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DannoXYZ DannoXYZ is offline
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Join Date: Feb 2003
Location: SF East Bay
Posts: 1,854
DIY - Harness Connectors

I'm listing sources for the engine-harness connectors to make repairs or to build your own replacement harness. Some items have multiple sources with slightly different configurations. Such as complete connectors with pigtails or individual components of housings, contact-terminals, seals and boots. Many thanks to IceShark for teaching me a lot of this stuff.

BACKGROUND
The Bosch/TE/AMP connectors used on the car are from the Junior Timer series. They are connection-compatible with the Junior Power Timer series as completed plugs & sockets. Although the contact-terminals inside the housings have to be from the same series. So if you're building a connector with Junior Timer housing, you have to use Junior Timer contact-terminals inside it. Same with Junior Power Timer housings and terminals. I recommend using the Junior Power Timer series whenever possible as they are more robust with double-catches, double-springs, and can accept wire-seals for better weatherproofing. Junior Power Timer terminals shown below.


INJECTOR/ECT/KNOCK-SENSOR CONNECTORS, 2-position
Mouser - TE/AMP 85202-1 - female housing, Junior Power Timer, new style finger-operated spring-clip, black
Mouser - TE/AMP 282680-1 - female housing, Junior Power Timer, new style finger-operated spring-clip, grey
Napa - CRB 218457 - new style finger-operated spring-clip, pre-assembled with pigtail
Napa - CRB 218545 - old style square spring-clip, pre-assembled with pigtail

SPEED&REF-SENSOR/SPEEDO/ISV CONNECTORS, 3-position
Mouser - TE/AMP 1-962581-1 - male plug, Junior Power Timer
Mouser - TE/AMP 368356-1 - female housing, Junior Power Timer, new style finger-operated spring-clip
Napa - Echlin ECH-EC173 - new style finger-operated spring-clip, pre-assembled with pigtail

AFM CONNECTOR, 5-position
Mouser - TE/AMP 282766-1 - female housing, Junior Power Timer, new style finger-operated spring-clip

TPS CONNECTOR, 6-position
Bosch 1 287 013 004
Nissan 300ZX MAF connector

TERMINALS, SEALS, BOOTS
Mouser - TE/AMP 925595-1 - female terminal, Junior Timer 17-13ga
Mouser - TE/AMP 927845-1 - female terminal, Junior Timer 20-17ga
Mouser - TE/AMP 925596-2 - female terminal, Junior Timer 20-15ga

Mouser - TE/AMP 964273-1 - female terminal, Junior Power Timer 17-13ga
Mouser - TE/AMP 964284-1 - female terminal, Junior Power Timer 20-17ga
Mouser - TE/AMP 964280-2 - female terminal, Junior Power Timer 24-20ga
Mouser - TE/AMP 964280-1 - female terminal, Junior Power Timer 24ga

Mouser - TE/AMP 1-965982-1 - male terminal, Junior Power Timer 22-18g
Mouser - TE/AMP 1-963860-1 - male terminal, Junior Power Timer 24-20g

Mouser - TE/AMP 828905-1 - wire seal white
Mouser - TE/AMP 828904-2 - wire seal blue
Mouser - TE/AMP 880810-1 - rubber boot, 2-position
Mouser - TE/AMP 880811-2 - rubber boot, 3-position

After crimping, I also like to dab a little solder at the tip of the wire (only enough to cover all bare wire and not past the strain-relief crimp). This is done in mil-spec, aerospace and F1 wiring. The solder adds mechanical strength to the joint (we've all pulled wire out of a crimped-only connector). It also seals the wire-end and prevents moisture from creeping up in between the wire-strands to cause black/green wire disease. Finally add a little strain-relief loop to the wire to prevent breakage where it enters the housing. These areas are the biggest issues with the factory wiring.

Although I don't like to use the rubber-boots as they have too much air-space inside and allow too much flexing of the wire right where they enter the connector. This is the weak-point in the factory harness where the wires for the injectors & speed/ref-sensor connectors will break. I prefer to apply 3-layers of staggered heat-shrink tubing over the joint to create a progressively stiffer wire as it goes into the connector. Will upload some photos later when I replace the female harness connectors and the male plugs on my sensors.

Last edited by DannoXYZ; 08-09-2015 at 06:52 PM..
Old 08-08-2015, 08:19 PM
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