Material & Rating
- Housing — PA66 or PBT glass-filled, keyed to the mating ECU header
- Contacts — brass or copper alloy, tin-plated or gold-plated, crimped or soldered
- Seal — silicone peripheral and wire seals for under-hood use
- Terminal range — sized to the wire cross-section used on the ECU circuits
- Temperature — rated to the connector supplier specification; stated on the drawing
- Voltage — 12 V and 24 V vehicle systems
- Ingress protection — sealed versions per supplier rating when mated and capped
Certification
Cactus Electronics is certified to ISO 9001, IATF 16949 and UL and manufactures to the IPC/WHMA-A-620 workmanship standard. Raw materials comply with RoHS. Every assembly passes 100 % electrical testing - continuity, insulation resistance and withstand voltage - before packing, and the QC-to-production personnel ratio is 1:3.
Application
ECU and TCU connectors are used wherever a control unit has to be mated with a harness on the vehicle or on a test bench.
- Engine control unit harness assembly
- Transmission control unit harness assembly
- Bench flashing and calibration fixtures
- Prototype vehicle wiring
- Motorsport and aftermarket ECU installation
- Service and repair of damaged ECU connectors
Custom Options
- Pin count and keying: 23 pin, 35 pin, or built from your sample
- Supplied loose, pre-terminated with leads, or assembled into a full breakout harness
- Terminal plating and wire seal range per circuit current
- Wire gauge, colour code and printed wire labels on terminated versions
- Samples in 3–7 working days; MOQ confirmed per project
- Customer carton marking and DDP delivery on request
FAQ
What is the operating temperature rating of this harness?
Standard PVC-insulated assemblies are rated to 80 °C; XLPE or TPE insulation raises the rating to 105 °C. Connector temperature rating follows the supplier specification for the housing and seal material; harnesses built with them are normally PVC at 80 °C or XLPE at 105 °C. The exact operating range for a part number is stated on its drawing and confirmed in the sample test report.
Is this overmolded harness waterproof?
Sealed ECU connectors use a peripheral and wire seal, so a mated and capped connector protects the contact area against water and dust per the supplier rating. The ingress protection level (typically IP67 for a mated pair) is specified on the drawing and verified during sample validation. Non-overmolded assemblies can be supplied with heat-shrink or grommet sealing instead.
Can I customize the pinout and connector type?
Yes. Pinout, connector series and gender, cable length, wire gauge, jacket colour and overmold shape are all customer-defined. Connectors can be supplied loose or terminated to your pinout, with wire gauge and colour code defined per circuit. Send a drawing, a sample, or a pinout table and we return a 2D/3D drawing prepared to IPC/WHMA-A-620 for approval before tooling.
What is your MOQ for custom cable?
MOQ is confirmed per project and depends on harness complexity, connector cost and tooling. Prototype and pilot batches are accepted before mass production, so a new programme can start with sample quantities. Samples are produced in 3–7 working days and mass production runs 20–30 days after approval.
What testing standards do you apply for harness?
Production follows IPC/WHMA-A-620. Every assembly is 100 % electrically tested for continuity, insulation resistance and withstand voltage; the in-house lab adds temperature and humidity cycling, salt spray, connector insertion and withdrawal force, and cable bending tests. Inspection records are kept in the ERP system.
