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               Apex 150 16 Way Connector System (FCI)
                       Test Report and DVP&R
             DVP&R #FCINPEL- Apex150 16Way- PV, 05-146
                  Production Validation (PV) Level


                   ESR# AM-030204; Test Request# 05-146

                                      Part Numbers
                        54241600- 16 Way male assembly
                        54241630- 16 Way female assembly with CPA
                        54241630N- 16 Way female assembly without CPA
                        54001625- Apex 150 female terminal, C194 MET,16-18 AWG
                        54001626- Apex 150 male terminal, C194 MET, 16-18 AWG
                        54002000- Apex 150 female terminal, C194 MET, 20-22 AWG
                        54002001- Apex 150 male terminal, C194 MET, 20-22 AWG




  September 30, 2005




  FCI Automotive Division
  28100 Cabot Drive, Suite 100
  Novi, MI 48377
  (248) 592-2700
                                                                           Lab Technicians
                                                                           Bruce Stuart
  _____________________________                                            George Balalas
                                                                           John Blades
  Glen Sparks                                                              Brian Kilian
  Product Evaluation Lab Manager                                           Jennifer Skwarski
  Phone ext. 2884                                                          Dragica Cemalovic
                                                                           George Williamson
  Original signed document on file.
Contents are guaranteed to be authentic (not modified) only if received from authorized FCI personnel.

                                     Apex 150 16 Way Inline Connector System - PV Level

                                                   TABLE OF CONTENTS

  EXECUTIVE SUMMARY ...........................................................................................................2

  DVP&R ...........................................................................................................................................3

  SAE/USCAR-2- PRODUCTION VALIDATION TESTS..........................................................8
  Terminal-Connector Engage/Disengage..........................................................................................9
  Connector-Connector Engage/Disengage......................................................................................15
  Polarization Feature Effectiveness.................................................................................................17
  Miscellaneous Components Engage/Disengage ............................................................................19
  Connector to Connector Audible Click .........................................................................................26
  High Temperature Exposure/ Pressure Vacuum Leak...................................................................28
  APPENDIX A - PHOTOS OF TEST SETUPS .........................................................................30

  APPENDIX B - EQUIPMENT CALIBRATION......................................................................36




                                                                  Page 1 of 38                                   Product Evaluation Lab
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                                  Apex 150 16 Way Inline Connector System - PV Level

  Executive Summary

          This report contains the DVP&R and individual test reports for the PV Level testing on
  the Apex 150 16 Way In Line connector system. Testing was completed versus SAE/USCAR-2,
  revision 4, May 2004.


  Results

           All components used in this level of testing have PASSED all pertinent SAE/USCAR-2
  test criteria for connector temperature class 3 (maximum 125°C).

  SAE/USCAR-2 tests performed in this DVP&R Level include the following:

  Terminal to Connector Engage/ Disengage ............................................................................... Pass
  Connector to Connector Engage/ Disengage ............................................................................. Pass
  Polarization Feature Effectiveness............................................................................................. Pass
  Miscellaneous Components Engage/ Disengage ....................................................................... Pass
  Connector to Connector Audible Click ..................................................................................... Pass
  High Temperature Exposure/ Pressure Vacuum Leak............................................................... Pass


  Comments and Observations

          For additonal testing on the Apex 150 connector systems please see the PV level test
  report for the Apex 150 10 Way In Line connector system, September 2005, test request series
  05-145.

         This test program for the 16 Way connector was abbreviated based on the results from
  the 10 Way connector testing.

            Photos of the various test set-ups are located in Appendix A starting on page 30 of this
  report.




                                                           Page 2 of 38                               Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                            DVP&R




                                             Page 3 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                             Page 4 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                             Page 5 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                             Page 6 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                             Page 7 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




            SAE/USCAR-2- Production Validation Tests




                                             Page 8 of 38                     Product Evaluation Lab
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                            Apex 150 16 Way Inline Connector System - PV Level

  Terminal-Connector Engage/Disengage
  SAE/USCAR-2, Revision 4
  Test Method 5.4.1.3
  Test Criteria 5.4.1.4



  Results:

  All parts PASSED Terminal-Connector Engage/Disengage test criteria.


  Procedure:

          All male and female terminals were machine crimped onto 22 and 16 AWG TXL wire.
  All testing requirements of SAE/USCAR-2 were performed; terminal insertion with removal of
  previously inserted terminals, terminal insertion without removal of previously inserted
  terminals, removal with wedge seated, removal without wedge seated, terminal push-thru, and
  terminal removal after moisture conditioning.

         All insertions were performed using a Thwing-Albert force machine at a rate of 50mm
  per minute. All removals were performed using a Chatillon force machine at a rate of 50mm per
  minute.


  Observations/Comments:

         No unusual circumstances to report.




                                               Page 9 of 38                      Product Evaluation Lab
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                                     Apex 150 16 Way Inline Connector System - PV Level
  Terminal - Connector Engage/Disengage Force                                                                     Start Date:    9/20/05
       Test Spec.: USCAR-2 Rev. 4                     Term. Sys.: Apex 150 on 22AWG TXL                          Finish Date:    9/23/05
     Test Number: 5.4.1                               Conn. Sys.: 16 Way Sealed Apex Connector                         Tech:      JDB
        Test Level: PV                                                                                          Test Request: 05-146A4,D4
                                                                                                                     ESR #:     AM030204
  Terminal Insertion
                                          Male                                          Female
     Terminal              Insertion                Insertion               Insertion            Insertion
     Cavity and          w/o Removal              w/ Removal              w/o Removal          w/ Removal
     Sequence            of Prev. Term.          of Prev. Term.           of Prev. Term.      of Prev. Term.
          1                    8.07                   8.09                     6.90                7.92
          2                    6.74                   7.23                     6.48                6.91
          3                    6.27                   8.18                     5.86                6.15
          4                    6.81                   6.94                     6.42                6.27
          5                    6.58                   6.94                     6.16                5.81
          6                    7.40                   6.32                     6.09                5.58
          7                    7.19                   9.51                     6.32                6.07
          8                    7.06                   7.14                     6.24                6.13
          9                    8.24                   6.21                     6.38                5.78
         10                    9.35                   7.06                     7.08                6.00
         11                    7.52                   6.82                     5.74                5.84
         12                    7.58                   7.03                     6.68                6.23
         13                    8.21                   6.47                     7.48                6.29
         14                    9.93                   6.30                     6.65                6.04
         15                   10.27                   6.06                     6.94                9.19
         16                    9.05                   6.48                     7.00                6.07

       Avg.                   7.89                   7.05                     6.53                 6.39
       Max.                  10.27                   9.51                     7.48                 9.19
       Min.                   6.27                   6.06                     5.74                 5.58

      Criteria               ≤ 30N                  ≤ 30N                    ≤ 30N                ≤ 30N

              Notes: All data is peak newtons.
                     Insertion rate= 50 mm/ minute




                                                                  Page 10 of 38                           Product Evaluation Lab
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                                        Apex 150 16 Way Inline Connector System - PV Level
  Terminal - Connector Engage/Disengage Force                                                                               Start Date:   8/24/05
       Test Spec.: USCAR-2, rev. 4                     Term. Sys.: Apex 150 female terminals, 16 AWG TXL wire             Finish Date:    8/24/05
     Test Number: 5.4.1                                Conn. Sys.: 16 Way sealed connector                                       Tech:     GHW
       Test Level: PV                                                                                                    Test Request:    05-146A1
                                                                                                                                ESR#: AM-030204
  Female Connector Engage

                          Insertion           Terminal                                   Insertion          Terminal
                        w/ Removal           Cavity and                                w/o Removal          Cavity and     Push
     Sample #          of Prev. Term.        Sequence                   Sample #       of Prev. Term.       Sequence       Thru
         1                  6.00                  1                         2                7.00                1          Pass
                            6.00                   2                                         7.50                8          Pass
                            6.00                  3                                          7.45               13          Pass
                            6.00                   4                                         7.15                9          Pass
                            6.00                   5                                         7.20                2          Pass
                            6.00                   6                                         7.40                7          Pass
                            7.00                  7                                          6.50               15          Pass
                            6.00                  8                                          6.75               10          Pass
                            6.00                  16                                         6.80                3          Pass
                            4.00                  15                                         7.15                6          Pass
                            7.00                  14                                         6.20               14          Pass
                            7.00                  13                                         6.65               11          Pass
                            7.00                  12                                         8.05                4          Pass
                            6.00                  11                                         8.10                5          Pass
                            6.00                  10                                         8.30               12          Pass
                            6.00                  9                                          8.50               13          Pass

       Avg.                 6.13                                                             7.29
       Max.                 7.00                                                             8.50
       Min.                 4.00                                                             6.20

      Criteria             ≤ 30N                                                             ≤ 30N

             Notes: All data is peak newtons.
                    All insertions performed by hand, not mechanized fixture.




                                                                      Page 11 of 38                                  Product Evaluation Lab
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                                  Apex 150 16 Way Inline Connector System - PV Level
  Terminal - Connector Engage/Disengage Force                                                         Start Date:    8/24/05
       Test Spec.: USCAR-2, rev. 4      Term. Sys.: Apex 150 female terminals, 16 AWG TXL wire       Finish Date:    8/25/05
     Test Number: 5.4.1                Conn. Sys.: 16 Way sealed connector                                   Tech:   GHW
       Test Level: PV                                                                               Test Request: 05-146A1
                                                                                                             ESR#: AM-030204
  Disengage
                                                         Female Connector
                                       Terminal                    Terminal         Conditioned      Terminal
                       Removal        Cavity and      Removal      Cavity and        Samples        Cavity and
     Sample #         w/o wedge       Sequence       with wedge    Sequence          Removal        Sequence
         1                127.0            1            121.00            1            124.0             1
                          121.0            2             127.0            2            128.0             2
                          121.0            3             116.0            3            117.0             3
                          122.0            4             126.0            4            122.0             4
                          118.0            5             120.0            5            122.0             5
                          127.0            6             118.0            6            122.0             6
                          117.0            7             125.0            7            123.0             7
                          122.0            8             122.0            8            133.0             8
                          120.0           16            125.0            16            125.0            16
                          119.0           15            124.0            15            118.0            15
                          125.0           14            124.0            14            120.0            14
                          131.0           13            133.0            13            129.0            13
                          125.0           12            129.0            12            125.0            12
                          126.0           11            133.0            11            124.0            11
                          118.0           10            118.0            10            116.0            10
                          122.0            9             124.0            9            122.0             9

       Avg.             122.56                          124.06                         123.13
       Max.             131.00                          133.00                         133.00
       Min.             117.00                          116.00                         116.00

      Criteria          ≥ 45N                           ≥ 85N                          ≥ 70N

             Notes: All data is peak newtons.
                    Removal rate= 50 mm/ minute




                                                       Page 12 of 38                             Product Evaluation Lab
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                                     Apex 150 16 Way Inline Connector System - PV Level
  Terminal - Connector Engage/Disengage Force                                                                       Start Date:   7/28/05
       Test Spec.: USCAR-2, rev. 4                Term. Sys.: Apex 150 male terminals, 16 AWG TXL wire            Finish Date:    7/28/05
     Test Number: 5.4.1                          Conn. Sys.: 16 Way sealed connector                                     Tech:      D.C
       Test Level: PV                                                                                            Test Request:    05-146d1
                                                                                                                        ESR#: AM-030204
  Male Connector Engage

                          Insertion         Terminal                                Insertion       Terminal
                        w/ Removal         Cavity and                             w/o Removal       Cavity and     Push
     Sample #          of Prev. Term.      Sequence                Sample #       of Prev. Term.    Sequence       Thru
         1                  8.80                 1                     2               10.35              5         Pass
                            8.50                 4                                      8.95             16         Pass
                            8.65                8                                       9.15             3          Pass
                            8.70                 9                                     10.20             11         Pass
                            7.50                12                                     9.10              13         Pass
                            9.00                11                                      8.85              4         Pass
                            7.65                 2                                      9.60             10         Pass
                            8.00                13                                     10.30             14         Pass
                            8.05                15                                      9.90              8         Pass
                            7.75                 7                                     10.55              6         Pass
                            7.90                3                                       9.60             1          Pass
                            8.50                5                                       8.05             2          Pass
                            7.70                10                                      7.70              7         Pass
                            9.10                14                                      9.50              9         Pass
                            8.35                16                                     10.05             15         Pass
                            7.80                 6                                      9.95             12         Pass

       Avg.                 8.25                                                        9.49
       Max.                 9.10                                                       10.55
       Min.                 7.50                                                        7.70

      Criteria             ≤ 30N                                                       ≤ 30N

             Notes: All data is peak newtons.
                    All insertions performed by hand, not mechanized fixture.




                                                                  Page 13 of 38                               Product Evaluation Lab
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                                 Apex 150 16 Way Inline Connector System - PV Level
  Terminal - Connector Engage/Disengage Force                                                       Start Date:    7/28/05
       Test Spec.: USCAR-2, rev. 4     Term. Sys.: Apex 150 male terminals, 16 AWG TXL wire        Finish Date:    7/29/05
     Test Number: 5.4.1               Conn. Sys.: 16 Way sealed connector                                  Tech:    D.C
       Test Level: PV                                                                             Test Request: 05-146d1
                                                                                                           ESR#: AM-030204
  Male Connector Disengage
                                                          Male Connector
                                      Terminal                     Terminal        Conditioned     Terminal
                       Removal       Cavity and      Removal       Cavity and       Samples       Cavity and
     Sample #         w/o wedge      Sequence       with wedge     Sequence         Removal       Sequence
         1                108             1             110              1            97.0             1
                          108             2             108              2            101.0            2
                          109             3             111              3            102.0            3
                          110             4             108              4            100.0            4
                          114             5             114              5            107.0            5
                          111             6             115              6            102.0            6
                          110             7             110              7            103.0            7
                          110             8             108              8            101.0            8
                          114            16             114             16            101.0           16
                          109            15             112             15            103.0           15
                          111            14             111             14            105.0           14
                          107            13             115             13            108.0           13
                          111            12             108             12            108.0           12
                          108            11             115             11            107.0           11
                          106            10             110             10            104.0           10
                          104             9             110              9            105.0            9
                                                                                                               8
       Avg.             109.38                         111.19                         103.38
       Max.             114.00                         115.00                         108.00
       Min.             104.00                         108.00                         97.00

      Criteria          ≥ 45N                          ≥ 85N                          ≥ 70N

             Notes: All data is peak newtons.
                    Removal rate= 50 mm/ minute




                                                      Page 14 of 38                            Product Evaluation Lab
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                            Apex 150 16 Way Inline Connector System - PV Level

  Connector-Connector Engage/Disengage
  SAE/USCAR-2, Revision 4
  Test Method 5.4.2.3
  Test Criteria 5.4.2.4




  Results:

  All parts PASSED Connector-Connector Engage/Disengage test criteria.


  Procedure:

         The connectors were assembled with all applicable seals, wedges, retainers, and terminals
  on 16 AWG TXL wire. No CPA units were used.

         All testing requirements of SAE/USCAR-2 were performed; connector insertion,
  connector removal with primary lock engaged, connector removal without primary lock engaged
  and connector primary lock unlatching force.

         All insertions were performed using a Thwing-Albert force machine at a rate of 50mm
  per minute. All removals were performed using a Chatillon force machine at a rate of 50mm per
  minute.


  Observations/Comments:

         No unusual circumstances to report.




                                              Page 15 of 38                      Product Evaluation Lab
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                                      Apex 150 16 Way Inline Connector System - PV Level
  Connector-Connector Engage/Disengage                                                                         Start Date:   7/29/05
       Test Spec.: USCAR-2, rev. 4                  Term. Sys.: Apex 150 - 16 Gage                            Finish Date:    8/3/05
     Test Number: 5.4.3                             Conn. Sys.: 16 Way Apex 150                                      Tech:   J.Blades
       Test Level: PV                                                                                      Test Request #:   05-146G
                                                                                                                    ESR #: AM-030204

                          Insertion             Removal              Removal         Lock Unlatching    Lock Unlatching
     Sample #               w/lock               w/lock              w/o lock             Force          Force w/CPA
        1                   55.02                 241.18
        2                   54.06                 226.24
        3                   54.41                 239.72
        4                   54.38                 236.12
        5                   58.93                 237.18
        6                   59.49                                      51.56
        7                   55.19                                      49.79
        8                   58.50                                      50.84
        9                   54.55                                      49.76
        10                  52.63                                      48.71
        11                  57.01                                                         38.50              Pass
        12                  55.68                                                         37.89              Pass
        13                  66.04                                                         37.25              Pass
        14                  55.98                                                         37.95              Pass
        15                  55.69                                                         39.11              Pass

       Avg.                 56.51                 236.09               50.13              38.14
       Max.                 66.04                 241.18               51.56              39.11
       Min.                 52.63                 226.24               48.71              37.25

      Criteria              ≤ 75N                ≥ 110N                ≤ 75N         ≥ 10N & ≤ 70N          ≥ 50N

             Notes: All data is peak newtons.
                    Insertion/ removal rate= 50 mm/ minute




                                                              Page 16 of 38                            Product Evaluation Lab
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                            Apex 150 16 Way Inline Connector System - PV Level

  Polarization Feature Effectiveness
  SAE/USCAR-2, Revision 4
  Test Method 5.4.4.3
  Test Criteria 5.4.4.4




  Results:

  All parts PASSED Polarization Feature Effectiveness test criteria.


  Procedure:

         The samples were prepared and tested in accordance with SAE/USCAR-2 Test 5.4.4. No
  terminals were used.

         Samples were tested in the “mis-orientated” configuration. The male and female halves
  were rotated so that testing was conducted at 180° from actual mating orientation.


  Observations/Comments:

         No unusual circumstances to report.




                                              Page 17 of 38                      Product Evaluation Lab
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                              Apex 150 16 Way Inline Connector System - PV Level
  Polarization Feature Effectiveness                                                         Start Date:   8/22/05
       Test Spec.: USCAR 2 rev 4            Term. Sys.: Apex 150 terminals                  Finish Date:   8/22/05
     Test Number: 5.4.4                     Conn. Sys.: 16 Way Inline Connector System            Tech:     GHW
        Test Level: PV                                                                   Test Request #:   05-146H
                                                                                                 ESR #: AM 030204


      Sample #         Polarization
         1                 Pass
         2                 Pass
         3                 Pass
         4                 Pass
         5                 Pass
         6                 Pass
         7                 Pass
         8                 Pass
         9                 Pass
        10                 Pass

          Criteria: No mating ≤ 220 N.

             Notes: All data is peak newtons.
                    Insertion rate= 50 mm/ minute
                    Testing was performed with one connector rotated 180°.




                                                      Page 18 of 38                      Product Evaluation Lab
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                            Apex 150 16 Way Inline Connector System - PV Level

  Miscellaneous Components Engage/Disengage
  SAE/USCAR-2, Revision 4
  Test Method 5.4.5.3
  Test Criteria 5.4.5.4




  Results:

  All parts PASSED Miscellaneous Components Engage/Disengage test criteria.


  Procedure:

        Male Wedge- Ten connectors were assembled with terminals on wire and pre-staged
  wedges. The force required to engage the wedge to the fully-seated position was measured.

         Ten additional samples were assembled without terminals and with pre-staged wedges.
  The forces required to engage the wedge to the fully seated position, to disengage it to the pre-
  staged position and then to fully remove it from the connector were measured.

        Female Wedge- Ten connectors were assembled with terminals on wire and pre-staged
  wedges. The forces required to engage the wedge to the fully-seated position and then to fully
  remove the wedge were measured.

          Ten additional samples were assembled without terminals and with pre-staged wedges.
  The forces required to engage the wedge to the fully seated position and then disengage it to the
  pre-staged position were measured.

        Male TCI (Terminal Cavity Insert)- Ten male connectors were tested. Wedges were
  removed for testing. TCI disengage only was performed.

         End Seal Retainer- Ten samples each of connectors and retainers without terminals or
  seals were used. The force required to disengage the retainer were measured. Retainer engage
  was not performed.

         CPA- Ten female connectors were assembled with pre-staged CPAs (no other
  components are required) and mated to male connectors. The force required to push the CPA
  from pre-staged to fully-seated and then to disengage it from the seated position back to the pre-
  staged position was measured.

         All engage and disengage testing was performed at 50mm per minute.



  Observations/Comments:

                                              Page 19 of 38                      Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level


         No unusual circumstances to report.




                                            Page 20 of 38                     Product Evaluation Lab
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                                   Apex 150 16 Way Inline Connector System - PV Level
  Miscellaneous Components Engage/Disengage                                                 Start Date:   7/20/05
       Test Spec.: USCAR-2, Rev. 4           Term. Sys.: none                              Finish Date:   7/20/05
     Test Number: 5.4.5                      Conn. Sys.: Apex 150 16 Way Female                  Tech:     GHW
        Test Level: PV                                                                  Test Request #:   05-146C1
                                                                                                ESR #: AM-030204


                                 CPA Mated
                        Pre-Stage to     Locked to
      Sample #            Locked         Pre-Stage
         1                  5.00              10.00
         2                  7.00              11.00
         3                  6.00              11.00
         4                  6.00              11.00
         5                  5.00              11.00
         6                  6.00               7.00
         7                  4.00               8.00
         8                  5.00              12.00
         9                  7.00              12.00
         10                 4.00               4.00

       Avg.                 5.50               9.70
       Max.                 7.00              12.00
       Min.                 4.00               4.00

      Criteria             ≤ 22N             10-30N

              Notes: All data is peak newtons.
                     Insertion/ removal rate= 50 mm/ minute




                                                        Page 21 of 38                   Product Evaluation Lab
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                               Apex 150 16 Way Inline Connector System - PV Level
  Miscellaneous Components Engage/Disengage                                                    Start Date:   9/23/05
       Test Spec.: USCAR-2, rev. 4           Term. Sys.: Apex 150                             Finish Date:   9/28/05
     Test Number: 5.4.5                     Conn. Sys.: 16 Way Inline Male Connector                Tech:    J.Blades
        Test Level: PV                                                                     Test Request #:   05-211
                                                                                                   ESR #: AM-030204


                                TPA Engage                           TPA Removal
                           With          Without              Full seat      Pre-set to
      Sample #           Terminals      Terminals            to Pre-set     full removal
         1                 51.56             44.02              42.43             50.48
         2                 52.43             43.44              41.66             55.15
         3                 46.80             45.33              42.43             51.61
         4                 53.30             53.15              34.85             53.62
         5                 50.35             45.81              38.80             61.20
         6                 51.53             49.97              39.37             67.02
         7                 49.13             43.09              38.59             50.98
         8                 49.85             49.91              36.25             53.63
         9                 50.87             43.73              39.54             45.07
        10                 49.88             47.41              41.72             56.92

       Avg.                50.57             46.59              39.56             54.57
       Max.                53.30             53.15              42.43             67.02
       Min.                46.80             43.09              34.85             45.07

      Criteria            ≤ 60 N            ≥ 15 N             ≤ 60 N            ≥ 25 N


             Notes: All data is peak newtons.
                    Insertion/ removal rate= 50 mm/ minute.
                    All insertions performed using Thwing-Albert unit.
                    All removals performed using Chatillon TCD 1000 unit.
                    Only connectors without terminals were used in TPA removal testing.




                                                        Page 22 of 38                      Product Evaluation Lab
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                               Apex 150 16 Way Inline Connector System - PV Level
  Miscellaneous Components Engage/Disengage                                             Start Date:   7/21/05
       Test Spec.: USCAR 2 rev 4                Term. Sys.: none                       Finish Date:   7/22/05
     Test Number: 5.4.5                         Conn. Sys.: 16 Way Male Connector            Tech:    GHW
        Test Level: PV                                     TCI Disengage            Test Request #: 05-146E2
                                                                                           ESR #: AM 030204
  Male connector

                            TCI
      Sample #           Disengage
         1                 182.0
         2                 294.0
         3                 237.0
         4                 223.0
         5                 201.0
         6                 242.0
         7                 215.0
         8                 248.0
         9                 228.0
        10                 223.0

       Avg.               229.30
       Max.               294.00
       Min.               182.00

      Criteria            ≥ 75 N


             Notes: All data is peak newtons.
                    Removal rate= 50 mm/ minute




                                                         Page 23 of 38              Product Evaluation Lab
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                               Apex 150 16 Way Inline Connector System - PV Level
  Miscellaneous Components Engage/Disengage                                                  Start Date:   7/21/05
       Test Spec.: USCAR-2, Rev. 4          Term. Sys.: Apex 150                            Finish Date:   7/21/05
     Test Number: 5.4.5                     Conn. Sys.: Apex 150 16 Way Female                    Tech:     GHW
        Test Level: PV                                                                   Test Request #:   05-146B
                                                                                                 ESR #: AM-030204


                           Wedge w/o Terminals                     Wedge w/Terminals
                       Pre-Stage to     Locked to            Pre-Stage to      Removal
      Sample #           Full Seat      Pre-Stage              Full Seat
         1                36.00              24.00              28.00          128.00
         2                30.00              23.00              28.00          157.00
         3                24.00              25.00              25.00          151.00
         4                31.00              20.00              27.00          128.00
         5                29.00              26.00              25.00          155.00
         6                39.00              30.00              28.00          151.00
         7                41.00              25.00              33.00          149.00
         8                40.00              27.00              34.00          145.00
         9                33.00              28.00              31.00          145.00
        10                23.00              23.00              28.00          130.00

       Avg.               32.60              25.10              28.70          143.90
       Max.               41.00              30.00              34.00          157.00
       Min.               23.00              20.00              25.00          128.00

      Criteria            ≥ 15N             ≤ 60N              ≤ 60 N          ≥ 25 N

             Notes: All data is peak newtons.
                    Insertion/ removal rate= 50 mm/ minute




                                                      Page 24 of 38                      Product Evaluation Lab
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                               Apex 150 16 Way Inline Connector System - PV Level
  Miscellaneous Components Engage/Disengage                                               Start Date:   8/19/05
       Test Spec.: USCAR 2 rev 4                Term. Sys.: none                         Finish Date:   8/22/05
     Test Number: 5.4.5                         Conn. Sys.: 16 Way Female Connector            Tech:    GHW
        Test Level: PV                                     Retainer Disengage         Test Request #: 05-146C2
                                                                                             ESR #: AM 030204
  Female Retainer

                          Retainer
      Sample #           Disengage
        1                  226.0
        2                  196.0
        3                  225.0
        4                  245.0
        5                  254.0
        6                  229.0
        7                  239.0
        8                  242.0
        9                  228.0
        10                 254.0

       Avg.               233.80
       Max.               254.00
       Min.               196.00

      Criteria            ≥ 110 N


             Notes: All data is peak newtons.
                    Removal rate= 50 mm/ minute




                                                         Page 25 of 38                Product Evaluation Lab
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                            Apex 150 16 Way Inline Connector System - PV Level

  Connector to Connector Audible Click
  SAE/USCAR-2, Revision 4
  Test Method 5.4.7.3
  Test Criteria 5.4.7.4




  Results:

  All parts PASSED Connector to Connector Audible Click test criteria.


  Procedure:

         The samples were prepared and tested in accordance with SAE/USCAR-2 Test 5.4.7
  using Apex 150 terminals on wire. Samples were tested as conditioned and unconditioned.

         The test samples were placed 600mm from the sound meter. An ambient reading was
  taken for each sample. All readings were taken using the C scale.


  Observations/Comments:

         No unusual circumstances to report.




                                              Page 26 of 38                      Product Evaluation Lab
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                                Apex 150 16 Way Inline Connector System - PV Level
  Connector to Connector Audible Click                                                                 Start Date:   7/25/05
       Test Spec.: USCAR-2, Rev 4                Term. Sys.: Apex 150 terminals                       Finish Date:   7/26/05
     Test Number: 5.4.7                          Conn. Sys.: Apex 16 Way Inline connector                   Tech:     D.C.
       Test Level: PV                                                                               Test Request:    05-146F
                                                                                                           ESR #: AM-030204



                       Unconditioned         Conditioned
     Sample #            samples              samples
         1                  13.60
         2                  13.80
         3                  13.40
         4                  12.90
         5                                      12.30
         6                                      13.30
         7                                      11.30
         8                                      11.50

       Avg.                 13.43               12.10
       Max.                 13.80               13.30
       Min.                 12.90               11.30

      Criteria             ≥ 7dB                ≥ 5dB


             Notes: All cavities were filled with terminals on 16AWG MS 8288 wire.
                    Samples were conditioned for 6 hours at 40°C and 95%Rh.
                    All readings were taken with an LA-1240 Integrating Sound Level Meter using C scale.
                    All readings are in decibels.
                    The ambient value of the sound was removed from the above calculations.




                                                        Page 27 of 38                              Product Evaluation Lab
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                                   Apex 150 16 Way Inline Connector System - PV Level

  High Temperature Exposure/ Pressure Vacuum Leak
  SAE/USCAR-2, Revision 4
  Test Method sequence ID U
  Test Criteria 5.5.1.4, 5.6.6.4




  Results:

  All systems PASSED all High Temperature Exposure test criteria.


  Procedure:

          The samples were prepared and tested in accordance with SAE/USCAR-2 Test 5.6.3
  using Apex terminals on 22 AWG TXL wire. The test oven was programmed for the USCAR-2,
  class 3 temperature level (125°C maximum).

         The Dry Circuit test was performed before and after oven cycling. Voltage Drop testing
  was performed post-test.


  Comments/Observation:

           No unusual circumstances to report.




                                                     Page 28 of 38                      Product Evaluation Lab
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                                   Apex 150 16 Way Inline Connector System - PV Level
  High Temperature Exposure and Pressure/ Vacuum Leak                                              Start Date:   7/15/05
       Test Spec.: USCAR-2, rev. 4                    Term. Sys.: Apex 150 terminal system        Finish Date:   9/8/05
     Test Number: seq. ID U                           Conn. Sys.: 16 Way connector system               Tech:    GHW
       Test Level: PV                                             maximum temp. 125°C          Test Request #:   05-146i
                                                                                                       ESR #: AM-030204
  Isolation Resistance
                                        Post-           Post-
     Sample #           Pre-Test       Temp/Rh        Press/Vac
        1                  ∞              ∞               ∞
        2                  ∞              ∞               ∞
        3                  ∞              ∞               ∞
        4                  ∞              ∞               ∞
        5                  ∞              ∞               ∞
        6                  ∞              ∞               ∞
        7                  ∞              ∞               ∞
        8                  ∞              ∞               ∞
        9                  ∞              ∞               ∞
       10                  ∞              ∞               ∞

     Test Criteria: ≥ 100MΩ

  Visual

     Sample #          Pressure        Vacuum
        1                Pass           Pass
        2                Pass           Pass
        3                Pass           Pass
        4                Pass           Pass
        5                Pass           Pass
        6                Pass           Pass
        7                Pass           Pass
        8                Pass           Pass
        9                Pass           Pass
       10                Pass           Pass

     Test Criteria: No bubbles or ingress of fluid.

            Notes: All readings are in megaohms.
                   All readings taken at 500 VDC with a megaohmmeter.
                   All cavities filled with 22 AWG TXL wire.




                                                            Page 29 of 38                    Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level

  Appendix A - Photos of Test Setups

        This section contains photos that document the test setups and the condition of the
  samples during and/or after the test.




                                            Page 30 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                            Page 31 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                            Page 32 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                            Page 33 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                            Page 34 of 38                     Product Evaluation Lab
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                         Apex 150 16 Way Inline Connector System - PV Level




                                            Page 35 of 38                     Product Evaluation Lab
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                          Apex 150 16 Way Inline Connector System - PV Level

  Appendix B - Equipment Calibration

          The following is a table listing the equipment which is used in our testing procedures.
  All of this equipment is not necessarily always used during testing, but these are the most
  commonly used units.




                                            Page 36 of 38                      Product Evaluation Lab
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                                        Apex 150 16 Way Inline Connector System - PV Level


                               Lab Equipment                         PEL ID       Calibration          Length of
                                                                     Number          Due               Calibration
    Base Line Calibration Equipment
    Wavetek 9100 Universal Calibration System                             67         11/23/05             1 YR.
    Omega CL-477 Calibrator Indicator                                     68         10/28/05             1 YR.
    Data Loggers and Meters (DMM, DVM etc.)
    Fluke 2286A Datalogger                                                216        1/12/06              1 YR.
    Fluke 79 DMM                                                          196         3/9/06              1 YR.
    Keithley 580 Digital Micro-ohmmeter - hi resolution                   331        5/18/06              1 YR.
    Keithley 580 Digital Micro-ohmmeter - hi resolution                    4         11/24/05             1 YR.
    Keithley Digital Multimeter 2000                                      314        10/27/05             1 YR.
    Keithley Digital Multimeter 2000                                      316        10/27/05             1 YR.
    Keithley Digital Multimeter 2000                                      332        1/10/06              1 YR.
    Omega HH-23 Thermometer                                               47         10/26/05             1 YR.
    Environmental Chambers And Ovens
    Espec Thermal Shock Chamber                                           287        1/11/06              1 YR.
    Thermotron Environmental Chamber #2                                   217         2/7/06              1 YR.
    Thermotron Environmental Chamber #3                                   386        1/24/06              1 YR.
    Tenney Thermal Shock Chamber #1                                       198         2/8/06              1 YR.
    Tenney Thermal Shock Chamber #2                                       376         2/8/06              1 YR.
    Cincinnati Sub-Zero CT/CTH-16-2-2-H/AC Test Chamber                   209         2/7/06              1 YR.
    Cincinnati Sub-Zero ZH16-2-2-H/AC Test Chamber                        324        1/26/06              1 YR.
    Despatch #6, LDB1-24 -4                                               203         5/3/06              1 YR.
    Despatch #4, LDB1-24 -4                                               205        8/19/06              1 YR.
    Despatch #7, LDB1-24 -4                                               319         3/8/06              1 YR.
    Despatch #8, LDB1-24 -4                                               320        1/13/06              1 YR.
    Despatch #5, LDB1-24 -4                                               204         5/2/06              1 YR.
    Despatch #3, LDB1-24 -4                                               30         4/15/06              1 YR.
    Despatch #2, LDB1-24 -4                                               29          1/6/06              1 YR.
    Despatch #1, LDB1-69-4                                                193        4/15/06              1 YR.
    Power Supplies
    Hewlett Packard 6672A Power Supply                                    18         10/29/05             1 YR.
    Hewlett Packard E3632A Power Supply                                   313        1/14/06              1 YR.
    Hewlett Packard 6652A Power Supply                                    308        1/18/06              1 YR.
    Hewlett Packard 6652A Power Supply                                    223        1/18/06              1 YR.
    Hewlett Packard 6672A Power Supply                                    309        10/29/05             1 YR.
    Hewlett Packard 6672A Power Supply                                    310        10/29/05             1 YR.
    Hewlett Packard 6652A Power Supply                                    307        1/18/06              1 YR.




                                                          Page 37 of 38                        Product Evaluation Lab
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                                           Apex 150 16 Way Inline Connector System - PV Level


                                   Lab Equipment                               PEL ID     Calibration         Length of
                                                                               Number        Due              Calibration
    Power Supplies
    Hewlett Packard 6672A Power Supply                                              311     10/29/05              1 YR.
    Hewlett Packard 6672A Power Supply                                              312     10/29/05              1 YR.
    12V Discontinuity Power Supply                                                  150      3/9/06               1 YR.
    12V Discontinuity Power Supply                                                  263      11/9/05              1 YR.
    12V Discontinuity Power Supply                                                  207      3/9/06               1 YR.
    12V Discontinuity Power Supply                                                  228      3/9/06               1 YR.
    Special Test Equipment
    Hewlett Packard 8753E Network Analyzer                                          357      5/20/06              1 YR.
    Unholtz-Dickie 4000 force lb. Vibration system.                                 151       N/A               Each Test
    Mitutoyo 6” Digital Calipers                                                    186      12/8/05             8 MO.
    Mitutoyo Blade Micrometer 0-1 inch                                              182      5/18/06             9 MO.
    Mitutoyo Digital Micrometer 0-1 inch                                            306      5/18/06             9 MO.
    Mitutoyo 6” Digital Calipers with SPC                                           334      5/11/06             6 MO.
    Mitutoyo 6” Digital Calipers with SPC                                           335      12/6/05             8 MO.
    Mitutoyo 6” Digital Calipers                                                    337      12/6/05             8 MO.
    Mitutoyo 1” Digital Micrometers                                                 346      5/18/06             9 MO.
    Mitutoyo Digital Micrometer 0-1 inch                                            347      5/18/06             9 MO.
    Mitutoyo 6” Digital Calipers                                                    354     10/25/05             8 MO.
    Chatillon Force Machine, TCD1000                                                276      3/7/06               1 YR.
    Chatillon Digital Force Gauge, DFGS-R-ND                                        294      3/3/06               1 YR.
    Chatillon Force Machine, TCD200                                                 355      3/7/06               1 YR.
    Chatillon Digital Force Gauge, DFGS-R-N and 200 lb. load cell                   356      3/3/06               1 YR.
    Chatillon Digital Force Gauge 0-200 lb.                                         91       3/3/06               1 YR.
    Chatillon Digital Force Gauge DFGS10                                            273      3/3/06               1 YR.
    Misc. Equipment
    Micro-Second Discontinuity Detector –1 Channel 12 Volt                          147     11/16/05              1 YR.
    Micro-Second Discontinuity Detector –2 Channel 12 Volt                          148      5/19/06              1 YR.
    Micro-Second Discontinuity Detector –2 Channel 12 Volt                          190     11/16/05              1 YR.
    Micro-Second Discontinuity Detector –4 Channel 12 Volt                          191      11/9/05              1 YR.
    Air Leak Test Timer                                                             36       3/9/06               1 YR.




                                                                    Page 38 of 38                     Product Evaluation Lab