9.3.7 GMW3191 Connector Tests.

Purpose: These tests shall verify the functionality and durability of the connector according to
GMW3191.

Applicability: All connectors of the component that interface to the vehicle harness. This includes
connectors that are permanently attached to a wiring harness (pigtail).
Note: Typically, for the first development of a new connector system (used in a new component),
the validation is performed as part of the entire GMW3191 execution, and those results may be
used as surrogate data to demonstrate these GMW3172 requirements.
When a component introduces a change to a component’s connector system or uses a connector
that has never been tested by GMW3191 on this application, these are the minimum tests from
GMW3191, which are identified here in GMW3172, that need to be executed.
Other tests from GMW3191 and/or GMW3172 may also apply to ensure appropriate connector
functionality, such as the Seal test. However, if a new connector supplier is implemented, the
connector system needs to be re-tested according to the entire GMW3191.

Operating Type: See GMW3191.

Monitoring: See GMW3191.

Procedure: The following GMW3191 (Connector Test and Validation Specification) tests shall be
executed on the component assembly:
Note: The test names and procedures are according to GMW3191, revision December 2007. The
tests shall be performed according to the latest version of GMW3191.
  Terminal Push-out Force

This test measures the minimum force needed to displace a terminal a small distance in the
component. This
assures that normal mating and un-mating operations do not cause a displacement that degrades
the electrical
performance of the connector system.
Note: This test will damage the component.
Note: This test requires 10 component samples. Each pin on each component shall be tested.

 Connector-to-Connector Engagement Force

The connection system to mate a component’s connector(s) to the vehicle’s wiring harness should
not require excessive force for a person to perform manually. Therefore, forces needed to engage
fully populated female and male connectors to each other cannot exceed specified levels.
Otherwise, the connection will be too difficult for people to manually perform.
This test verifies that the mating force of a connector system is not excessive (reference USCAR-25
for the ergonomic requirements) during the vehicle assembly process and service operations.
Note: This test should not damage the component.
Note: This test requires 10 component samples with connectors that are fully populated with
terminals and wires in order to test 10 mating connector pairs for each connector of the component.

 Locked Connector Disengagement Force

Connectors use locking mechanisms to lock the connection system together as an added
assurance against disengagement due to vibration events or external forces applied to the harness.
This test verifies that a connector system (with a primary locking feature) will not become unmated
when a minimum force is applied. This will ensure that a connector system remains mated in a
vehicle application.
Note: This test will damage the connector housing.
Note: This test requires 10 component samples with connectors that are not populated with
terminals and wires in order to test 10 mating connector pairs for each connector of the component.

 Unlocked Connector Disengagement Force

Connectors may need to be disengaged during vehicle service, i.e., to replace a failed component
or make repairs to a component. If the locking features are properly disengaged, the connection
system should not require excessive manual force to disconnect. Likewise, the lock feature itself
should not require excessive manual force to disengage.
Otherwise, these tasks will be too difficult for people to perform manually.
This test verifies that the un-mating force of a connector system (with all locks disengaged) is not
excessive during service operations. Also, this test verifies that the force to disengage the primary
locking feature(s) is not excessive during service operations.
Note: This test will damage the connector housing.
Note: This tests requires 10 component samples with connectors that are fully populated with all
terminals, wires, TPA’s, and seals. 5 of these test samples will have the connector lock physically
removed or otherwise disabled.
Criteria: See GMW3191.

9.3.8 Connector Installation Abuse – Side Force.

Purpose: This test shall verify that the connector(s) of the component are not affected by resting on
the connector by hand or elbow loads as a result of side forces during connector attachment or
other assembly operations.

Applicability: All components that have connectors with at least a 13.0 mm diameter area.
Operating Type: 1.2

Monitoring: Not applicable

Procedure: The component shall be set up to allow testing on the connector surface with a 13.0
mm or larger diameter area. Subject the connector to an evenly distributed 110 N force about each
13.0 mm diameter area for 1.0 s, as shown in Figure 34. Repeat this test for all applicable surfaces
and connectors.
Perform a 1-Point Functional/Parametric Check after all surfaces have been tested.

Criteria: Functional Status Classification shall be C. Additionally, during the Visual Inspection and
Dissection –DRBTR, the connector(s), housing, and circuit board to which the connector is attached
shall not show any damage.

9.3.9 Connector Installation Abuse – Foot Load.

Purpose: This test shall verify that the connector(s) of the component are not affected by foot loads
on the connector.

Applicability: All components that may experience foot loads during vehicle assembly or servicing.

Operating Type: 1.2

Monitoring: Not applicable

Procedure: A simulated foot load of 890 N of a distributed force shall be applied normally through a
(50 x 50) mm (or appropriately sized) rigid steel plate for 1 minute to the connector and connector
header as shown in Figure 35. This plate represents the sole of a person’s shoe. Repeat this test
for all applicable directions and connectors.
Perform a 1-Point Functional/Parametric Check after all surfaces have been tested.

Criteria: Functional Status Classification shall be C. Additionally, during the Visual Inspection and
Dissection –DRBTR, the connector(s), housing, and circuit board to which the connector is attached
shall not show any damage.