 The connector on the engine control unit has more than 100 wires. |
In the past, unreliable connectors have been the source of many electrical problems. Connectors have to be waterproof (modern connectors have several seals to keep out moisture), corrosion proof and provide good electrical contact for the life of the vehicle.
The connector pictured below is an eight-terminal connector -- it connects eight wires to each other.
 The parts of a typical automotive connector: Everything on the left connects to everything on the right. |
To make this connection, there are a total of 23 separate parts. The main parts are:
The Shell
The shell
is an intricate piece that has a complicated shape. There is a
locking clip on the outside that holds the two halves of the
connector together. There are holes for the pins, and there
are special barbs that lock the pins in place once they are
inserted. There are numerous grooves to hold seals and make
sure things fit together tightly. All of these features are
molded into the piece when it is made.
The Pins and
Sockets
The pins and sockets are responsible for
conducting electricity from one half of the connector to the
other. These are made very precisely so that the pins and
sockets fit together with just enough force to ensure a good
connection, but not enough force to make connecting and
disconnecting too difficult.
 A socket (left) and a pin (right) |
The pins are crimped to the wires using a special crimping tool. Part of the pin wraps around the bare wire, while another part clamps onto the insulation. This makes it harder to pull the wire away from the pin.
The Pin/Socket
Retainer
The pin/socket retainer is a piece of
plastic that slides into the connector from the front. It
wedges against all of the plastic locking barbs so they can't
release. This piece makes it nearly impossible for the pins
and sockets to work their way loose.
 The retainer keeps the pins and sockets in place. |
The Seals
The seals
prevent water from entering the connection once the connectors
are locked together. Each connector has a rubber seal through
which all of the wires are fed. This seal fits firmly into the
back of the connector. One side of each connector has a round
seal that keeps water from entering the space between the
connectors once they are locked together.
 The wires pass through a rubber seal on the back of each connector (the seal, seen on the right, has been pulled out for this picture). |
For more information on wires, fuses, connectors and related topics, check out the links on the next page!
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