Delphi (now Aptiv) is one of the world's largest automotive connector manufacturers. Their connectors are found in virtually every vehicle brand — GM, Ford, Chrysler, Toyota, Honda, and more. Understanding Delphi connector families helps with repair, replacement, and custom wiring.
Delphi vs Aptiv
Delphi's automotive components division was spun off as Aptiv in 2017. The connector product lines continue under the Aptiv brand, but the connectors are still widely referred to as "Delphi connectors" in the aftermarket. Both names refer to the same products.
Major Delphi/Aptiv Connector Families
Metri-Pack (MP)
The most common Delphi connector family. Used throughout the vehicle for sensors, actuators, and general wiring.
Series:
- Metri-Pack 150: Small, 1–6 circuit. Used for sensors, switches, small actuators.
- Metri-Pack 280: Medium, 1–6 circuit. Higher current than MP150.
- Metri-Pack 480: Larger, higher current. Used for relays, solenoids.
- Metri-Pack 630: High current (up to 40A per circuit). Used for power distribution.
- Metri-Pack 800: Very high current. Used for battery and power connections.
Sealing: Available in sealed (with wire seals and connector seal) and unsealed versions.
Terminals: Push-in, lock-in terminals. Require a terminal removal tool for extraction.
Weather Pack
Designed for harsh environments — underhood, underbody, and exterior applications. Features:
- Individual wire seals on each terminal
- Connector-level seal (silicone seal between mating halves)
- IP67 rated
- Available in 1–6 circuit configurations
- Terminals: Crimp-type, available in multiple wire gauge ranges
Weather Pack connectors are color-coded by circuit count:
- 1-circuit: Gray
- 2-circuit: Black
- 3-circuit: Natural (white)
- 4-circuit: Gray
- 6-circuit: Black
GT 150 (Global Terminal)
A newer, more compact connector family designed for global vehicle platforms. Features:
- Smaller package than Metri-Pack
- Available in 2–12 circuit configurations
- Sealed and unsealed versions
- Used in modern GM, Ford, and other OEM vehicles
Micro-Pack 100
Very small connector for tight spaces. Used for:
- Instrument cluster connections
- Interior lighting
- Small sensors in confined areas
Circuit count: 2–8 circuits Wire gauge: 20–26 AWG
Delphi 56 Series
Used in GM vehicles for body control modules, instrument clusters, and ECM connections. Large multi-pin connectors (up to 56 circuits).
Delphi Sealed (DPS)
High-performance sealed connectors for powertrain and safety-critical applications. Used in:
- Engine control modules (ECM)
- Transmission control modules (TCM)
- ABS modules
- Airbag systems
Terminal Types
Delphi terminals are designed for specific connector families and wire gauges. Key terminal types:
| Terminal Series | Wire Gauge | Connector Family |
|---|---|---|
| 150 Series | 20–26 AWG | Metri-Pack 150, Micro-Pack |
| 280 Series | 18–22 AWG | Metri-Pack 280 |
| 480 Series | 14–18 AWG | Metri-Pack 480 |
| 630 Series | 12–16 AWG | Metri-Pack 630 |
| Weather Pack | 14–20 AWG | Weather Pack |
| GT 150 | 20–24 AWG | GT 150 |
Terminal locking: Delphi terminals use a primary lock (the terminal's own retention feature) and a secondary lock (a terminal position assurance/TPA device in the connector housing).
Repairing Delphi Connectors
Tools needed:
- Terminal removal tool (pick or Delphi-specific tool)
- Ratchet crimping tool with correct die
- Wire stripper
- Heat gun (for heat-shrink connectors)
Terminal removal:
- Release the secondary lock (TPA) — push or slide it to the open position
- Insert the terminal removal tool into the connector cavity alongside the terminal
- Depress the terminal's locking tab
- Pull the wire to extract the terminal
Terminal installation:
- Strip wire to the correct length (typically 5–6 mm)
- Crimp the terminal using the correct die for the terminal series
- Insert the terminal into the connector cavity until it clicks (primary lock engages)
- Re-engage the secondary lock (TPA)
Identifying Delphi Connectors
Delphi connectors are usually marked with:
- A part number on the connector housing
- The Delphi/Aptiv logo (triangle or "D" mark)
- Circuit count and wire gauge range
If the part number is worn off, identify by:
- Connector size and shape
- Number of circuits
- Terminal size (measure with calipers)
- Vehicle application (use a wiring diagram)
Common Applications by Vehicle
| Vehicle System | Common Delphi Connector |
|---|---|
| O2 sensors | Metri-Pack 150 (3-4 circuit) |
| Fuel injectors | Metri-Pack 150 or 280 (2 circuit) |
| MAF sensor | Metri-Pack 150 (5-6 circuit) |
| Coolant temp sensor | Metri-Pack 150 (2 circuit) |
| Throttle position | Metri-Pack 150 (3 circuit) |
| Transmission solenoids | Metri-Pack 280 or 480 |
| Underbody connectors | Weather Pack |
| ECM/PCM | Delphi 56 Series or DPS |
Summary
Delphi/Aptiv connectors are the most common automotive connectors in North American vehicles. Key families:
- Metri-Pack: General purpose, multiple sizes (150/280/480/630/800)
- Weather Pack: Sealed, for harsh environments
- GT 150: Modern compact connector
- Micro-Pack: Small connectors for tight spaces
Always match the terminal series to the connector family and wire gauge. Use the correct crimping tool and terminal removal tool for reliable repairs.
CZT supplies Delphi-compatible automotive connectors, terminals, and repair kits. Browse our automotive connector range for compatible products.
