TE CONNECTIVITY’S
CYLINDER HEAD
WIRING SOLUTIONS
FOR INDUSTRIAL & COMMERCIAL VEHICLES
WE GO TO EXTREMES TO MAKE EVERY CONNECTION COUNT
INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD WIRING SOLUTIONS
CYLINDER HEAD
WIRING SOLUTIONS
FOR INDUSTRIAL & COMMERCIAL VEHICLES
INDUSTRIAL & COMMERCIAL TRANSPORTATION (ICT),
WHICH IS PART OF TE CONNECTIVITY (TE), OFFERS
A FULLY COMPREHENSIVE RANGE OF CONNECTORS
AND CABLE ASSEMBLY PRODUCTS AND SOLUTIONS
FOR CYLINDER HEAD WIRING.
Coupled with our continuously expanding range of
capabilities, we are providing the commercial
transportation market with highly integrated
systems and cost effective solutions.
We at TE Connectivity are working with our
customers providing them turnkey solutions by
integrating all of TE’s key technologies of
electrical interconnect, sealing capabilities,
Raychem wires and fuel injectors interconnect. This extensive experience in connectors and cable
assembly enables TE to provide its customers with:
• Turnkey Solutions
• High Performance Solutions
• Cost Competitive Solutions
TE Connectivity is developing cylinder head wiring for heavy duty diesel engines with cable
channels and pass-through connectors. Cylinder head wiring assemblies are designed to withstand
a highly dynamic temperature range, which is caused by a massive thermocycling, substantial
vibration load by the engine and overspray of engine oil. Cylinder head wiring assemblies have
proven themselves in a variety of engines in truck, agricultural, and construction applications under
harsh environment applications.
INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD WIRING SOLUTIONS
CYLINDER HEAD
WIRING SOLUTIONS
TURNKEY ENGINEERING SOLUTIONS
TE Connectivity offers fully tested custom designs to the OEM´s specifications utilising not only connectors and
wires but also the design of brackets, cable arrangements and cable channels and a selection of related materials. The OEM is only required to design the required opening in the cylinder head and /or valve cover.
Product Portfolio
MECHANICAL
• Single Cylinder
• Amount of positions:
• Two Cylinder
• Operating temperature: -40° C to 140° C
• Three Cylinder
• Mating Force:
max. 10 N (2 pos.)
• Four Cylinder
0.6-3 Nm (6-24 pos.)
• Six Cylinder
• Mating Cycles:
max. 50
(silver plated terminals)
• Vibration:
ISO 16750-3, Test VI
and more.
Applications
• Heavy Duty Diesel Motors
• Common Rail Engines
• Pump Nozzle Engines
2 – 24 pos.
ELECTRICAL
• Withstanding Voltage:
max. 36 VDC (at sea level)
• Insulation Resistance:
> 107 Ω (at 500 VDC)
• Harness System Undervalve Cover for Injector
• Sensors to Cylinder Head Exit Connection
PRODUCT
PORTFOLIO
Key features
• Cylinder head wiring includes electrical connections
for injectors, glow plugs, sensors and actuators
• Oil tight pass-through connectors range based on
different interfaces, like DT, AMPSEAL 16, AMP MCP
and Circular Connectors
• Connectors accept multiple terminals including
• Captured screw designs for cable channel fixation
• Cable support channel design
• Cable protection solutions
• High temperature wires
• Push back test of terminals
circular or flat, stamped and formed or screw
• Integrated secondary locking device delivered
machine terminals
in pre-locked position
• Leakage check on the interface connector
• Capability for fully tested design according to
• Polarization, mechanical, color coded keying
options
• Ring tongue solutions for injector terminations
OEM specifications
• 100% tested harness with electrical
end of line check
• Cleanliness requirements according to OEM
PAGE 3
CYLINDER HEAD
WIRING SOLUTIONS
COST COMPETITIVE SOLUTIONS
The combination of cable support channels, high temp. wires and oil tight connectors not only helps the customers to have high performance customized solution at low costs, but it also supports the reduction of the
total installed cost of a Cylinder Head Wiring. Oil tight connectors enable installation cost reduction, reliable
sealing and connection by accepting non-oil blocking, high temperature wires up to 200° C.
The support channel simplifies installation, avoids additional cable ties and fixation. The self-finding guides for
the injector reduce significant handling time, avoid mismatching of ring terminals and make motor installation
easy and cost effective.
Benefits of Cylinder Head Wiring
• Less Damage Risk
• Secured Assembly
–wires withstand high temp. up to 200° C,
– the captured parts are prepositioned according to
mechanical protection of wiring, oil blocking
the requirements of the cylinder head
connectors
•Reliability
• Easy Service
– components designed and tested for the
– clear handling of cable assembly for cylinder head
application, wires guided inside the engine
• Easy Handling
– components designed for the application
– motor installation time reductions by simplicity
of designs and routing
• Less time in Assembly
– cable guide aligns with fixing points
– qualified CHW interfaces and components adapt-
able for various applications, e.g. engine sensors,
gear box applications, etc.
• Cost saving
INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD WIRING SOLUTIONS
CYLINDER HEAD
WIRING SOLUTIONS
HIGH PERFORMANCE CABLE SOLUTIONS
200° C rated T6 Class F Thin Wall and Ultra Thin Wall wires are used for Cylinder Head Wiring. TE Connectivity
provides customers with high performance cables at a lower price. Using tough advanced TE Raychem radiation
cross-linked fluoropolymer insulation offers exceptional high temperature performance and resistance to hot
surface damage. It also increases safety in case of accidental contact with hot surfaces, with a lower unit cost
compared to alternative fluoropolymer solutions.
The tough mechanical characteristics also allows TE Connectivity under the trademark Raychem to produce
these wires in thin-wall constructions, providing superior harness shop processing as well as significant space
and weight savings, whilst offering the opportunity to remove overprotection.
Benefits
• Lower unit cost at true T6 performance level.
• Improved mechanical and abrasion
• Designed to be compatible with typical
performance – compared to PTFE and FEP.
wire handling equipment used in harness shops.
• Irradiation cross-linked insulation does
• Smaller, lighter wires – with the same
withstand termocycling and oil overspray.
temperature performance.
• Offers the opportunity to remove
• Thin-wall designs – providing improved
costly overprotection.
handling, space savings and miniaturized
connector compatibility benefits.
PAGE 5
CYLINDER HEAD
WIRING SOLUTIONS
HIGH PERFORMANCE OIL TIGHT CONNECTORS
The oil tight connector system offers receptacle and pin housings with capability for waterproofing and resistance to conditions of extreme vibration. The system is designed for electronic and electrical applications in
motor vehicles, where vibrations and mechanical stress, in the long term, can affect the quality on the contact
system. Designed to the specific needs of the cylinder head wiring, installations and motor design a choice
of oil tight connectors based on various product family interfaces.
2 Position Connector
• MCON 1.2 LL
• PN 1-1718643-1
(2 pos. Receptacle Housing)
• Feed through hole: Ø 12 x 16mm
• Interface drawing: on request
Up to 6 Positions Connector
• 1.5mm diameter circular terminals
• Feed through hole: Ø 30mm
• ISO 15015170 style
• Interface drawing: 114-18682
• PN 967650-4
(up to 6 pos. Receptacle Housings)
• PN 965577-1 (Right-angle Backshell)
• PN 965785-1 (Vertical Backshell)
Up to 16 Positions Connector
• AMP MCP 1.5
• PN 1-1718284-1
Bayonet Style Connector
(Right-angle Backshell)
• PN 0-1703768-2
• Feed through hole: Ø 32mm
(up to 14 pos. Receptacle Housings)
• Interface drawing: 114-18753
• PN 1-1703963-1
(up to 16 pos. Connector Housings)
Up to 24 Positions Connector
• AMP MCP 1.5
• Feed through hole: Ø 36,4mm
• Bayonet Style Connector
• Interface drawing: 114-18812
• PN 1703399-1
(up to 24 pos. Receptacle Housings)
• PN 1703402-1
(Right-angle Backshell)
INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD WIRING SOLUTIONS
CYLINDER HEAD
WIRING SOLUTIONS
HIGH PERFORMANCE OIL TIGHT CONNECTORS
Features
• High reliability status supported for long term use
• Wire-to-Wire sealed
• High vibration level supported
• Polarisation, several keyings options
• Design to avoid quality problems, reduce
• Locking mechanism for smaller connectors/mating
manufacturing and service cost
aid for higher numbers of ways
• Integrated secondary locking device delivered
• Oil tight connectors
in pre-locked position
4 Position DEUTSCH Connector
• DTP Series
• Size 12 circular terminals
• PN DTP06-4S
• Feed through hole Ø 22mm.
• Interface drawing on request
4 Position DEUTSCH Connector
• DT Series
• Size 16 circular terminals
• PN DT06-4S
• PN 1011-263-0405 (180° Backshell)
• Feed through hole Ø24.93mm.
• Interface Drawing on request
Up to 8 Positions Connector
• AMPSEAL 16 Connectors
• Size 16 circular terminals
• PN 776494-1
(Up to 8 positions receptacle housing)
• Feed through hole: Ø32mm.
• Interface Drawing on request
Contacts
The AMP MCP 1.5, MCON 1.2, round 1.5mm2 and size 16 contact systems are
mainly used in the cylinder head wiring. Each contact consists of a flat or a
round receptacle, which mates with a flat or round tab.
Every contact has a steel spring and a copper alloy body. The two-piece contact
design means that the electrical and mechanical properties are separated.
PAGE 7
Tyco Electronics AMP GmbH,
a TE Connectivity Ltd. company
AMPèrestrasse 12–14
D-64625 Bensheim
Germany
Phone: +49 (0)6251 133-0
Fax:
+49 (0)6251 133-1600
www.te.com
www.te.com/ict
Tyco Electronics AMP GmbH certified
acc. ISO 14001 and ISO/TS 16949:2002
© 2014 TE Connectivity family of companies. All rights reserved.
AMP MCP, AMPSEAL, AMPSEAL 16, DEUTSCH, MCON, Raychem, TE, TE Connectivity,
and TE connectivity (logo) are trademarks.
TE’s only obligations are those stated in TE’s General Terms and Conditions of Business
(http://www.te.com/aboutus/tandc.asp). TE expressly disclaims any implied warranty
regarding the information contained herein, including, but not limited to, the implied
warranties of merchantability or fitness for a particular purpose.
1654325-1 | Issued 09-2014 | 1 M · ST
INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD WIRING SOLUTIONS