Fuel Injector connector Removal and replacement

[anpk05]

Hi

So the fuel injector connectors are brittle and cracked, just pulls out without any resistance from the injectors.
I ordered new easy remove connectors to replace them with and got to work on the connector removal.
Even with a terminal remover i cant separate the connector from the spade. I cut the old connector to pieces to free the spades but it ended up braking the spade in half. I think it's best to cut the wire at the tip with the old connectors on.

If i cut the wire at the tip, what kind of wire can i use to extend the wire lost when cutting.

Here's a picture to put things in perspective. What did you do to replace those old, hard to remove connectors ?

[86GT635]

Ahhh man.

These cars are typically good with connectors, unless it's been handled 50x. I feel your frustration.

Typically they come off easily, but sometimes they do get sticky and fall apart.

I really can't recommend a type/brand of wire. In your position I would force myself to splice better factory used connections- if I couldn't find a whole engine harness.

The engine harness on the b34 cars really isn't that bad to do. B35 is a touch or 4 worse. There's really no off the shelf mainstream parts list for the wiring harness. If you want factory ends you'll have to look it up and likely be disappointed by the offerings.

[86GT635]

BTW those ends are the same as the power window switches if you wanna cut.

[anpk05]

Ahhh man.

These cars are typically good with connectors, unless it's been handled 50x. I feel your frustration.

Typically they come off easily, but sometimes they do get sticky and fall apart.

I really can't recommend a type/brand of wire. In your position I would force myself to splice better factory used connections- if I couldn't find a whole engine harness.

The engine harness on the b34 cars really isn't that bad to do. B35 is a touch or 4 worse. There's really no off the shelf mainstream parts list for the wiring harness. If you want factory ends you'll have to look it up and likely be disappointed by the offerings.

Thanks 86GT635, yeah i was thinking about going to a junk yard and cutting some wires to extend the connection a bit, to replace wire i lost when cutting them off.
I guess i need to go that route.

[Federico]

In my experience ('82 528i) the terminals were staked in, so I either had to destroy the housings or cut the wires flush. Ended up cutting the wires, since I needed new terminals anyway.
Also, I replaced the original Junior Timer terminals with the beefier Junior Power Timer. Moar Clamping = Moar Better! Much recommended

JT:



JPT:

[brickwhite]

Do a google search for "bosch 2 wire injector connector" Should find what you need.

I bought some here last year...

https://www.autohausaz.com/pn/12813502- ... r7EALw_wcB

[demetk]

Cut the ecu connector off with some wire and you instantly have about 30 pins you can use.

[Mike W.]

I've found the injector terminal to be fairly easy to remove. From the open end, on the back side, the opposite side from the picture, you can get in there and bend back the locking tab. I'm sure there is an extract tool but I've never even seen one let alone used one. I'll use a piece of 1/16" welding rod, ground to size, maybe a very small allen wrench, lever the tab back to the center of the connector and off it comes. Note this technique only works on the 2 terminal connectors apparently they use a double tab on the 3+ ones and I've been unable to remove those in spite of much effort.

[Bimmerguy2002]

Solder on quick releases and call it a day.

lmao @ demetk

[demetk]

Solder on quick releases and call it a day.

lmao @ demetk

I wasn't suggesting you cut off your own ecu connector, just someone else's ecu connector.

[Shawn D.]

You don't need to add any wire. Just clip as close as you can to the terminal and crimp on the new one. When I've done it, I clip both off so the wire lengths are the same (doesn't matter electrically, helps with fit).

To get the terminals out of the old housings without damaging the terminals, I've used a Dremel with a teensy toothed cutoff, scored down close to the terminals, then pried the cut pieces apart with a flat-blade screwdriver.

Do a google search for "bosch 2 wire injector connector" Should find what you need.

I bought some here last year...

https://www.autohausaz.com/pn/12813502- ... r7EALw_wcB

IMO, if you're going to be replacing a bunch of connectors, don't waste your time with those PITAs with that type of wire. Get the kind where you can simply press the wire with your finger.

https://www.autohausaz.com/pn/1287013003

[anpk05]

As many suggested, i tried to remove existing spade but didn't work.

So i cut those damn things at the wire, then soldered (got same gauge wires from a junk yard e28 harness) the Autohauaz easy connectors from Bosch. DONE !!

Thanks for all the replies.

[boomvader]

You don't need to add any wire. Just clip as close as you can to the terminal and crimp on the new one. When I've done it, I clip both off so the wire lengths are the same (doesn't matter electrically, helps with fit).

To get the terminals out of the old housings without damaging the terminals, I've used a Dremel with a teensy toothed cutoff, scored down close to the terminals, then pried the cut pieces apart with a flat-blade screwdriver.

Do a google search for "bosch 2 wire injector connector" Should find what you need.

I bought some here last year...

https://www.autohausaz.com/pn/12813502- ... r7EALw_wcB

IMO, if you're going to be replacing a bunch of connectors, don't waste your time with those PITAs with that type of wire. Get the kind where you can simply press the wire with your finger.

https://www.autohausaz.com/pn/1287013003

Hi Shawn. I purchased the above terminals in the URL. OK to clip at the end of each wire of old terminal, strip the insulation off each of the two wires and crimp on new spades of the new terminal? When you state "press the wire with your finger', do you mean the newly crimped spades into the new connector?

Sorry... this is my first time and I don't want to screw up the harness. "measure twice, cut once", you know? Thanks!