Connector of Death Replacement
*To be moved the the Electrical articles section
This is a basic guide on a sealed connector option to replace the unsealed connector of death located on the passenger side front wheel arch. It is the connector that connects the main engine wiring loom to the loom that runs inside the front of the passenger chassis rail, the one that gets caked in dirt and grease and the terminals stop making contact.
The standard OE connector is 13 ways but not all of these are used. The replacement connector option is 12 way, for my installation I only used 10 ways.
The Connector:
Deutsch DT 12 Way
You can buy all the parts from www.polevolt.co.uk
You will need to buy:
The plug: http://www.polevolt.co.uk/acatalog/info_DT06_12SA.html
http://i160.photobucket.com/albums/t...ps3ol57tjb.jpg
The receptacle: http://www.polevolt.co.uk/acatalog/info_DT04_12PA.html
http://i160.photobucket.com/albums/t...pszs8zsfy4.jpg
Get yourself 10 of each size of the pins and sockets, so 40 in total this will cover you for the different size cables and also give a few spare when you make a mess of crimping them….
Also get a few cavity seals for the ways that you don’t use and a mounting tab to fix onto the wing.
http://www.polevolt.co.uk/acatalog/D...onnectors.html
Tools:
Good wire cutters
Good wire strippers
Good crimps like Ferrule crimps, you can use others just make sure the cable is tight in the pin or socket when crimped. Or you can solder them.
Rivet gun and a large rivet.
Method:
1. Un plug the OE connector.
2. If you have removed your perc fan now is a good time to remove all the unused cables, connectors and relay etc associated with the perc fan. Best to check the Haynes manual for which cable to remove as I found that some of the colours of cables in my loom didn’t match the Haynes manual wiring diagram. So use the diagram as the location reference then remove the cable based on what it is doing not what colour it is!
3. You will need to remove the loom off the engine to remove the perc fan wiring as its much easier.
4. Write down the wiring arrangement on both OE connectors, take a picture on your phone as well of both connectors so you can double check the wiring.
Like this:
http://i160.photobucket.com/albums/t...psgnihqwzq.jpg
http://i160.photobucket.com/albums/t...pscxf927ds.jpg
5. Now cut the cables about 1cm before the connectors, so you have a bit left that you can double double check the wiring arrangement again if required.
6. Clean the cables with some white spirit, replace any cable tubing etc.
7. Layout your new connector parts so you can check you have everything.
8. Slide the orange rubber seal onto the cables one at a time in order as per the original connector. Make sure you mirror the wiring on each connector so it all joins up correctly, follow the numbering on the connectors for this.
9. Once you have all the cables in the rubber seals you can then terminate the ends. Pins are for the receptacle, sockets are for the plug. Slide the pins and sockets in to the associated connector following the numbering so it all matches up as per step 8. Then push in the green wedgelock from the front. Then slide up the rubber seal into the back of the connector, you can spray a bit of WD40 or lick the cable :p to help it slide into the back of the connector.
10. Remove the old OE connector mount, then rivet on the new mounting tab.
11. Mount the connector, plug in the loom. Job done.
12. Beer, food, bed..
Loom with perc fan wiring removed
http://i160.photobucket.com/albums/t...psh44ypyzw.jpg
Other thread on RTOC that helped me:
Engine Loom connector names etc
https://www.rtoc.org/boards/showthrea...ht=Engine+loom
Hope this is helpful,
Jeff
