Rebuilding Thermosensor connector
 

I'm fixing problem areas on my S5 N/A harness before my engine goes back in.

I've got what I thought were two spare S5 N/A harnesses to steal parts from. I started putting a better water thermosensor plug/connector when I realized that "one of these is not like the other"
http://a5.sphotos.ak.fbcdn.net/hphot..._6281627_n.jpg

Turns out that none of my spare thermosensor connectors are better and my best connector is not what I thought it was. I've cut enough wires with the terminals to use what I have if I have to. I can either grind down the notch on the sensor or cut a notch in my plug.

What I would prefer is to get new terminals and a new correct plug. The wires on connectors are a little hardened and I'd prefer to do this right while the harness is out of the car.

I've been on mouser.com,eastern beaver, alliedelec and I've googled with no luck so far. I've been to local auto parts stores, local electronic supply stores..no luck.

Where can I get two of these terminals?
http://a3.sphotos.ak.fbcdn.net/hphot..._5365418_n.jpg

and one of the plugs of course. If anyone can help out I'd be grateful.

i don't know of any shops that sell our connectors induvidually and i've looked all over. a little better luck with the later model S5/6 though but S4 is pretty difficult to find new connectors for without massive bulk orders.

best bet may be just cut the notch off the sensor, that plug looks pretty pristine IMO.

S4 inector clips will also work and can be found new but also require cutting the locating lug off the sensor.

GP sorenson makes one that looks almost identical to the stock injector clip and here are some others:

GP sorenson: 800-9213
airtex: 1p1000
BWD: 27427

those are all center locating lug clips however.

for the injector clips, we found that worldpac had them, and id just pull the plastic part of the new one and put it right on the cold wire/pins. the only part that is bad is the plastic, so i just changed that.

BMW lists connectors separate too. www.realoem.com look it up for like a 1990 e30 or something

Worst case scenario, ditch the plug and use 14-16 insulated female spades, and add some adhesive shrink wrap to make it all nice and isolated.

I haven't looked too closely at s5 harnesses but I have an early s4 and a late s4 harness, which have the two different types of injector connectors. The water thermosensor plug is the same square connector with offset tab that is used on an s4 BAC valve and the late model/88 injector connectors. You can source injectors from those parts of the harness.

The thermosensor plug is identical to the Bosch EV1 injector connector pigtail and uses the same terminals for the wires. The only difference is the offset tab on the thermosensor plug as opposed to the centered tab on an EV1 connector.

Thanks for the feedback everyone.

I've got a total of 4 of the terminals/spadethingies and the one good connector. 2 of the 4 terminals is off of a thermosensor connector, those wires aren't in much better shape than what I'm replacing. The wires are discolored from heat and hard in places..they don't have much life left in them.

The other two terminals I have have wire in good shape, but I didn't cut off very much and I'd prefer to have the soldered in wires further away from the heat as possible. Well one other thing is that I'd prefer the splice and solder to be further back on the harness so I'm not manipulating those areas of the wiring while plugging and unplugging things.

What I"m going to try to do is simply pull apart the terminals with suspect wiring and recrimp good wires.