Terminal Removal Procedure

Fig 1: View Of Typical Kostal Connector

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View of typical connector.

Fig 2: View Of Connector In Released Position

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View of connector in released position.

1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position.
2. Disconnect the connector from the component.
Fig 3: Using Small Flat-Blade Tool To Remove Dress Cover
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3. Use a small flat-blade tool to remove the dress cover.
Fig 4: Sliding Dress Cover Forward & Off Of Kostal Connector (Glow Plug Control Module)
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4. Slide the dress cover forward and off of the connector.
Fig 5: Locating TPA In Front & Rear Of Connector
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
NOTE:

The front TPA cannot be removed from the connector. Only move it to the preset position.

6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm).
Fig 6: Using Small Flat-Blade Tool To Remove Rear TPA
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7. Use a small flat-blade tool to completely remove the rear TPA from the connector.
Fig 7: Releasing Terminals
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8. Use the J-38125-24 or the J-38125-560 tool to release the terminals by inserting the tool into the terminal release cavity.
9. 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.
10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) , Repairing Connector Terminals (Terminal Repair)  procedure.