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Part numbers of common electrical connectors with LS engine swaps
LTX and LSXPutting LT1s, LS1s, and their variants into Third Gens is becoming more popular. This board is for those who are doing and have done the swaps so they can discuss all of their technical aspects including repairs, swap info, and performance upgrades.
Part numbers of common electrical connectors with LS engine swaps
Special thanks to contributors vorteciroc, scooter, and Pocket.
This is a guide to part numbers of electrical connectors commonly used during an LS swap into a 3rd gen F-body.
Part numbers are listed for,
- Electrical connectors that mate to devices on engine and transmission.
- Wire splices for making common power and ground breakouts in wiring harness.
- Some examples of tools.
If you are having trouble reading the graphics then click on the images for higher resolution.
Pocket's how to prep a 3rd gen harness (Sep 2009)
Part I of the wiring guide. Stripping and prepping stock 3rd gen harness for integration with an LS engine swap. Key posts #1-3,25. The rest is Q&A.
Pocket's LS1 harness revisited (Mar 2010)
An abridged overview of a "plug & play" harness from beginning to end. Example based on LS1/T56 swap into 89 GTA. Key posts #1,2.
Re: Part numbers for common electrical connectors with LS engine swaps
WIRE SPLICES
Below is a splice selection guide I created that is based on data from TE Connectivity datasheets for AMPLIVAR wire splices.
I found everything at the TE Connectivity website (which is awesome by the way). If you're interested to investigate for yourself then search for these documents:
Document 82561, Calculating circular Mil area for a splice
Document 114-2088, Crimp specifications for AMPLIVAR splices
The key to all this is knowing what is CMA for each wire that you want to splice together. CMA is Circular Mil Area and it is a large number that is calculated from the physical geometry of the wire. Here is a Wiki link if you want to learn more, https://en.wikipedia.org/wiki/Circular_mil
Now if you skipped the Wiki link, and you skipped reading any of the documents I provided, then it's your lucky day because I did all the hard work for you and created a simple worksheet to knock this out quick.
Step 1: Find the CMA range for the wires you want to join together. I have provided data for common TXL type automotive wire. Your wire might vary some depending on the number of strands but it will be reasonably close.
Example: If you want to join four 22 AWG wires then walk across the top row to 22 (x1) AWG. Then walk down the left column to 22 AWG (x3). The cell where those two cross (2800) is the total CMA of the four wires.
Step 2: Select a splice part number that is appropriate for the sum total CMA range of the wires you want to join.
Example: The CMA range from Step 1 was (2800). Any part number splice can be used that has a minimum CMA smaller than that (listed in left-hand column), and a maximum CMA larger than that (listed in top row). That gives you a lot of choices but the best area to land is probably at the intersection of 600 left, and 3000 top (it is desirable that the crimp be as full as possible). A 5 or 7 serration brass splice would be a good choice (part numbers 42076 if going thru the splice, or 62000-1 if all wires coming in from same side of splice).
Here is an instructional video by HP Academy that explains how to make the splice.
Re: Part numbers of common electrical connectors with LS engine swaps
Thank you. I'll update with any corrections you can provide. And feel free to add more subject matter if you want and I'll make a slide for that too. I know I haven't captured everything.
Re: Part numbers for common electrical connectors with LS engine swaps
Originally Posted by vorteciroc
WOW!
That Super-Seal 1.0 Terminal looks very familiar...
Wait! It looks just like the Delphi Micro-Pack 100W Terminal!?!?
I bought the TE terminal and I saw how similar it was to the Delphi/Aptiv. I actually prefer the Delphi terminal, I like the crimp on the insulation better, IIRC
They are totally interchangeable though
Re: Part numbers of common electrical connectors with LS engine swaps
This thread is gold. Thanks for all the hard work @QwkTrip . Are you planning to post your original file(s) as well? Only asking as when I get around to using this, my old eyes are going to do some squinting on some of that small text. When they're made into graphics, it's just a bit hard to see. You put a ton of work into this... it'd be a shame if people can't read what you wrote. (For me, it's mainly posts #13 and #14. The others are legible either as-is, or with a slight zoom).
Re: Part numbers of common electrical connectors with LS engine swaps
I also use a ton of Holley EFI Products.
I used to just use an OEM PCM for all the Gen-III and Gen-IV Power-Train Swaps.
I would need to use HP-Tuners this way.
When the Holley Dominator EFI System got all its bugs worked out...
I moved over to using it 100 percent of the time for all Customer Cars (and my own also).
With Holley EFI, I can have an absurd amount of Data Inputs monitored.
Some additional inputs that I use are:
-Engine Oil Temp.
-Engine Coolant Pressure.
-ATF Pressure.
-ATF Temp.
-Radiator Water Temp.
-Inter-cooler Water Temp.
-Turbo Oil Temp.
-Power-Steering/ Hydro-Boost Pressure.
-AC Refrig. Pressure for Inter-cooler.
-Turbo Back-Pressure.
-Boost before Throttle-Body.
-Boost in the Intake-Manifold.
Re: Part numbers of common electrical connectors with LS engine swaps
That's quite a list QT!! I was researching 4th Gen EVAP systems and ran across this site, looks like it could be helpful as well. https://lt1swap.com/all_lt1.htm
Re: Part numbers of common electrical connectors with LS engine swaps
@QwkTrip I have been looking for some more Connector information to add here.
Since you included the C100 Bulk-Head Electrical Connector information...
I wanted to include the Ignition-Switch Connectors/ Information.
I do not know exactly what you guys include with your "Swap-Harnesses".
...I am guessing that you only include the Engine-Compartment side of the C100 Bulk-Head.
I usually include the Passenger-Compartment side of the C100 Bulk-Head as well (unless the Customer is keeping the Stock Fuse-Panel).
When done this way, this version of my Harnesses, eliminates the Stock Bussed Electrical Center.
Instead it provisions Connections for 2 Bussed Electrical Centers (1 for the Interior and 1 for the Engine Compartment).
Any way, the harness includes the 2 Ignition-Switch Connectors (or I solder new Wire-Leads, and Pot the Switch for Sealed-Connectors).
The last time I purchased the Ignition-Switch Connectors was in 2007 (I purchased 216 Connector Bodies)...
I have been looking everywhere, to purchase more.
I can ONLY find the Pigtails now (ACDelco #PT289 and PT2134).
Have you guys found the Connector-Bodies anywhere?
Maybe included with a new Ignition-Switch?
Re: Part numbers of common electrical connectors with LS engine swaps
Also, I forgot to say...
My Race-Spec version of the Swap-Harness (and Sub-Harnesses) eliminates the Original C100 Bulk-Head, and the Passenger-Side Fender Electrical Pass-Through.
What I mean by "Passenger-Side Fender Electrical Pass-Through" shown below:
Just like Pocket shows in the Image below, I cut-out the "Pass-Through Body"...
and I replace it with a Sealed Bulk-Head:
The Sealed Bulk-Head Electrical Connector that I use for both the C100 Location, and the Pass-Through Location, is shown below:
Last edited by vorteciroc; 12-23-2021 at 11:18 PM.
Re: Part numbers of common electrical connectors with LS engine swaps
Both of those are quite nice vorteciroc. From what I've seen thirdgenners do, it ain't pretty (mine included). The sealed bulkhead connector in the passenger footwell either is no longer sealed well and the cables are just run through, or some folks put a new hole in the firewall and run them. Few people ever change out the C100 for anything else, with some repinning parts of it as they need but very few. I may have seen 1 or 2 folks replace the interior bussed electrical center in all my years of reading here. So what you're proposing is miles above what's typically done here, likely due to folks having a lack of parts to achieve it and many people fearful of electrical work.
Re: Part numbers of common electrical connectors with LS engine swaps
Sealed Bulk-Head Components (Delphi):
I do NOT use Component "F".
Component "G" is available in 2 different versions.
The version without a Flange is pictured, but with the opposite Part Number.
Part Number 12160809 is pictured, and does not have a Flange.
I use the version with a Flange, Part Number 12161191.
Both the Fire-Wall, and the Passenger Side Pass-Through will require a new piece of sheet-metal as the dimensions of the pre-existing Holes do not fit the new Sealed Bulk-Head Connectors.
Re: Part numbers of common electrical connectors with LS engine swaps
@QwkTrip I forgot to give you the 3rd Connector Information for the AD230 and AD244 Alternators.
I'll delete this Post after you update your Thread.
Delphi #15355066.
Metri-Pack 150 Series Sealed 4-Way Connector with 2 Usable Positions (A and D Blocked).
Color: Tan, Seal: Orange.
.
.
More little Corrections and Additions to come.
I am sorry that it is taking me so long.
People say that short day-light Hours, can really affect people...
and that the Month of December has the highest rates of people whom do not want to be here anymore...
To any and all who are suffering from Depression, you are not alone.
Please try and stay strong!
I am trying to fight it too!
Last edited by vorteciroc; 12-24-2021 at 06:41 PM.
Re: Part numbers of common electrical connectors with LS engine swaps
Thanks, got it.
I gotta know, where do you put the Dominator ECM? I was able to put the HP ECM in stock location but this Dominator is a bit of a challenge. Seeing those pass-thru's suggests to me you're not passing the ECM thru the firewall and you got it somewhere outside the cab?
I found a Caterpillar 70 pin bulkhead 214-4208 and 160-7690 that has enough pinouts for J1A/B (basic engine) and J4 (Trans). It uses Deutsch machined terminals and it's spendy, especially considering I still have no pass thru for J2A/B and J3.
Re: Part numbers of common electrical connectors with LS engine swaps
Originally Posted by QwkTrip
Thanks, got it.
I gotta know, where do you put the Dominator ECM? I was able to put the HP ECM in stock location but this Dominator is a bit of a challenge. Seeing those pass-thru's suggests to me you're not passing the ECM thru the firewall and you got it somewhere outside the cab?
I found a Caterpillar 70 pin bulkhead 214-4208 and 160-7690 that has enough pinouts for J1A/B (basic engine) and J4 (Trans). It uses Deutsch machined terminals and it's spendy, especially considering I still have no pass thru for J2A/B and J3.
I install the Holley PCMs in the Engine-Compartment.
Most of the time, on the Passenger Side Fire-Wall, where the AC Evaporator used to be.
I will usually make some Aluminum Brackets for the Holley PCM and a UBEC.
The Delphi Sealed Bulk-Head Connectors go up to 78-Way:
I am not crazy about the Deutsch (DTM, DT, DTP, DTHD) Connectors.
I do like that the Terminals are very robust (being solid).
I also like that there are very few options, which keep things very simple for people that are not very familiar with the products.
I do like that TE produces many Accessories for these Connectors.
I do not like the Ampacity Ratings.
I do not like that there is no Secondary Terminal Retention Device (TPA).
I do not like that there is no Secondary Connector Retention Device (CPA).
I do not like the Sealing Design.
I do not like that only the DTM (7.0A) and DT (14.0A) Connectors are offered with more than 2 or 4 Terminals.
The DTP Series (25.0A) only have 2-Way and 4-Way Connectors, and the DTHD Series only has a 1-Way Connector.
Metri-Pack 280 and GT-280 Connectors have way more options at 30.0A.
BTW, Does CAT have any Delphi/ Aptiv Contracts for the modern Connectors?
They used to anyway...
Does this Connector look familiar to you, LOL!
Re: Part numbers for common electrical connectors with LS engine swaps
Originally Posted by QwkTrip
A question somewhat relating to the content here and it's in regards to the tooling posted above.
I've done thousands (more like tens of thousands) of crimps while plying my trade. Some of my crimp tools eclipse the $500 mark and I have several. But this is mostly the traditional fork and ring type of deal for control panels and device field wiring. I could have even more invested if I were to follow every manufacturer's guideline for a specific crimp material (say nylon vs vinyl) or even brand vs tool required but I don't.
So, my question is, since I have to invest further in order to update the wiring harness in my non-LS engine bay, which style of "weather pack" would be best suited to most applications?
As an example, I have individual weatherproof fuse holders (for the ATO/ATC style fuses) and these come with a female weather pack socket. I need to splice the male end of things onto my harness so I can plug and play.
As pictured below:
Similarly, my MSD ignition box has a single wire pig tail for power and another for the tach output (plus other inputs and outputs). Presently I'm going with male/female disconnect type of connections (.250" female disconnect with a .250" male tab) but would like to change that to a single sealed style plug.
Suggestions?
Re: Part numbers of common electrical connectors with LS engine swaps
Weather-Pack female terminals are round like what you see in the picture for T56 Backup Lights Switch in post #11. The fuse holder you show is a form of Metri-Pack female terminal 280, 480, or 630 series. You just need the correct crimper for that series of terminals.
The ratcheting 3186 CT (12085270) and non-ratcheting 3306 MPCT is specifically designed for Weather-Pack terminals. They cross over into Metri-Pack but only in the 14 - 20 AWG range. I own the 12085270 and it does 12 AWG okay but does not do 22 AWG wire. I have to double up the wire (fold it over) to crimp 22 AWG or it will simply slip out of the crimp.
I'm not playing that game any more so I recently bought the 3305 MPCT (actually a less expensive rebranded version at Summit Racing). That tool has the most versatile jaws of all the tools and will let me do the small wire properly. It's very complimentary to the Weather-Pack crimper I already owned and I can cover almost anything now. But the 3305 doesn't have the seal crimps so I have to finish off the seals using my Weather-Pack crimper. I still need to get myself a proper 10 AWG crimper for unsealed wire. Sargent has those but I didn't list it.
If you know the terminal part number and are wondering what is the right tool then you can look it up in this guide at the Sargent website. Delphi has a similar guide but it's harder to dig up on the web.
1-wire connectors are always a risk because the wire isn't usually strong enough to handle the weight. If you must use a 1-wire connector then tie down the connector firm to something in such a way that the wire is strain relieved and moves in sync with the connector. And use a style of connector that supports the wire for a good length behind the crimp. (You already know the crimp is where the wire is most likely to break)
Re: Part numbers of common electrical connectors with LS engine swaps
I spent hours getting that Sargent crimp guide imported into Excel so I could figure out which tool best complimented the one I already had. I could probably use that same spreadsheet to make a general guide. Give me some time to work on that.
Re: Part numbers of common electrical connectors with LS engine swaps
I'd like to find a kind of universal tool for my general needs. I don't have the myriad of connector bodies that all of the different generations of SBC's have used over the years.
This is for a general cleanup and modernization of my existing and soon to be modified harness.
Any and all information posted here is excellent and appreciated.
I can see my repertoire of tooling is soon to expand...
Re: Part numbers of common electrical connectors with LS engine swaps
After many Years of Crimping...
And many, many Crimping-Tools...
My recommendations for General "Open-Barrel" Crimping (most GM Terminals) without purchasing 25 Different Crimpers, would be:
-Sargent Model: 3186CT (Delphi #12085270) Crimps on the Cable-Seals for 150 through 630 sized Wire/ Cable; and also Crimps some of the Smaller Terminals.
-Sargent Model: 3187CT (Delphi #12085271) Crimps most Terminals for 150 through 630 sizes for 20AWG through 12AWG and some 10AWG.
-Delphi #15155975: Crimps larger Wire/ Cable for 12AWG, 10AWG, and some 8AWG (#12040070 also works, and is better for 8AWG... but has no provision for Cable Seals; use 12085270 for Seals).
-Sargent Model #3191CT: Crimps most Terminals for Micro-Pack 100/ 100w, Micro-Pack 064, and other Terminals smaller than 150.
I use these 4 Crimpers for most every "Open-Barrel" Crimp that I need to make.
I have tons of Crimpers that I practically never use (including a set of 18 Delphi Crimpers).
I do use other Crimpers for Power Cables (0000AWG, 00AWG, 0AWG, 2AWG, 4AWG, and some 8AWG).
And also "Closed-Barrel" Terminals, like Delphi HES:
Or like TE/ Deutsch DTM, DT, DTP, and DTHD Terminals.
Last edited by vorteciroc; 05-07-2022 at 07:30 PM.
Re: Part numbers of common electrical connectors with LS engine swaps
Originally Posted by QwkTrip
I could probably use that same spreadsheet to make a general guide.
No need to make the guide, vorteciroc laid out the answers.
Originally Posted by vorteciroc
-Sargent Model: 3187CT (Delphi #12085271) Crimps most Terminals for 150 through 800 sizes for 20AWG through 12AWG and some 10AWG.
Just a note for the cost conscious, the less expensive non-ratcheting version is 3305 MPCT. Re-branded versions are even cheaper if you can spot them in catalogs.
-Delphi #15155975: Crimps larger Wire/ Cable (ONLY) for 12AWG, 10AWG, and 8AWG.
Re: Part numbers for common electrical connectors with LS engine swaps
Originally Posted by skinny z
So, my question is, since I have to invest further in order to update the wiring harness in my non-LS engine bay, which style of "weather pack" would be best suited to most applications?
As an example, I have individual weatherproof fuse holders (for the ATO/ATC style fuses) and these come with a female weather pack socket. I need to splice the male end of things onto my harness so I can plug and play.
As pictured below:
Similarly, my MSD ignition box has a single wire pig tail for power and another for the tach output (plus other inputs and outputs). Presently I'm going with male/female disconnect type of connections (.250" female disconnect with a .250" male tab) but would like to change that to a single sealed style plug.
Suggestions?
The Connector that you Posted for Fuses, uses "Pull to Seat" Metri-Pack 630 Series Terminals...
The Sargent Model: 3187CT (Delphi #12085271) Crimper would be used here.
For single Wire Connectors, there are only a few Options... and they are Amperage dependent:
-Metri-Pack 150 (14A Max. Continuous-Load).
-Weather-Pack (20A Max. Continuous-Load).
-Metri-Pack 280 (30A Max. Continuous-Load).
-Metri-Pack 800 (60A Max. Continuous-Load).
The Sargent Model: 3187CT (Delphi #12085271) Crimper again, would be used for all of these.
Let me know what you need, and I will Post the Delphi Part Numbers.
Re: Part numbers of common electrical connectors with LS engine swaps
@vorteciroc what are you using to crimp the Metripack 640, 480 with the large size wire for the INSULATION part? All the crimpers I have used are not "right" for crimping onto the insulation. I can describe the problem in more detail, but it would be a pain. Suffice to say I have the crimpers you're recommending in that post and they do not work correctly. I also have this problem on the 59 series Packard terminal and some of the 56 series
Re: Part numbers of common electrical connectors with LS engine swaps
Also when Crimping the Wire Insulation for UnSealed Terminals...
Large enough Wire can sometimes use the O-Shaped (Cable Seal) Crimp Locations of the 12085270 Crimpers.
Re: Part numbers of common electrical connectors with LS engine swaps
Mentioning this because I was surprised, not because it particularly answers your direct question. I've found that my local Grainger can get GXL wire pretty quickly and I don't have to think about shipping. They don't seem to carry TXL though, so if you must have the thinnest wall cross-linked PE wire, they're a no-go.
Re: Part numbers of common electrical connectors with LS engine swaps
Got wire from Del City. It's the lowest price I found in my search and they told me it is American made. 100 ft minimum and comes on a handy dandy spool. Solid colors only but they do have a good range of choices.
Re: Part numbers of common electrical connectors with LS engine swaps
You've all noticed by now that this is not a complete list of connectors yet. I'm going to depend on the community from this point forward to help add to the list. I'll make new slides if somebody can identify some of the missing stuff.
12-22-2021, 02:45 PM
