Electrical connector repair - advice needed

[Pistom]

The wiring to the air con compressor on my R58 Mini has broken at the connector and I'm not sure if replacements are easy enough to source or if what I've got is repairable.

I've managed to dismantle it to the point that I've just got the 2 connector pins in the body of the connector block but not sure how or if they will release.

Has anyone any experience of doing work like this? I've never had to repair/replace an electrical connector other than the old style Lucas ones which virtually fall apart in your hand.

Any help or advice appreciated.



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[Richard-D]

Most terminals are removed by inserting a small pin down the side of them (from the connection end, not from the cable end). There's always a special tool but you can usually make do with a sewing needle or similarly thin, rigid metal item. Ideally it should have a blunt end.

Edit: you need to pull the terminal out from the cable end (needle nose pliers are helpful) as you do this.

Edited by Richard-D on Thursday 24th April 10:28

[Krikkit]

Looking around that's a Delphi Sicma connector, you can de-pin them with a little tool but it can be quite fiddly.

If you can't get the pins out you can replace both sides for about £10.

Edit, this might help?

https://www.youtube.com/watch?v=8Ilbmb9xAw4

Edited by Krikkit on Thursday 24th April 10:29

[Pistom]

It does look very similar. It stands to reason that the metal connector part has some form of retainer.

I assume there's different detail versions as I think this one looks very similar but not quite the same.

[E-bmw]

If you look closely at most of these pins

https://www.ebay.co.uk/itm/152718025255?_skw=auto+...

you will see most have a small "tang" that keeps the pin in the plug/socket.

As others have said you would need to depress this to be able to remove the pins.

I generally find the easiest way to do what you are hoping to do is as follows.

Push the pin from the wire end further in & use a jewellers screwdriver to push the "tang" down & the pin will pop out to the back of the plug.

If you can then carefully open up the crimp wings with a small screwdriver, you can normally solder the wiring back on & rebuild the plug.

[paul_c123]

2nd pic shows the plastic is broken. I'd be looking at replacing the entire plug, to be confident it won't cause issues in the future.

[Pistom]

paul_c123 said:

2nd pic shows the plastic is broken. I'd be looking at replacing the entire plug, to be confident it won't cause issues in the future.

Thanks - that's my thoughts too. I'm currently scouring the net trying to match it now that I've got more to go off.

[Richard-D]

https://www.ebay.co.uk/itm/365355491255?mkcid=16&a...

Edit: ignore, thought I'd found it.

BMW parts may be able to sell you a repair 'pigtail', plug pre terminated with short sections of cable.

Edited by Richard-D on Thursday 24th April 12:58

[Pistom]

Thank you - I might try BMW but this seems to be the connector on its own. There seems to be about 7 or 8 very similar but very slightly different but for this application - this looks like it should be the one https://uk.farnell.com/aptiv-delphi/10820162/conne...

[Sensibleboy]

This might be useful. Double check the connector is identical to yours.
If you buy a new one you can see how the terminals are locked in.

https://www.simtekuk.co.uk/index.php/automotive_co...

[Pistom]

Thanks - that is very helpful. Good to be able to see that detail.

[Pistom]

Now I've got a replacement connector, I've been happy to dismantle the old one and I can now see that had I known what I was dealing with, I could have probably re-used the existing one but for the cost of these, even though it's only an air-con connector, it's better to replace and know I won't have any issues.

The help from everyone here has been really useful - a big thank you.

I'm a bit more confident with connectors now.

[Panamax]

Richard-D said:

BMW parts may be able to sell you a repair 'pigtail', plug pre terminated with short sections of cable.

Yup, repair parts are often sold like that. You then just need to splice the wiring and away you go.

[Pistom]

Panamax said:

Yup, repair parts are often sold like that. You then just need to splice the wiring and away you go.

That option would have been easier but I've found it a lot more rewarding getting to understand how these connectors go together thanks to the inputs here.

Plus it's always satisfying to find and OEM part which hasn't come from a dealer.

[P2KKA]

Panamax said:

Yup, repair parts are often sold like that. You then just need to splice the wiring and away you go.

This is what I did with a Hyundai reverse switch plug. I spent a lot of time looking for the right plug on it's own and have a decent idea what I'm doing. Ended up being about a week's backorder and £20 pre terminated with 20cm or so if wire.