I have a disconnected wire and a plug. What can I do?
 

Ok, so just to give a little bit of history, I made a code puller and generated a code on my 88 Turbo II. The code said Water Thermo Sensor. Well, it turns out that the wire which connects to the water thermo sensor has torn.

For those of you who have changed your thermostats, you may have an idea of the extremely confined area. The water thermo sensor is basically near the thermostat, but is located about an inch lower than the thermostat.

Like I said before, the problem is that the wire has become disconnected. This is not as easy as it sounds because the wire itself is supposed to go to a PLUG and then this PLUG connects to the water thermo sensor. The point where it has disconnected is at the base of the PLUG (which makes things a little difficult).

More or less, I have a plug in one hand and a piece of wire in the other.

What are my options? I have a soldering gun which I can use, but remember that there is very little space to make a proper connection. Also, there are two tiny wires which compose of the wire connection. This makes soldering very difficult.

For everyone that has no idea what I'm dealing with, here is a very similar example. Take your standard appliance. Look at the end of the power cord. Imagine that the cord itself was snapped off at the base of the plug.

I think I may be able to cut open the plug in order to solder the wires together. But I am hoping for some suggestions from you guys before tackling this problem. I need to ensure that the wires will not snap off again after I repair it.

Why don't you just replace it???

Replace the plug?

I didn't think that Mazda sold the plugs individually. They sell the Water Thermo Sensor (which is new BTW).

What I need is the wire/plug. How do I replace the plug? The only option I see for a direct replacement would be to either obtain another harness or to repair the connection.

Icemark, Care to clarify what you mean?

Your making this too hard. Its the plug on the end of the harness, that has one of its wires broken off. Thats what I understand.

Take the plug off the sensor.

Look into the plug from the sensors view.

See the notch in the middle of the broken wires connector???? (Looking into the plug)

Push a very small screwdriver into that empty looking notch . You will unlock the socket when you do this. At the same time pull the wire that is broken. When the socket unlocks, the wire with the socket and wire will come out of the plug.

Strip the broken wire and reattach the socket. Shove it back into the hole. It should lock in.

Only problem with that is now one wire is longer than the other and perhaps you should shorten both wires the same length i.e. remove and reattach both after cutting the two wire harness the same length. Thats where you really should just go buy a new connector at MAZDA and replace the plug along with the two new sockets that come with it.

When I say socket, I mean that piece of the connector that is crimped onto the end of the wire.

I just went out to the garage and grabbed a wiring harness, shoved a small blade screwdriver in the notch, and pulled the wire and socket out. Very small blade screwdriver.

jpg attached

Hailers,

You're right on the money. That is the exact connector/plug I was talking about.

Basically, both wires are snapped off. I'll have to strip the wires a little bit and remake the connection. Mazda carries the connector piece???

BTW, Thanks for your advice

Dom

Real easy...

Go to nearly any auto parts store and find a Bosch fuel injector connector. I know Pep Boys typically has 'em in stock - the connector is assembled and good to go.

Remove the alternator for a little working room. Splice the new plug into the 2 wires - which wire goes to what doesn't matter.

The sensor has a "key" on it that won't line up with the key slot on the new plug - no biggie. File/dremel the key off the sensor. Plug in. Rock and roll.

I've done this a few times - it's really super easy. If you take the alternator off, you have plenty of room to get in there and splice in the new connector.

The thing to watch is the nut on the back of the alternator's pivot point - it rotates sometimes when you put it back on, and the tab coming from it breaks off that connector. That's the most common cause I've seen of a broken water temp sensor.

Dale