Andy A

Recently I replaced the head gaskets on my 94 3VZE pickup. During the teardown process all of my old blue fuel injector connectors broke. My options were to reuse the old ones and zip tie them or do some searching and see what I could come up with. I was able to find Denso connectors at a couple of different places. These are a perfect match and were reasonably priced, approx 35 dollars for me including shipping.

www.bmotorsports.com
www.connectorsfast.com

I went with bmotorsports just because they are closer to me. I have no affliation with either company.

The connectors can be purchased in 3 configurations.

1) connector only

http://www.bmotorsports.com/shop/pro...roducts_id/563

2) connector + terminal + seal

http://www.bmotorsports.com/shop/pro...roducts_id/571

3) connector + pigtails

http://www.bmotorsports.com/shop/pro...oducts_id/1069

I went with #2 on the above list, connectors + terminals + seals and this is what I will be writing about. Pardon some of my pics as they are not the best but they should get the idea across. Do not go with #1 thinking you can de pin the old terminals and insert them into the new connectors as they are a differnet design and will not work.

Tools you will need.

1) the proper crimper

http://www.bmotorsports.com/shop/pro...roducts_id/364

2) wire stripper
3) paper clip

The Stuff



Pay attention as to where each of the 2 wires go. On mine I had 1 white wire with red stripe and 1 black wire.

To remove the old connectors look at the end of the connector and you will see a small white locking tab and a small hole between the 2 terminals.

[IMG=http://a.imageshack.us/img826/8333/img2993n.th.jpg][/IMG]



Insert the end of the paper clip in the hole and with an upward motion start to pry up the white locking tab. Once you get enough of it out you can take you fingers and pull it out all the way.






What does the locking tab do? Down inside the connector there 2 release tabs, one on each terminal. The white locking tab keeps the 2 release tabs from releasing by accident.

Now that you have the white locking tab removed insert a very small flat blade screwdrive (jeweler type) into the connector and release the lock on each terminal, while gently pulling on the wire. The wire will eventually pull out with seal and terminal attached.






If your connectors are like mine were, they basically just crumbled.

Once the terminals are removed it is now time to cut off the old terminals, install the seals, strip the wires and crimp new ends onto the newly stripped wire. I found it easier after cutting the terminals off to go ahead and slip the new seals on before stripping the wire. When stripping it is important not to have too much exposed wire, approx 3/8th inch or just a little less.





IMPORTANT:
Before you crimp the new terminal on make sure the seal is on the wire.

Time to grab the crimper and crimp that new terminal on. The proper crimper is a must. When properly crimped the crimp will have a B shape to it when looking at the terminal from the side. The seal uses an O shaped crimp.

I put the terminal into the crimper first, making sure it is square and straight, then slide the wire in, and crimp the wire, after the wire is crimped you can slide the seal down and crimp it using the proper crimping holes on the crimper.

Now that both terminals are crimped (you did remember to put the seals on right) they can be slid into the new connector. They will click when they are fully seated. Thats all there is to it. Good luck and hope this helps some of you.