Replace engine wiring harness connectors

[bissellh]

I want to replace some engine wiring harness connectors that are worn on my car. Specifically, I need the connector for the engine oil level sensor. It comes on periodically eventhough the oil level is full. I have already replaced the oil level sensor itself. The connector is in bad shape though. I also want to replace the connector for the oxygen sensor eventhough it is working fine. It is damaged and the oxygen sensor just plugs in but is not fastened in place. I figure it is just a matter of time before it comes apart or I get a bad connection and some fault codes result from it.

I found the connectors I need on www.realoem.com. Can I also order from realoem.com or do I need to find a supplier that carries them if one even does carry them?

I may also order some lighting connectors that broke while I was changing some bulbs.

I saw this covered in the forum recently, but have not been able to locate it again. Sorry if I am duplicating a thread!

[Evan]

a lot of us order from BMA in Ventura, California.

I always compare prices and shipping charges/time with my local dealer.

You can find BMA at www.bmaautoparts.com

[Blitzkrieg Bob]

some of the common Bosch type connectors at most auto shops, and the rest it will be off to the dealer.

[shogun]

The dealer has them all for small money.
Or here
http://www.action-electronics.com/ampcpc.htm#Extract
Just yesterday I bought one from the aux fan switch on the right side of the radiator.
The oxy sensor connector is broken inside, there is a plastic ring which breaks, then you can pull out the plug without unscrewing
But you need a special extraction tool.
All plugs are from AMP-Tyco and there is a special tool, which costs about 50 $.
But you can make such a wire extractor by yourselves with an old telescopic car antenna and a knitting needle.
http://www.bimmerboard.com/forums/posts/186160/
Pics do not work anymore
But here you can see how such thing looks
http://www.action-electronics.com/grc/ca40746.jpg
PIN EXTRACTION TOOL
To extract pins from CPC connectors
# 305183 AMP#305183

[Kibokojoe]

Last time I bought a connector from the dealer it came to $18.00 and all I got was one side of the connector and the 5 bullet pins. Can you say holy cow.


some of the common Bosch type connectors at most auto shops, and the rest it will be off to the dealer.

[bissellh]

The dealer has them all for small money.
Or here
http://www.action-electronics.com/ampcpc.htm#Extract
Just yesterday I bought one from the aux fan switch on the right side of the radiator.
The oxy sensor connector is broken inside, there is a plastic ring which breaks, then you can pull out the plug without unscrewing
But you need a special extraction tool.
All plugs are from AMP-Tyco and there is a special tool, which costs about 50 $.
But you can make such a wire extractor by yourselves with an old telescopic car antenna and a knitting needle.
http://www.bimmerboard.com/forums/posts/186160/
Pics do not work anymore
But here you can see how such thing looks
http://www.action-electronics.com/grc/ca40746.jpg
PIN EXTRACTION TOOL
To extract pins from CPC connectors
# 305183 AMP#305183

Does anyone know of a trick to releasing the pins from the old three pin connector goiing to my oil level sender? The three pins are not circular in shape as in the demonstrations you posted. They have two split square shaped metal blades. I do not think I could fit a hollow antenna over these pins in order to release them.

I guess I could cut the old damaged connector apart in order to free up the three pins for insertion into the new connector. It would be a lot easier to find a way to release them though because there is not much room under the car to cut the old connector apart. Does anyone know how I can release these pins in order to install them in the new connector?

[Kalevera]

Once the connector itself is unlocked, the pins are usually released with a special tool that looks like a little two pronged fork. Same type of tool is used for fuse blade connectors and the like. I don't have a picture or a part number, and there are multiple sizes of this kind of tool, so that info might not be of much help. But, basically, I'd figure out where the retaining tabs are on the pin and go from there.

[shogun]

The extractor tool is shown here
http://www.action-electronics.com/ampcpc.htm#Extract

or make one by your own as I have done it
http://www.bimmerboard.com/forums/posts/186160/

[bissellh]

Once the connector itself is unlocked, the pins are usually released with a special tool that looks like a little two pronged fork. Same type of tool is used for fuse blade connectors and the like. I don't have a picture or a part number, and there are multiple sizes of this kind of tool, so that info might not be of much help. But, basically, I'd figure out where the retaining tabs are on the pin and go from there.

This three prong/pin connector is one solid piece and does not unlock, unless by unlock you mean disconnect or unplug. I am hoping to avoid buying a tool to release the pins/prongs since I do not think I will be doing this very often. I tried releasing the pins/prongs with a variety of implements including pins, small nails and a hair pin. Does anyone know of a way to release the pins with readily available implements.

[Blitzkrieg Bob]

will be able to release the pin on the wiring harness side, on the sensor side...it's molded together.

[bissellh]

The extractor tool is shown here
http://www.action-electronics.com/ampcpc.htm#Extract

or make one by your own as I have done it
http://www.bimmerboard.com/forums/posts/186160/

The connector I am trying to remove pins from has two opposing metal blades as opposed to a molex female round style pin. The corresponding male pins would be single blade pins that slide down between the two female blades. Is the extractor tool the same or different for this style pin?

I don't think the antenna will fit around the two female blades and inside the plastic connector to allow me to release the pin. There does not appear to be enough clearance in there. I could be wrong though.

If I had an old antenna around I would try it.

[shogun]

All connectors on a BMW car are made by AMP TYCO. BMW dealers have a complete set of extraction tools, have a look here
http://www.e38.org/breakoutboxesandconenctors.pdf

Use the function at the bottom to go to next pages.

[Chris'91'525i]

I want to replace some engine wiring harness connectors that are worn on my car. Specifically, I need the connector for the engine oil level sensor. It comes on periodically eventhough the oil level is full. I have already replaced the oil level sensor itself. The connector is in bad shape though. I also want to replace the connector for the oxygen sensor eventhough it is working fine. It is damaged and the oxygen sensor just plugs in but is not fastened in place. I figure it is just a matter of time before it comes apart or I get a bad connection and some fault codes result from it.

I found the connectors I need on www.realoem.com. Can I also order from realoem.com or do I need to find a supplier that carries them if one even does carry them?

I may also order some lighting connectors that broke while I was changing some bulbs.

I saw this covered in the forum recently, but have not been able to locate it again. Sorry if I am duplicating a thread!

It might be this type. I'm pretty sure RadioShack carries it too.

http://www.aerostich.com/catalog/US/Connector-Pin-Tool-p-17528.html

http://www.aerostich.com/files/images/2576_1sa.jpg

[shogun]

That thing does not work, I bought it from Autohaus az, the extractor pins are too short.
That part is made by Lisle

Terminal Tool for G.M.

Eliminate Damaged Wires and Terminals.
Lisle Wire Terminal Tools are designed to remove wires from terminals without damage to either. 14900 is designed for Pack-Con and Weather-Pack terminals on GM C3 Systems. Tool can also retrieve trouble codes from engine computer on late model GM vehicles.

http://www.lislecorp.com/tool_detail.cfm?detail=96

[bissellh]

That thing does not work, I bought it from Autohaus az, the extractor pins are too short.
That part is made by Lisle

Terminal Tool for G.M.

Eliminate Damaged Wires and Terminals.
Lisle Wire Terminal Tools are designed to remove wires from terminals without damage to either. 14900 is designed for Pack-Con and Weather-Pack terminals on GM C3 Systems. Tool can also retrieve trouble codes from engine computer on late model GM vehicles.

http://www.lislecorp.com/tool_detail.cfm?detail=96

It looks like there is a variety terminal tools on the market. I found three on eBay alone.
- http://cgi.ebay.com/ebaymotors/MAC-Tools-Wire-Terminal-Tool-WT565-NOS_W0QQcmdZViewItemQQcategoryZ43996QQihZ020QQitem Z300113679520QQrdZ1
- http://cgi.ebay.com/ebaymotors/NEW-WIRE-CONNECTOR-TERMINAL-REMOVAL-TOOL-2PC_W0QQcmdZViewItemQQcategoryZ43989QQihZ013QQitem Z230133662647QQrdZ1
- http://cgi.ebay.com/ebaymotors/Wire-Terminal-Tool-Ferrari-Jaguar-Rolls-Royce-Auto_W0QQcmdZViewItemQQcategoryZ43998QQihZ008QQite mZ180121725915QQrdZ1

It looks to me that the shape of the one Chris recommended is the same shape as the Lyle brand one that Shogun recommended which are the same shape as the red and green one and the MAC Tools one on eBay. The only one that looks differet is the swis knife style one on eBay. Of course there are no dimensions given to compare.

I never thought that it could be so difficult to get the right too to do such a seemingly simple job of changing out a connector. The way things are going, I will probably end up cutting off the old connector as carefully as possible to ensure that I do not damage the pins so I can reuse them.

[shogun]

is the same shape as the Lyle brand one that Shogun recommended
I did NOT recommend the Lisle one, I said it does NOT fit.

You need one extractor tool for AMP-TYCO connectors, not for GM, Ferrari, RR or whatever.