Help reconnecting blue wire on alternator!

[Hexie]

Hey all. After having a dead van the past few weeks, I finally discovered (thanks to this forum) that the blue wire running out of my alternator may be disconnected, which may be resulting in my resulting in a very dead battery.

It feels loose in the plastic connector (picture attached), but I can't really find a way to re-secure it or even open the connector. Any recommendations here? Or is it best to just yank the wires out and find some spade ends to re-attach them to the alternator?

Thanks for the help!

[fxr]

Just looking at that connector - isn't there a tab each side where the wires come out? Just prise these gently apart and the connector body should hinge open, giving access to the terminals.
_________________
Jim Crowther
1984 1.9l EJ22 Westy Wolfsburg Edition
Vespa GTS 300

[Hexie]

[VicVan]

If you want to keep the connector, and it is glued shut, you could cut it open at the seam using a small cutting whell (i.e. Dremel) or a saw with qa metal blade. You can reclose it using glue, or a zip tie and/or silicon
_________________
'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[crazyvwvanman]

If you are handy, replacing that connector is one way to go, all new parts.
Either a new pigtail with wires or new shell and pins.

https://www.ebay.com/itm/Lucas-Alternator-Repair-P...905481257?

https://www.ebay.com/itm/Bosch-Alternator-Harness-...815251184?

https://www.ebay.com/itm/Bosch-Lucas-Alternator-Ha...074546259?


Mark

[Hexie]

Worked with it a bit more yesterday and had no luck prying the connector apart. It seems to either be glued or molded shut, and I don't have much slack to pull it out of the engine bay to get a better shot at it for prying open.

Would you all recommend to just cut the wires off to get it out, then just buy a new one of these connectors? I assume its a pretty standard Bosch fitting. It looks like I can also attach the wires with spade fittings, but then the terminals would not be insulated. Not sure how important insulation is here, but it looks like later vans don't even have this plastic connector.

[Hexie]

[crazyvwvanman]

Yes, that is fine. In wire size the smaller wire has the bigger number.
So 14 is heavier wire than 20.

Mark

[buspor63]

Hexie,
That Westy in your pic looks familiar, did you get it from Bryan and Nicole?
_________________
Imagine that, theres not an "h" in either Westfalia or Syncro?

[Hexie]

[Hexie]

Quick update that I could use some assistance on:

I purchased this connector that was recommended above, and am going to keep working today to get my old one off.

Could anyone give me some tips on how to seat the wires into these sort of connectors? I'm unfamiliar if you need a special crimping tool, etc.

Thanks!

[DanHoug]

if you still have the bare, female, disconnect on the end of the wire it, inserts into the housing and there is a barb on the disconnect that latches into the housing when inserted far enough. it is common for the barbs to get folded flat so just bend it back so the tooth sticks up a tad.
_________________
-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com