1. Connection Systems USCAR and Delphi’s USCAR Compliant Connection Systems USCAR and Delphi’s USCAR Compliant Connection Systems Presented by : John Yurtin John Yurtin May, 2002 1

2. Connection Systems The USCAR / EWCAP Organizations USCAR/EWCAP Objectives USCAR Compliance Requirements Delphi’s USCAR Compliant Connections Delphi’s Continuing Commitment to USCAR Agenda 2

3. Connection Systems What Is USCAR ? The United States Council for Automotive Research (USCAR) is an organization formed by DaimlerChrysler, Ford, and General Motors to strengthen the technology base of the domestic auto industry through cooperative pre-competitive research. Located in Southfield, Michigan. http://www.uscar.org/ 3

4. Connection Systems WHAT IS EWCAP? ELECTRICAL WIRING COMPONENT APPLICATION PARTNERSHIP  Mission: Facilitate and encourage cooperative research and development including sharing of technologies and resources to develop common electrical connection systems and standard electrical components (e.g., motors, relays, and switches)  Staff: Four full-time engineers, representing Ford, GM and DaimlerChrysler, located in Southfield, MI http://www.uscarteams.org/ 4

5. Connection Systems USCAR/EWCAP OBJECTIVES 1.Develop common electrical connector specifications 2.Establish a standard “footprint” for electrical connections 3.Reduce the number of different connectors on a vehicle by using common device connection footprints 4.Establish and Catalog common families of “Best-in- Class” connection systems 5

6. Connection Systems USCAR/EWCAP OBJECTIVES 1.Develop common electrical connector specifications SAE/USCAR-2: Performance Standard for Automotive Electrical Connector Systems SAE/USCAR-3: Standard for Testing Automotive Miniature Bulbs SAE/USCAR-4: Standard for Cigar Lighters and Power Outlets SAE/USCAR-12: Wiring Component Design Guidelines SAE/USCAR-13: Standard for In-Tank Electric Fuel Pumps SAE/USCAR-17: Specification for Automotive RF Connector Systems SAE/USCAR-18: FAKRA SMB RF Connector Supplement SAE/USCAR-20: Field Correlated Life Test 6

7. Connection Systems Centerline Spacing Mating Shroud Dimensions Lock Feature Detail Index Feature Detail 2. Establish a standard “footprint” for electrical connections USCAR/EWCAP OBJECTIVES 7

8. Connection Systems USCAR/EWCAP OBJECTIVES Cigar Lighter Fuel Injector Conn. Oil Press Switch Light Bulb Housing Power Seat Motors ABS Controller Connection Mirror Connection Batteries Windshield Wiper Motors Power Outlet Connection Trailer Connectors A/C Pressure Switch Air Bag Initiator Conn. Horn Connector O 2 Sensor Conn. Fan Motors 3. Reduce the number of different connectors on a vehicle by using common device connection footprints 8

9. Connection Systems USCAR/EWCAP OBJECTIVES 4. Establish and Catalog common families of “Best-in- Class” connection systems 0.64 mm Sealed Systems 0.64 mm Unsealed Systems 1.5 mm Sealed Systems 1.5 mm Unsealed Systems 2.8 mm Sealed Systems 2.8 mm Unsealed Systems 6.3 mm Sealed Systems Hybrid Systems Example of listing of 0.64mm unsealed systems from the USCAR website 9

10. Connection Systems What Is USCAR Compliance? A Device connection that meets the dimensional requirements (footprint) specified by USCAR, and… A Harness connection that mates to a device which meets USCAR dimensional requirements and….. When mated, a Connection System that meets the performance requirements of the SAE/USCAR 2 specification and… A connection system that conforms to SAE/USCAR-12 Wiring Component Design Guidelines… 10

11. Connection Systems USCAR Compliant Connections 11

12. Connection Systems USCAR Compliant Connections Off Shelf Device Connections USCAR Specific Device Connectors 0.64mm USCAR Header Connections 3.5 mm Slim-Line Connections 12

13. Connection Systems These connections meet all USCAR design and performance requirements. USCAR Compliant “Off Shelf” Device Connections 2 Way 1.5 mm Sealed Index A Knock Sensor 2 Way 1.5 mm Sealed Index B Crank Sensor 3 Way 1.5 mm Sealed Index C (Gray) 3 Way 1.5 mm Sealed Index B ( Dk Gray) 5 Way Sealed 1.5 mm Index A (Gray) 5 Way Sealed 1.5 mm Index B (Black) 13

14. Connection Systems USCAR Compliant Specific Device Connections 30 Way Sealed ABS Connector 7 Way Sealed Trailer Tow Connector 2 Way Sealed Fuel Injector, Horn & Underhood Lamp Connector 3 Way Unsealed Cigar Lighter/Power Outlet Connectors These connections meet all USCAR design and performance requirements. 14

15. Connection Systems Mates to USCAR standard 3.5mm footprint Smaller package size Mates to existing devices tooled for “pull-to-seat” connections Uses same terminal design as the 4.5mm USCAR connectors Meets SAE/USCAR-2 performance requirements with exception of Immersion after High Temp Exposure ( meets immersion after High temp exposure of ESA 710 Metri-Pack spec and ISO-8092). Available “off-shelf” in 2 thru 6 way configurations 3.5 mm Slim-Line Connections 15

16. Connection Systems Delphi’s Continuing Commitment Delphi will continue support of USCAR/EWCAP activities, and harmonization with ISO standards New connectors will be designed and tested to USCAR requirements. Connectors with footprints not yet specified by USCAR will also meet USCAR performance and guidelines. With a customer commitment, we will quickly tool any design or index as requested. Delphi is also committed to meeting the USCAR-20 Field Correlated Life Test (Key Life) requirements. 16

17. Connection Systems Delphi USCAR Connections Systems Functionality Delphi USCAR connections are… …connections that meet USCAR dimensions and… …harness connections that mate to USCAR devices, and …when mated, meet the performance of SAE/USCAR-2, and …conform to SAE/USCAR-12 guidelines. Benefits Delphi has all current USCAR connections available and has the largest portfolio of USCAR standard connections of any supplier. Leadership Delphi has actively participated in the Electrical Wiring Component Applications Partnership (EWCAP) since its formation in 1984. Commitment Delphi is committed to providing connections that meet all USCAR requirements. 17