TPA should never be removed from the connector.
Step 1: Insert a small (2.0mm maximum) flat blade screwdriver into the TPA
service hole at one end of the connector (Fig. 5-10) and pry up. The TPA will
stop when it reaches its pre-lock position for terminal servicing.
Step 2: On the other end of the TPA, repeat Step 1 (Fig. 5-11) until the TPA
reaches its pre-lock position at both ends of the harness connector.
Approximate TPA travel will be 5.0mm (See Figs. 5-12 and 5-13 on next page).
Step 1: Pry up TPA Step 2: Pry up opposite end of TPA
Fig. 5-10 Fig. 5-11
12
MX123 Connection System User Manual - AS-34566-001 Rev B 35
Views of TPA in “Pre-Lock” Position
Section 5: Service Instructions
D. TPA Servicing (continued)
5.0mm
Fig. 5-12
5.0mm
Fig. 5-13
MX123 Connection System User Manual - AS-34566-001 Rev B 36
Section 5: Service Instructions
E. MX64 Receptacle Terminal Removal
Ensure TPA is in pre-lock position!
Holding the 0.64mm service tool (Fig. 14: Molex part no. 63813-1400 or alternate GM part
no. J-38125-213) between middle finger and thumb, with index finger on top of the tool,
insert the tip of the tool into the terminal service hole adjacent to the terminal to be
serviced (Fig. 5-15).
After first pushing the wire/terminal forward, use your index finger to push the service
tool (Fig. 5-15) until a large amount of resistance is felt. This wedges the service tool
between the terminal and the lock finger, therefore deflecting the lock finger. (Fig. 5-16).
Fig. 5-14 Fig. 5-15
Receptacle Terminal
Service Tool
Lock Finger
Fig. 5-16
MX123 Connection System User Manual - AS-34566-001 Rev B 37
E. MX64 Receptacle Terminal Removal (continued)
Fig. 5-17a shows proper insertion of the service tool. Avoid inserting the
service tool into the terminal opening (Fig. 5-17b) as this may damage the
terminal.
Proper Insertion Incorrect Insertion
Fig. 5-17a Fig. 5-17b
WRONG!
Section 5: Service Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 38
E
.
MX64 Receptacle Terminal Removal (continued)
Once the terminal lock finger has been disengaged, transfer middle finger and
thumb to connector housing, while maintaining index finger pressure on the
tool. Pull on the wire to remove the terminal (Fig. 5-18). If the terminal resists,
the service tool may not be fully engaged. Repeat the servicing instructions,
starting at page 33.
Do not use excessive force. Excessive force can damage the lock finger. Do
not apply any lateral force. The lock finger is displaced by linear insertion
alone.
Fig. 5
Fig. 5-
-18
18
Section 5: Service Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 39
F. MX64 Grommet Seal Plug Removal
Step 1. Remove dress cover to access the 0.64mm grommet seal plugs
Step 2. Use needle nose pliers to hold head of 0.64mm grommet seal plugs.
Step 3. Pull grommet seal plug out of back of grommet cap.
Do not re-use grommet seal plug once it has been removed!
Head
Section 5: Service Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 40
Section 5: Service Instructions
G. 2.80mm Receptacle Terminal Removal
While pushing the terminal forward, insert the 2.80mm service tool (Yazaki
p/n X39899-J374). Insert the tip into the terminal service opening (Fig. 5-19).
Avoid inserting the service tool into the terminal opening (Fig. 5-19a). This
may cause damage to the 2.80mm terminal.
Proper Insertion
Fig. 5-19 Fig. 5-19a
Improper Insertion
WRONG!
MX123 Connection System User Manual - AS-34566-001 Rev B 41
G. 2.80mm Receptacle Terminal Removal (continued)
Once the tool is inserted into the terminal service opening, push the service
tool (Fig. 5-20) until it wedges between the female terminal and the lock finger
(Fig. 5-21).
Service Tool
Lock Finger
Section 5: Service Instructions
Fig. 5-20 Fig. 5-21
Female Terminal
MX123 Connection System User Manual - AS-34566-001 Rev B 42
Section 5: Service Instructions
G. 2.80mm Receptacle Terminal Removal (continued)
Once the terminal lock finger is disengaged, pull on the wire (Fig. 5-22) to
remove the terminal. If the terminal resists, the service tool may not be fully
engaged. Push the service tool further into the service hole to ensure that it
has disengaged the terminal lock finger.
Fig. 5-22
MX123 Connection System User Manual - AS-34566-001 Rev B 43
Section 5: Service Instructions
H. Terminal Crimping
If the 0.64mm receptacle terminal needs to be replaced, a new one can be
hand crimped using GM Crimp Tool #XX019825 or Molex Crimp Tool #63811-
4200.
3.) Insert the wire until the wire
hits the wire stop. Squeeze the
handles through the last “click”
until they release.
1.) Identify the wire gauge you need
to crimp. Notice the rectangular
shape of the terminal cavity.
2.) Insert the correct terminal
and press the wire-stop down.
MX123 Connection System User Manual - AS-34566-001 Rev B 44
Section 5: Service Instructions
J. Completing Assembly of Serviced Product
For steps required to complete the assembly of this product, please refer
to Section 3 of this manual.
I. Terminal Crimping (continued)
Contact Molex for terminal sales drawings. Hand crimp instructions, strip
length recommendations, and crimp height requirements are available in
the Molex Spec. Sheet for Tool #63811-4200.
If the Yazaki 2.80mm receptacle terminal needs to be replaced, a new one
can be hand crimped with the appropriate cable seal using crimp tools #J-
38125-6 and #J-38125-7. These tools can be ordered from SPX Kent-Moore
(1-800-345-2233).
MX123 Connection System User Manual - AS-34566-001 Rev B 45
Spherical Tip
5.75 mm
0.53 mm
TPA Stop Surface
Section 6: Electrical Continuity Checking
A. Pogo Pin Recommendation - 0.64mm Terminal
Pogo Pin Specification – See next page.
MX123 Connection System User Manual - AS-34566-001 Rev B 46
Probe Pin Details (0.64mm terminal)
Manufacturer: Lone Star Industrial
Part number: LS040RS-ELW-277-N-4.7
Pin diameter: 0.020” (0.53 mm)
Tip shape: Spherical
Tel: (915) 779-7255
Section 6: Electrical Continuity Checking
POGO PIN
A. Pogo Pin Recommendation - 0.64mm Terminal (continued)
LS040RS
LS040RS-
-ELW
ELW-
-277
277-
-N
N-
-4.7
4.7
MX123 Connection System User Manual - AS-34566-001 Rev B 47
Spherical Tip
7.40 mm
0.76 mm
TPA Stop Surface
Section 6: Electrical Continuity Checking
B. Pogo Pin Recommendation – 2.8mm Terminal
Pogo Pin Specification – See next page.
MX123 Connection System User Manual - AS-34566-001 Rev B 48
Probe Pin Details (2.8mm terminal)
Manufacturer: Lone Star Industrial
Part number: LS054RS-ELW314
Pin diameter: 0.030” (0.76mm)
Tip shape: Spherical
Tel: (915) 779-7255
Section 6: Electrical Continuity Checking
B. Pogo Pin Recommendation – 2.8mm Terminal (continued)
LS054RS
LS054RS-
-ELW314
ELW314
POGO PIN
MX123 Connection System User Manual - AS-34566-001 Rev B 49
2.54
2.54
6.52
2.54 Typ.
44.45
2.80 Pogo
Test Pogo Pin Probing Array
Test Pogo Pin Probing Array
Section 6: Electrical Continuity Checking
C. Pogo Pin Layout Recommendation (73-way)
MX123 Connection System User Manual - AS-34566-001 Rev B 50
Molex Receptacle connector Opening for probe pin/male terminal
Check electrical continuity on the terminal by inserting probe pin down
the center of receptacle TPA opening.
Section 6: Electrical Continuity Checking
D. Pogo Pin / Probe Opening
MX123 Connection System User Manual - AS-34566-001 Rev B 51
When testing the connector for continuity, it is imperative that you do
not damage the terminals!
Pogo pins should be checked for damage or sticking several times a shift:
First, a visual inspection of all the pins for damage should be performed.
Next, a testing block should be used to depress all the pogo pins up into
the barrel. If there is a bent or sticking pin, it should remain stuck in the
barrel of the pogo pin. A damaged or stuck pin should be replaced
before any additional testing is performed.
Section 6: Electrical Continuity Checking
E. Recommendations
Probing damage can occur…
If a sharp-ended probe is inserted into the terminal. This may damage
the plating and increase contact resistance.
If an oversized diameter probe is inserted into the terminal. This will
overstress the beam in the terminal, creating an environment for
intermittent contact and/or increased electrical resistance.
If a probe is inserted into the terminal at an angle or off center. This
may damage the terminal and/or the connector.
MX123 Connection System User Manual - AS-34566-001 Rev B 52
F. Manual Probing of the Connector
If the connector must be probed off-line, please use:
–
GM probe tool #J-35616-64B for the 0.64mm terminal, and
#J-35616-65B for the ECM pins. (Fig. 6-1).
–
GM probe tool # J-35616-4A for the 2.80mm terminal (Fig. 6-1).
Insert the probe through the terminal opening as shown in Fig. 6-2.
Fig. 6-2
Section 6: Electrical Continuity Checking
Fig. 6-1
MX123 Connection System User Manual - AS-34566-001 Rev B 53
Manual probing damage can occur…
If a probe is inserted into the back of the connector. This may
damage the wire seal, creating an environment for fluid ingress.
F. Manual Probing of the Connector
Section 6: Electrical Continuity Checking
If the wire insulation is pierced or chafed. This may create a leak-
path for fluid ingress and/or wire corrosion.
WRONG!
WRONG!
MX123 Connection System User Manual - AS-34566-001 Rev B 54
Contact your Molex Inside Sales Representative at (800) 786-6539.
For electronic copies and future updates of this document, refer to
the Molex Website at http://www.molex.com/ind/mx123.html.
Section 7: Tool Ordering Information
Tool Description Molex Part No. GM or Supplier Part No.
0.64mm Service Tool 63813-1400 XX019826
2.80mm Service Tool - Yazaki P/N X39899-J374
0.64mm Probe Tool - J-35616-64B, J-35616-65B
2.80mm Probe Tool - J-35616-4A
0.64mm Hand Crimp Tool 63811-4200 XX019825
2.80mm Hand Crimp Tool - J-38125-6 : SPX #12085270
J-38125-7 : SPX #12085271
MX123 Connection System User Manual - AS-34566-001 Rev B 55
Revision Level Publication Date
B Oct 22, 2009
9 (same as revA) Dec 1, 2006
8 July 22, 2005
7 Feb 15, 2005
6 Aug 20, 2004
5 Jan 16, 2004
4 Oct 13, 2003
3 Sept 15, 2003
2 Sept 5, 2003
1 June 16, 2003
Section 8: Revision History
MX123 Connection System User Manual - AS-34566-001 Rev B 56
Section 10 (Appendix A): Document Change
History
• Rev 1: Initial Release
• Rev 1 to Rev 2:
– Modified the Connector Mating and Unmating Procedure
– Updated and Released Only Sections 4 and 5
• Rev 2 to Rev 3:
– Updated the Connector Mating and Unmating Procedure Based on Customer Input
– Updated and Released Only Sections 4 and 5
• Rev 3 to Rev 4:
– Incorporated the Connector Modified Mating Procedure into the Full Reference Manual
• Rev 4 to Rev 5:
– Revised Section 4 – Connector Mating Instructions
– Revised Section 5 – Service Instructions
– Added Appendix A – Document Change History
– Added Appendix B – Connector Mating Instructions – Modified Mating Procedure
– Added Appendix C – Service Instructions – Modified Unmating Procedure
• Rev 5 to Rev 6: Production Copy
– Revised All Sections for Production Release
• Rev 6 to Rev 7:
– Revised Multiple Sections with Formatting Updates .
– Revised Section 5: Terminal Crimping.
– Revised Section 5: Harness Connector Removal from Module.
– Revised Section 6. Added Pogo Pin and Probing Recommendations.
– Added Section 7: Tool Ordering Information.
• Rev 7 to Rev 8:
– Revised Section 2: Product Summary
– Revised Section 5: Servicing Instructions
– Added Appendix B: Cleaning Instructions
• UG Models Available Through GM IMAN
• Molex Drawings Available Through Molex Sales
Section 9: Files
MX123 Connection System User Manual - AS-34566-001 Rev B 57
Section 11 (Appendix B): Cleaning Instructions
STEP 1: While the ECM connection is secure, use a small squirt bottle to squirt
water liberally and directly onto the connector slides and around all
exposed surfaces, top and bottom, to loosen dirt, grit, and small
rocks. The area around the CPA and primary latch should also be
sprayed off. The more water used, the cleaner it will become. Do not
attempt to un-mate any connectors until Step 4.
Water stream paths
Repeat Step 1
until there is no
visual evidence
of dirt, grit, or
other debris.
MX123 Connection System User Manual - AS-34566-001 Rev B 58
STEP 2: Use high pressure air to remove loosened debris. Direct air pressure
around connector slides and all exposed surfaces, top and bottom. When
done, ECM and connectors should be visibly dry and debris free. Do not
attempt to un-mate any connectors until Step 4.
Air stream paths
Repeat Step 2
until there is no
visual evidence
of dirt, grit, or
other debris.
Section 11 (Appendix B): Cleaning Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 59
“Gritty” slides “Clean” slides
Enlarged area to show detail
Section 11 (Appendix B): Cleaning Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 60
STEP 3: Carefully remove any remaining debris from the slide area with a small
brush. Do not attempt to un-mate any connectors until Step 4.
STEP 4: You will need to start to cycle the lever arm to determine if you have
excessive resistance. If lever arm binds, or resistance is felt. Repeat steps
1, 2, and 3 until the connector is visibly clean and offers little resistance to
un-mating.
Step 1 Step 2
Section 11 (Appendix B): Cleaning Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 61
STEP 5: If excessive resistance is felt while un-mating the connector, continue
cleaning connector with the lever arm raised to the point of resistance as
shown below. Rotating the lever arm back and forth will help loosen
additional debris.
STEP 6: Repeat Steps 1 through 5 until you can un-mate the connector with little
resistance.
Water and Air Spray Paths
Water and Air Spray Paths
DO NOT APPLY WATER TO ANY
ECM ASSEMBLY IF
ANY CONNECTORS ARE
UN-MATED FROM THE ECM
HEADERS!
Section 11 (Appendix B): Cleaning Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 62
STEP 7: Once the connector is removed, inspect for damage and grit. Additional
cleaning of the connector housing may be necessary. To avoid dropping
grit into terminal openings clean connector with the TPA facing the
ground. Using a clean damp (NOT DRIPPING WET) paper towel or rag,
brush off the heavy deposits. This effort should be directed at the
connector housing, not the TPA or terminal openings.
“Gritty” J2 Connector
DO NOT APPLY WATER TO TPA OR EXPOSED TERMINAL OPENINGS!
“Cleaned” J2 Connector
DO NOT WIPE HERE
CLEAN HERE
Section 11 (Appendix B): Cleaning Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 63
STEP 8: After connector removal, additional cleaning of the ECM header may be
necessary. The amount of dirt pictured on the left below is unacceptable.
Using a damp (NOT DRIPPING WET) clean paper towel or rag, brush off
the heavy deposits. This effort should be directed at the outside of the
ECM header, not the internal area where the terminal pins are.
STEP 9: Blow off with high pressure air to dry and remove any grit particles inside
the header.
“Gritty” ECM Header
DO NOT
APPLY
WATER TO
HEADER
PINS OR
EXPOSED
CONTACT
AREAS
“Cleaned” ECM Header
Section 11 (Appendix B): Cleaning Instructions
MX123 Connection System User Manual - AS-34566-001 Rev B 64
STEP 10: Once the connector is in pre-stage, use a few drops of water to lubricate
the slides while re-mating. This will limit any potential binding.
Arrows show where to place drops of water
Section 11 (Appendix B): Cleaning Instructions
