Electrical Terminals FAQ

[telford dorr]

To link to this thread

[Bulli Klinik]

Great info. Thanks for taking the time to post.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[jtauxe]

Would you recommend a favorite crimping tool for these?
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John
"Travelling in a fried-out Kombi, on a hippie trail, head full of zombie..." - Colin Hay and Ron Strykert
http://vw.tauxe.net
1969 Transporter, 1971 Westfalia, 1976, 1977, 1976, 1977, 1971, 1973, 1977 Westfalias,
1979 Champagne Sunroof, 1974 Westfalia Automatic, 1979 Transporter, 1972 Sportsmobile, 1973 Transporter Wild Westerner, 1974 Westfalia parts bus, 1975 Mexican single cab *FOR SALE*, 1978 Irish 4-door double cab RHD

[aerosurfer]

Removable dies i used in my harness and continue to use regularly.

https://www.amazon.com/gp/product/B00788IUJU/ref=o...k129040-20

I have a generic (Harbor Freight) wratcheting crimper they drop into
_________________
Rebuild your own FI Harness..My Harness

77 Westy 2.0L Rockin and Rolling Resto!

72 Sportsmobile (sold)
79 Tran$porter... Parts car money machine (gone)

[Al Capulco]

These are the ones I use most.

[static]

Sadly, I could not find the awesome crimping tools shown above, so I took Mayor Ratwell's advice and bought a similar ($$$) tool from Del City.
https://m.delcity.net/productsearch?search=crimp%20tool

[airschooled]

There was a green/black ratcheting crimper sold on Amazon a few years ago with Paladin jaws; I love mine, but I can't find it at the moment. Any crimper with replaceable jaws will allow you to replace the cheap ones in a few years, or the good ones in a few lifetimes.

Robbie
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Learn how your vintage VW works. And why it doesn't!
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[alman72]

I want someone to hold my hand and show me the male connector to use on the diagnostic box for the small holes. (trailer wire harness)

[Hoody]

Thank you so much Telford for posting this. I am about to tackle every single connector on my restoration. You are a true asset to the Bus community!

[gleason]

Thanks for locating. I didn't find through the search.

[Tcash]

t2a

[Tcash]

Electrical Wire

I'm am going to link this, so I can find it later.
Looking to buy bulk wire

Note: Metric wire was used in VW's

[furgo]

A couple of additional notes on the Junior Power Timer (JPT) connectors for the FI harness, for those replacing a broken connector or making their own harness:

• You cannot use the new style connector with the release bar everywhere: the Auxiliary Air Regulator (AAR) connector needs to be original style, as otherwise the release bar hits the AAR hose to the plenum. A bit of a shame really, as it is one location which could have really benefitted from an easier release.
• Another tight spot is the Thermo Time Switch (TTS). You can in fact use the new style connector (I've done it), but the release bar ends up pointing to the case splitting line underneath the plenum. This makes it fairly awkward to push on. However, it still beats the old style connector in that location, which is nearly impossible to disconnect with a mounted plenum.
• Watch out for the style of the back of the connector. If you look at the picture below, you can use either the EV1-1 or EV1-3 style. EV1-1 is waterproof and you use some rubber boots on the terminals that are then held in place by the small trident-like lid on the back. They work perfectly fine also without the rubber boots, but they look slightly less stock as the back of the connector not covered by the big rubber boot is longer. I would have prefered tp use EV1-3, as they are stock (plus release bar upgrade), but I also wanted the connectors be color-coded. I could only find EV1-3 connectors in black, whereas there were EV1-1 connectors in green, blue, brown and black. Also, the longer EV1-1 connector works fine at the Cold Start Valve (CSV), but it makes everything a bit more cramped in that area.

Another stock connector that comes in very handy to insulate two wires connected to each other by a male/female terminal is VW 111 971 977. I've not found a source for the equivalent non-VW part, but I'm sure there is:

Also, to TCash (or any other mods): could this fine thread be added to the tech tips section? Thanks!
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'79 Westy, P22 interior, FI 2.0 l Federal, GE engine (hydraulic lifters)

Decode your M-Plate

[spacebiscuit]

Again, thanks for posting this information which is a great help to me as I am re-wiring my bus. I have been in search of the female terminal A27937CT-ND - for the thicker 4.0mm wire. Have searched online and couldn't find the part for love nor money... until now.

Some of my own observations - I bought a crimper on Amazon with yellow handles, these seem to be made in china and although they look the part the jaws broke in mine after 3 uses.

https://www.amazon.co.uk/gp/product/B0743FCFZS/ref=oh_aui_detailpage_o08_s00?ie=UTF8&psc=1[url]

I have since puchased a set from a seller in Germany which have been great and did not break the bank:

https://www.amazon.co.uk/gp/product/B001ILAG2M/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1

I also found that some of the terminal connectors are of questionable quality and are easily crushed out of shape. I found the silver finihses ones to be better than the gold/copper type.

[Mal evolent]

bit of trivia: the connection made by those crimpers is known in the trade as a double buttcheek crimp. If you say this on a military base, everybody in earshot wants to make a crimp so they can say they are rated to make a double buttcheek crimp.

I made the mistake of getting double buttcheek crimp dies with a flat bottom. when you crimp with them the connector wedges in and you have to hammer a jewelers screwdriver in to drive the connector out. very not safe.
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73 Beetle Baja, Ghia front brakes, Type 3 rear brakes, 2220 ( 94 X 80 ), Weber Progressive, Bosch SVDA, '97 Mustang seats

Baja Bugs for Volkswagen Virgins: Index

[xyzzy]

[sestino]

Telford, thanks for posting this. Does anyone know which type of connector I should order to connect some trailer wiring through the diagnostic plug?

This posting by TCash shows that I can access tail light, lleft turn, right turn, and brake light through terminals 9-12 at the diagnostic plug.

[telford dorr]

[sestino]

Telford, thanks for your prompt and thorough reply.

Unfortunately, when I went out to start on this project this morning, I discovered that my diagnostic socket was removed long ago.

The socket that I remember was in my previous bus, which I sold in 2002. I guess I'm getting old.

Without the diagnostic socket, I tapped into the tail light wires, mostly in the bundle of wires that is on the top left of the rear engine hatch.

The trailer I will be pulling is a 1970s Coleman Versa trailer with a tilt top. I will post photos in the Bays and trailers thread soon.
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1977 Fuel-Injected Sage Green Westy

[RONIN10]