yellow coolant sensor plug

[rsweeney 40]

just realised that one of the four wires that goes into the yellow plug which attaches to the yellow coolant sensor

has snapped of flush inside of the plug.

how do i re wire this as the wire has snapped off flush inside the plug?

Rich

[DrRich 1]

Unfortunately, the answer here is 'with difficulty and special tools'...

These are called 'Junior Power Timer' (JPT) connectors - there are also Junior Timer (JT) terminals which are the same except a different method of weather-sealing.

More info about the connectors and differences: http://www.clubgti.com/showthread.php?239997-Difference-between-Junior-Timer-and-Junior-Power-Timer-connectors

You'll need to remove the terminals from the plug, which is very difficult without the right tool. Fortunately, Laser do just such a tool and I think it cost me about 9 quid or so - not too terrible.

Here's the link: http://www.lasertools.co.uk/item.aspx?item=3175

Once you've done that, you'll have to hope you can solder the wire back onto the connector and still fit it back in the housing, because if you can't, then you'll need to fit a new female terminal which is a big hassle.

Here's an example terminal, housing and weather proofing:

The left hand parts of the metal connectors are what you see as you look into the plug. The other ends need crimping around the wire. HOWEVER, they need crimping properly, with a special tool (not a normal crimping tool), so that they fit properly in the housing - get it wrong and they won't...

The blue weather seals go over the wire and then slip down to fit into the circular parts of the back of the housing.

For the tool, last time I looked this was the best price - still not cheap though for a one off or occasional repair...

http://www.autoelectricsupplies.co.uk/product/923/category/163

As an alternative, I think VW sell 'repair' wires with the connector already crimped on, so you would only need to cut off the existing wire, solder the repair wire to the existing wire and then fit into the housing. Not sure how much these are though, but probably cheaper than tool if you're only doing occasional repairs rather than a full-on rewire!

Hope this helps - good luck!!

[rsweeney 40]

thanks for your comprehensive answer!

could you tell me if what i have done is alright?

today i pressed the pin out of the connector which had the snapped off wire attached to it.

removed a similarly sized pin from a plug off an old gti loom and pressed it into the plug.

soldered wires together

[DrRich 1]

I suspect this would work OK - a bit like using the VW repair wires. Only problem I can see is that the reason you need to use the tool is that it disengages the 'locking' tabs (you can see them on the side of the boxy section of the metal connector) allowing you to remove the connector intact.

By pressing them out, you may have damaged the tabs so that they no longer stay fixed in place; did you feel a 'click' as you pushed the new wire into the plug housing? From memory it's subtle but definitely detectable.

If the connector is not 'locked' in place properly, then the male pin will just push out the female connector rather than slipping inside it (erm, ahem, if you get my meaning...!).

[rsweeney 40]

ok im with you. i plugged the sensor in and removed it and the pin doesnt seems to have been pushed out of place so i think its happy as it is.

i now realise that i should shorten the replacement wire as it is now too long and kinks.

is soldering really best or can i crimp it with a 'butt' crimp?

[DrRich 1]

Soldering is without doubt the best, especially in the nasty engine environment. A butt crimp will work at first but can easily shake loose or corrode and change its conductivity leading to all sorts of hilarious troubleshooting consequences...

[rsweeney 40]

ok , and a heat shrink butt connector wouldnt do it then ?

if not i will solder, thanks again for your help