Injector connectors

I received my order of 2-pin injector connectors and housings from Finjet. Before installing, I test fitted in a spare injector.. The connectors were such a loose fit that they would fall off the injector spades by gravity if I turned injector upside down.

I then took one old plug apart. One connector was a tight fit, but the other one was almost as loose as the new ones.

Seems like each connector will need to be squeezed to make a good fit before crimping and installing in the housings.

I am starting to understand why this type of connector was abandoned by the manufacturers. Picture below is of new and old. Dimensions are similar, but fit on spades is not the same.

Hi Graham,
the problem is well known by me.
I once replaced the connectors at motor temp. sensor - the car 'died' a few kilometers later when the enigine got hot.

There exist connectors 2.8x0.8 mm and 2.8x0.5 mm. The wrong ones are more common....

This is one of the things we found out since jetronic.org exists.

In the chapter 'engine wiring harness' of Volker's compendium you find 'einsaware', the distributor I buy the correct ones.

But it won't be very difficult to find the correct ones elsewhere - now the problem is known to you.

Regards
Norbert

Hi Norbert,
I did read that in Volkers compendium, but didn't fully understand that the injector spades are actually 2.8mmx0.5mm.

Because I bought the connectors and housing as a Djet set from Finjector, I assumed the connectors would be correct for the injectors. This is the Finjet link:
www.finjector.com/verkkokauppa/eng/2_nap...anturiin-p-2564-171/
As you can see, they say the connectors are good for 0.5 to 1.0mm. This may be true, but they will require squeezing to fit the 0.5 injector spades! I would have thought that they would fit 0.5mm and expand to fit 1.0mm.
Measuring new against old, the connectors are close to same external size.

I think I can make these work, but the design is far from ideal. If I can find a source for the internal part of an EV1 connector (as used on Audis, for example) I would switch to those - much more positive connection.

Finjector was a convenient place to buy from. I didn't try einsaware. Have to look and see if there is anyone selling those connectors here in small quantities.

Hi Graham,

when Finject talks of a coonector to be good for 0.5 to 1.0mm, that means for cable squares of 0.5 to 1.0 mm². It has nothing to with the width of the receptacles. You should have ordered them from repro-parts.de, they have the right ones.

Volker wrote: Hi Graham,

when Finject talks of a coonector to be good for 0.5 to 1.0mm, that means for cable squares of 0.5 to 1.0 mm². It has nothing to with the width of the receptacles. You should have ordered them from repro-parts.de, they have the right ones.

I see that now that you mention it! I made the mistake of assuming that if the connector set was for the D-jet, that it would have the correct connectors.
When I looked up the individual connector on Finjector site, it did say it was 0.8mm. Wish I had seen that earlier!

I finally found the 0.5mm connectors on the Repro site. I did buy my boots from them, but the picture of the 2-pin connector they showed was round instead of rectangular. That confused me, so I went to Finjector.

Hi Graham,

well these are the ones for VW, Porsche and Citroen fuel pumps. He sells the receptacles you are looking for with article no. 4487000 for 0.25€ per piece plus VAT. The housing for 2 poles is 4485002 and costs 1,00€ plus VAT. Time for him to do some translations on his website.

Volker wrote: Hi Graham,

well these are the ones for VW, Porsche and Citroen fuel pumps. He sells the receptacles you are looking for with article no. 4487000 for 0.25€ per piece plus VAT. The housing for 2 poles is 4485002 and costs 1,00€ plus VAT. Time for him to do some translations on his website.

Ok thanks! Wish I had known that when I ordered the boots.

I found that if I use the same proper crimper that is needed for the wire end of the connector, I can lightly crimp the other end down so it is a tight fit on the injector spades. It doesn't take much force.

I noticed something on the Finjector site.

This is the english link to the connectors:

www.finjector.com/verkkokauppa/eng/client/view/457340

This is the Finnish link:

www.finjector.com/verkkokauppa/fin/client/view/457340

Notice the Finnish link gives the 0.8mm thickness, but the English does not!

Maybe I wouldn't have made mistake if I had understood Finnish

Terve Graham,

mitä kuuluu? Pelkä hyvää, kiitos. Kippis!

Those are about the only Finnish words I still remember from 3 months in Helsinki. They mean How are you, I feel fine and more important Cheers !

I would recommend that you rather learn German, the language of Mercedes-Benz and Bosch! Then you can translate my website

BTW: Do you know what happened to PB Anders? I tried to contact him to show him the Bosch internal testers. But there was no reply and he last updated his website some years ago. I hope he is fine.

Volker wrote: I would recommend that you rather learn German, the language of Mercedes-Benz and Bosch! Then you can translate my website

BTW: Do you know what happened to PB Anders? I tried to contact him to show him the Bosch internal testers. But there was no reply and he last updated his website some years ago. I hope he is fine.

I have been to Germany, Austria and Switzerland a number of times and understand some German. But mainly I use Chrome or Google Translate! No Finnish though.

I don't know if Brad Anders is still active. Maybe someone on one of the Porsche forums would know.

I sent an email to Finjectors about them supplying the 0.8mm contacts in sets clearly marked as for DJet use. Also that they did not specify 0.8mm except in Finnish!

They did not reply! (I wasn't asking for a refund or anything) Will use Repro next time!

I am in process of upgrading my harness. I have two plans

- First, I will upgrade my existing harness. I will install the New style double cantilever connectors on all connections but with Repro boots. Brad Cushman on Benzworld is being very helpful in sourcing the plug end housings and connectors for me. I have found a source for Silicone coated fibreglass wire sleeves that should stand the engine heat better than the original ones.
- I have the harness off now and am making a full size wiring plan. I am accumulating parts and will in future make a complete new harness using marine grade tinned wire and most likely with original style connectors (0.5mm!). May never use it, just like other spares I have!