Overview & assembly instructions (English)
AMPSEAL 16
Sealed Strength for Demanding Environments
When a vehicle harness sits near engines, aftertreatment, or exposed chassis routing, small connection issues can turn into downtime. AMPSEAL 16 connectors are sealed wire-to-wire, wire-to-device and wire-to-panel connectors built for vibration, moisture, dust, and heat. You get a one-piece housing that comes fully assembled and includes Connector Position Assurance (CPA) plus integrated contact retention features. Choose standard versions up to 125°C or high temperature versions up to 150°C for hotter zones.
AMPSEAL 16 Connector Series
Spec Snapshot
AMPSEAL 16 Connector Series
Positions
2 to 12 positions
Operating Current
Up to 13 A per circuit with size 16 contacts
Operating Voltage
Up to 250 V DC
Degree of Protection
IP67, with backshell options for IP68 and IP6K9K
Operating Temperature
Standard temperature up to 125°C, high temperature options up to 150°C
Contact System
HDSF (Heavy Duty Stamped & Formed) Size16 contacts OR DEUTSCH solid contacts
Vibration resistance
Vibration tested at 21 G RMS up to 2000 Hz
Flammability
UL94 HB (UL 94 V-0 - High Temp)
Key Benefits
AMPSEAL 16 Connector Series
- Reduce build steps in high-volume harness production
One-piece housings come fully assembled, so you handle fewer loose parts during harness build
- Add a secondary lock without extra add-ons
Integrated CPA helps reduce accidental unlatching after mating, which is helpful in high vibration zones
- Support contact seating and retention
Integrated Terminal Position Assurance functions through Primary Latch Reinforcement to help reduce contact back-out risk
- Reduced complexity and cost savings
Integrated CPA and TPA not only reduce build steps and simplify ordering and inventory/storage management, both of which can result in a reduction in cost
- Handle harsh exposure with sealed performance
IP67, IP68 & IP6K9K (with rear protection like backshells) sealing helps resist dust and water ingress, with backshell options for higher ingress ratings
- Extend into hotter application zones
High temperature variants support up to 150°C and UL94 V-0 for on-engine, aftertreatment, and powertrain areas
- Simplify error prevention in dense harness layouts
Mechanical keying and color coding help reduce mismating in builds that use multiple similar connectors
Features and Applications
Key Features
AMPSEAL 16 Connector Series
| Feature | Specification |
|---|---|
| Connector type | Sealed wire-to-wire and wire-to-device connectors |
| Positions | 2, 3, 4, 6, 8, 12 |
| Contact system | HDSF size 16 contacts or DEUTSCH solid contacts |
| Wire range | 14 to 20 AWG (2.50 to 0.50 mm²) |
| Current rating | Up to 13 A per circuit, depends on wire and loading |
| Voltage rating | Up to 250 V DC |
| Operating temperature | Standard: -40°C to 125°C. High temperature: -40°C to 150°C |
| Ingress protection | IP67. With backshell : IP68 and IP6K9K |
| Locking features | Integrated CPA, integrated contact retention through PA |
| Keying and coding | A, B, C, D mechanical key options with color identification |
| Mating durability | 50 mating cycles per SAE J2030 |
| Vibration performance | Tested at 21 G RMS up to 2000 Hz |
Real World Applications
AMPSEAL 16 Connector Series
Engine compartment and hot zonesUsed where heat and vibration are common. High temperature variants support up to 150°C for on-engine, aftertreatment, and powertrain areas.
Aftertreatment modules and nearby harnessing
Applied around DOC (Diesel Oxidation Catalyst), DPF (Diesel Particulate Filter), and SCR (Selective Catalytic Reduction) systems where connectors can see elevated temperature and harsh exposure.
Chassis harness breakpoints and frame rail routing
Used in areas exposed to spray, debris, and vibration where sealed connections help reduce contamination-related issues.
Brake units and control modules
Applied where secure mating matters. Integrated CPA supports secondary locking after mating to help reduce accidental unlatching.
Sensors, actuators, motors, and gearboxes
Used for wire-to-device connections in harsh duty equipment where contact retention features support stability under vibration.
Construction and agricultural equipment harnessing
Used in machines that see mud, dust, washdown, and mechanical shock, where sealed connectors are often specified.
Assembly Videos
Crimping Instructions (English)
AMPSEAL 16 Contacts (HDSF size 16)
AMPSEAL 16 Connector Series Parts and Accessories
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AMPSEAL 16 Accessories
AMPSEAL 16 Series Installation Tooling
AMPSEAL 16 hybrid connectors
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AMPSEAL 16 Connector Series Additional Information
Dimensions
AMPSEAL 16 Connector Series
| Cavity | AMPSEAL Plug | AMPSEAL Header | |||||
|---|---|---|---|---|---|---|---|
| Overall Length A | Overall Height B | Overall Width C | Overall Length Straight D | Overall Height E | Overall Width F | Overall Lenght 90° G | |
| 8 | 1.32 (33.6) | 1.36 (34.6) | 1.08 (27.4) | 1.35 (34.3) | 1.26 (32.1) | 1.61 (40.8) | 1.49 (37.9) |
| 14 | 1.32 (33.6) |
1.36 (34.6) |
1.39 (35.4) | 1.35 (34.3) | 1.26 (32.1) | 1.92 (48.8) | 1.49 (37.9) |
| 23 | 1.32 (33.6) | 1.36 (34.6) | 1.87 (47.4) | 1.35 (34.3) | 1.26 (32.1) | 2.39 (60.8) | 1.49 (37.9) |
| 35 | 1.32 (33.6) | 1.36 (34.6) | 2.50 (63.4) | 1.35 (34.3) | 1.26 (32.1) | 3.03 (76.9) | 1.49 (37.9) |
Quick Selection Guide
AMPSEAL 16 Connector Series
| Decision | When to choose it | What to check |
|---|---|---|
| Standard temperature housing |
Use for most harness zones that stay within -40°C to 125°C | Expected ambient at the connector, proximity to engine and exhaust heat |
| High temperature housing | Use when the connector can see higher heat, up to -40°C to 150°C, such as on-engine, aftertreatment, and powertrain zones | Target zone temperature, heat soak, and nearby aftertreatment equipment |
| Standard wire seal option | Use when wire insulation outside diameter fits the standard seal range | Measure insulation OD and match to the published wire seal range |
| Reduced wire seal option | Use when wire insulation outside diameter is smaller and needs a reduced seal | Measure insulation OD and match to the reduced seal range |
| Keying A, B, C, or D | Use when you have multiple connectors of the same cavity count in one harness and want to reduce mismating risk | Define harness build strategy and assign key codes per mating pair |
| Add backshells | Use when you need added strain relief, cleaner routing, or added rear protection in exposed harness locations | Harness bend radius, pull forces, abrasion risk, and routing constraints |
| Fill unused cavities with sealing plugs | Use whenever you have unused positions and still need environmental sealing | Confirm cavity count versus loaded circuits before final assembly |
Frequently Asked Questions
AMPSEAL 16 Connector Series
Q: What is CPA on AMPSEAL 16 connectors?
A: CPA stands for Connector Position Assurance. After mating AMPSEAL 16 connectors, the CPA slides into place as a secondary lock. It helps reduce the chance of accidental unlatching in high vibration environments such as engine compartments, construction equipment, and heavy-duty vehicles.The CPA works with the primary latch to provide an additional mechanical safeguard. This supports secure connector engagement during shock and vibration, which is common in industrial and commercial transportation applications
Q: What is TPA in AMPSEAL 16 connectors?
A: TPA means Terminal Position Assurance. In AMPSEAL 16 connectors, the TPA is integrated into the housing as a Primary Latch Reinforcement feature.
After crimped contacts are inserted into the housing, the TPA is pushed into its final locked position. This helps confirm that each contact is fully seated and helps prevent contact back-out under vibration or mechanical stress
Unlike connector systems that require separate wedgelocks, AMPSEAL 16 connectors integrate this function into the one-piece housing design.
Q: What temperature range do AMPSEAL 16 connectors support?
A: Standard AMPSEAL 16 connectors operate from -40°C to +125°C.
High-temperature AMPSEAL 16 connectors extend this range up to +150°C and meet UL94 V-0 flammability requirements. These variants are designed for on-engine, aftertreatment, and powertrain applications where elevated temperatures are common.
Q: Are AMPSEAL 16 connectors sealed against water and dust?
A: Yes. AMPSEAL 16 connectors are designed to meet IP67 ingress protection. With rear protection or backshells installed, they can achieve IP68 and IP6K9K performance in demanding environments
Sealing is achieved through:
- A silicone interface seal between plug and cap
- Individual wire seals at each cavity
- Optional cavity plugs for unused positions
This multi-layer sealing approach helps reduce the risk of moisture, dust, and overspray entering the connection.
Q: What current and voltage ratings do AMPSEAL 16 connectors support?
A: AMPSEAL 16 connectors use HDSF and DEUTSCH solid size 16 contacts rated up to 13 amps per circuit, depending on wire gauge. They support 14–20 AWG (2.50–0.50 mm²) wire sizes and are rated up to 250 V DC
Actual allowable current depends on wire gauge, contact plating, and thermal conditions.
Q: How do AMPSEAL 16 connectors help reduce harness assembly time?
A: AMPSEAL 16 connectors feature a fully assembled one-piece housing with integrated TPA and CPA.
Because the terminal lock and connector lock are built into the housing, there are no separate wedgelocks or secondary components to install. This can help reduce assembly steps, simplify industrialization, and support consistent quality in high-volume harness production
Q: What wire sizes and cavity counts are available?
A: AMPSEAL 16 connectors are available in 2, 3, 4, 6, 8, and 12 positions.
They support 14–20 AWG wire sizes and provide standard and reduced wire seal options depending on insulation diameter
This allows engineers to select the appropriate configuration based on current requirements and harness layout.
Q: How durable are AMPSEAL 16 connectors in service?
A: AMPSEAL 16 connectors are rated for 50 mating cycles per SAE J2030 and are tested to withstand 21 G RMS vibration from 25 to 2000 Hz for 20 hours per axis
This supports stable electrical performance in high vibration applications such as engines, transmissions, and off-highway equipment.
Q: How do I disassemble an AMPSEAL 16 connector?
A: Disassembly can mean two different actions:
• Unmating the connector (separating the two halves)
• Depinning the connector (removing contacts from the housing)
Q: How do I unmate the connector?
A:
1. Release the secondary lock (CPA) so the main latch can move.
2. Press the primary latch and pull the two halves apart in a straight line.
Tip: If the connector does not separate easily, check that the secondary lock is fully disengaged before applying force.
Q: What is the secondary lock (CPA)?
A: It is a safety feature that prevents accidental unmating. It must be released before the main latch can be disengaged.
Q: How do I remove contacts from the connector (depin)?
A:
1. Remove any rear accessories such as a backshell or conduit support.
2. Remove the terminal position assurance (TPA) from the housing.
3. Insert a contact extraction tool into the cavity to release the retention feature.
4. Gently pull the wire from the rear until the contact is removed.
Q: What tool is needed for contact removal?
A: A dedicated contact extraction tool sized for the contact system is recommended to properly release the retention feature without damaging the housing.
Q: What should I do if the contact will not come out?
A:
• Recheck tool alignment inside the cavity
• Make sure the retention feature is fully released
• Avoid pulling with excessive force, as this can damage the connector or seals
Q: How do I reassemble the connector after depinning?
A:
1. Insert the contact until it locks into place.
2. Reinstall the TPA to secure all contacts.
3. Remate the connector and re-engage the secondary lock.
