SAE/USCAR-2 REVISION 8 Revised 2022-06
PERFORMANCE SPECIFICATION FOR
AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 2 -
5.2 Terminal Mechanical Tests ......................................................................................................................... 14
5.2.1 Terminal to Terminal Engage/Disengage Force ......................................................................................... 14
5.2.2 Terminal Bend Resistance .......................................................................................................................... 15
5.3 Terminal - Electrical Tests........................................................................................................................... 17
5.3.1 Dry Circuit Resistance ................................................................................................................................. 17
5.3.2 Voltage Drop ............................................................................................................................................... 19
5.3.3 Maximum Test Current Capability ............................................................................................................... 21
5.3.4 Current Cycling ........................................................................................................................................... 24
5.4 Connector - Mechanical Tests .................................................................................................................... 26
5.4.1 Terminal - Connector Insertion/Retention and Forward Stop Force ........................................................... 26
5.4.2 Connector-Connector Mating/Unmating/Retention/Lock Deflection Forces (Non-Assist) .......................... 30
5.4.3 Connector to Connector Mate/Unmate Forces (Mechanical Assist) ........................................................... 32
5.4.4 Polarization Feature Effectiveness ............................................................................................................. 34
5.4.5 Miscellaneous Component Engage/Disengage Force ................................................................................ 35
5.4.6 Vibration/Mechanical Shock ........................................................................................................................ 40
5.4.7 Connector-to-Connector Audible Click ........................................................................................................ 46
5.4.8 Connector Drop Test ................................................................................................................................... 46
5.4.9 Cavity Damage Susceptibility ..................................................................................................................... 47
5.4.10 Terminal/Cavity Polarization Test ............................................................................................................... 48
5.4.11 Connector Mounting Feature Mechanical Strength .................................................................................... 49
5.4.12 Mechanical Assist Integrity (Connectors with Mechanical Assist Only) ...................................................... 51
5.4.13 Connector Seal Retention - Unmated Connector ....................................................................................... 52
5.4.14 Connector Seal Retention - Mated Connector ............................................................................................ 53
5.4.15 Airbag Inflator Connector Self-Rejection Assessment ................................................................................ 53
5.4.16 Bolt-Assembled Connector Function .......................................................................................................... 55
5.5 Connector - Electrical Tests ........................................................................................................................ 58
5.5.1 Insulation Resistance .................................................................................................................................. 58
5.6 Connector Environmental Tests .................................................................................................................. 59
5.6.1 Thermal Shock ............................................................................................................................................ 59
5.6.2 Temperature/Humidity Cycling .................................................................................................................... 60
5.6.3 High Temperature Exposure ....................................................................................................................... 61
5.6.4 Fluid Resistance .......................................................................................................................................... 62
5.6.5 Submersion ................................................................................................................................................. 63
5.6.6 Pressure/Vacuum Leak ............................................................................................................................... 64
5.6.7 High Pressure Spray ................................................................................................................................... 65
5.7 Tests for Headers ........................................................................................................................................ 67
5.7.1 Header Pin Retention .................................................................................................................................. 67
5.8 Severe Duty Tests ....................................................................................................................................... 68
5.9 Test Sequence ............................................................................................................................................ 69
5.9.1 General Notes on Test Sequence ............................................................................................................... 69
5.9.2 Test Sequence Chart .................................................................................................................................. 69
5.9.3 Terminal Mechanical Test Sequence .......................................................................................................... 69
5.9.4 Terminal Electrical Test Sequence ............................................................................................................. 69
5.9.5 Connector System Mechanical Test Sequence .......................................................................................... 69
5.9.6 Connector System Electrical Test Sequence ............................................................................................. 71
5.9.7 Sealed Connector System Environmental Test Sequence ......................................................................... 72
5.9.8 Unsealed Connection System Environmental Test Sequence ................................................................... 73
5.9.9 Stand-Alone Sealing Performance Test Sequence .................................................................................... 73
APPENDIX A DEFINITIONS ............................................................................................................................................. 74
APPENDIX B ABBREVIATIONS USED ............................................................................................................................ 78
APPENDIX C TESTS FOR MOVED TOOLS, ADDITIONAL TOOLS, AND MATERIAL CHANGES ................................ 79
APPENDIX D TESTS FOR NEW TERMINAL, CONNECTOR, AND SEAL DESIGNS ..................................................... 81
APPENDIX E SOURCE LIST FOR AUTOMOTIVE FLUIDS USED IN TESTING ............................................................ 83
APPENDIX F DESIGN NOTES - TEMPERATURE AND CURRENT RATING ................................................................ 84
APPENDIX G REVISIONS ................................................................................................................................................. 85
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