What do you do to all unused holes in a connector?

In the context of maintaining connectors in aircraft systems, it is essential to ensure that all unused holes are managed properly to prevent contamination and electrical failure. Filling unused holes with unwired contacts and sealing plugs is the most effective method because it not only protects the connector from moisture, dirt, and other contaminants but also helps maintain the integrity of the electrical connections.

This practice ensures that any potential entry points for debris or moisture are sealed adequately, which can be critical in preventing corrosion or short circuits that could affect the functionality of the connector. Additionally, using unwired contacts allows for future expandability of the connector if additional contacts are needed later on, while sealing plugs keep the internal environment of the connector clean.

Other methods, such as leaving them empty or sealing them with tape, do not provide the same level of protection and could lead to issues over time. Covering unused holes with a cap might seem like a viable alternative; however, it's often not a standard practice in aviation maintenance due to the risk of the cap becoming dislodged or lost during operations. Hence, filling with unwired contacts and sealing plugs establishes a standard for reliable and effective connector maintenance.