Bosch Connectors BSK

Special Tools

For equivalent regional tools, refer to Special Tools.

Terminal Removal Procedure

1. Disconnect the connector from the component.
2. Remove the wire dress cover, if necessary.
3. Push the wire side of the terminal that is being removed toward the connector and hold it in position.



4. Insert the EL-38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.

Terminated Lead Repair

1. Remove the terminal.
2. Find the appropriate terminated lead.
3. Use the appropriate splice sleeves depending on the gage size.
4. Refer to Splicing Copper Wire Using Splice Sleeves.

Bosch Connectors 0.64

Special Tools

For equivalent regional tools, refer to Special Tools.

Terminal Removal Procedure

1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel.
2. Disconnect the connector from the component.
3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover.
4. Place the connector locking lever in the center of the connector.



5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up.



6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up.
7. Remove the dress cover.
8. Cut the tie wrap on the wire bundle.



9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in position.



11. Insert the EL-38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.

Terminated Lead Repair

1. Remove the terminal.
2. Find the appropriate terminated lead.
3. Use the appropriate splice sleeves depending on the gage size.
4. Refer to Splicing Copper Wire Using Splice Sleeves.

Terminal Replacement Procedure

1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector.
2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector.
3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing.
4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.

Bosch Connectors 2.8 JPT

Special Tools

For equivalent regional tools, refer to Special Tools.

Terminal Removal Procedure

1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel.
2. Disconnect the connector from the component.
3. Remove the wire dress cover, if necessary.
4. Push the wire side of the terminal that is being removed toward the connector and hold it in position.



5. Insert the EL-38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.

Terminated Lead Repair

1. Remove the terminal.
2. Find the appropriate terminated lead.
3. Use the appropriate splice sleeves depending on the gage size.
4. Refer to Splicing Copper Wire Using Splice Sleeves.

Bosch Connectors ECM

Special Tools

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.



2. Disconnect the connector from the component.



3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover.



4. The terminal positive assurance (TPA) is located in the front of the connector.



5. Use a small flat-blade tool to remove TPA from the connector.



6. Use the EL-38125-213 or the EL-38125-556 tool to release the terminals by inserting the tool into the terminal release cavity.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector.

Terminated Lead Repair

Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component.

1. Remove the terminal.
2. Find the appropriate terminated lead.
3. Use the appropriate splice sleeves depending on the gage size.
4. Refer to Splicing Copper Wire Using Splice Sleeves.