Fuel Injector Wiring Harness

[BradInTexas]

The Sun analyzer results are that the ignition circuit is all working correctly (previous post). So last nite I pulled the injector half of the harness out to replace it with my spare. The spare looks just as bad. I need to replace all the broken plastic terminals that attach to the injectors. I hope to source the kind with the push type locking wire (Tyco type C) instead of the original ones (Tyco type A) that you pretty much have to destroy to get off.

Has anyone done this? Is there a way to extract the wires from the terminal without just destroying the plastic ends? Even if I remove them by destruction, what is the trick to putting the new ends on? I'd rather not cut the wires or ends.

[Mike W.]

I'm sure there is an extract tool somewhere for sale, but I've never seen one. I have had pretty good luck removing them from the 2 conductor injector connectors, but not any of the 3 or more conductor ones. You need to try and fab a tool, I've always used 1/16" welding rod, but even a large paper clip might work. ground into a more or less square shape with a little kick at the end. Insert that into the plug end, there is a little notch, kind of lever it in against the main part of the terminal, then pull. It'll take a little practice, but it can be done.

[Peter Florance]

Pull the boots off and check the groove that the boot fits in. If there are 2 little rectangular dents, forget about extracting; they will not come out.

I'd cut the wire as close to the contact as you can and use the MSD type from Summit. They don't use boots and you have to push the wires through the shells, crimp, then pull back to seat.

If you can get the Bosch shells, you can probably re-use the contacts if you can melt the shells where they are crimped (I think the contacts used to slide out until BMW started doing this)

[T.Hanson]

For what it's worth, I've done twelve by using an xacto blade point. Lean over until your legs shake, pick at one end of the little wire clip.( Not the middle.) Teeny thin blade can wiggle under the clip enough to insert a second small screw driver blade.

Then it's walking the clip around, out from the cap. No clip, caps slipped right off. ('79 -'81) Yes, the plugs, caps are very brittle and if a clip wants to go tinkling into the dark recesses or flang off the ceiling, they are hard to find.

[BradInTexas]

The new connectors have about 4-5 inches of wire on them. So I'll try to preserve the rubber boots and solder them, put shrink stuff on them and put it back on. The connectors I got are the newer ones (type C), where you can push on the wire to release them, unlike the originals that you have to pick off. I think they have a Bosch part number, not a BMW part number.

Thanks for the inputs.

[thomas_m535i]

The new connectors have about 4-5 inches of wire on them. So I'll try to preserve the rubber boots and solder them, put shrink stuff on them and put it back on. The connectors I got are the newer ones (type C), where you can push on the wire to release them, unlike the originals that you have to pick off. I think they have a Bosch part number, not a BMW part number.

Thanks for the inputs.

My injector harness has the same problem. Is it possible to post the part number here of the 'newer one' (type c) so I can order them @ BMW's. By the way, are you sure those will fit? Thanks.