flightline

So, as the title says, I'm gearing up to make a new DME harness for my car. I don't have any particular electrical gremlins, but much of the sheathing is cracking and some of the plugs are in not-so-great condition. Also, in the new harness I'm going to be running wires to power a few goodies like a wideband unit that is currently wired independently (and somewhat sloppily)

I'm going to be mostly reusing connector housings, but I need to replace the pins for the new wires. Many of these are what I've seen referred to as Bosch/AMP, or AMP Junior Timer, and what I think is part # 999 652 456 22 in the Porsche catalog:

The cheapest I've seen these is $0.77 apiece at KayJayCo.

That's not all that expensive, but there's more than 70 in the harness, and if there's somewhere cheaper than that would be great. Anyone know of a Mouser equivalent?

Another issue is wire size for these pins. Of course the original wires are in metric sizes, and I'll most likely be using AWG. The pins, on the KayJayCo site, list an acceptable wire diameter of 16-14 AWG. Some wires, like the wire from the DME to the coil, are listed as 2.5mm^2 on the diagrams. Is it acceptable to use 14 gauge wire (area 2.08mm^2) for these?

What I think I've figured out as far as connector pins for everything, if anyone can confirm or disconfirm or add to that would be awesome:

DME, KLR, Injectors, Airflow Sensor, Speed and Reference Sensors, Throttle Switch, Idle Positioner, Knock Sensor, NTC Water Temperature Sensor:
Bosch/AMP, i.e. AMP Mini Timer, i.e. 999 652 456 22

Cycling Valve
Body: 999 652 167 40
Terminals:111 971 959

4 Pin Plug, DME
Body: ???
Terminals: 111 971 985

Test Connector
Appears to be injection molded, only available as pigtail: 901 612 333 00

Oxygen Sensor
Body: 944 612 435 00
Terminals: ???

Bellhousing ground, MP IX
8mm Ring Terminal

Engine Block Ground, MP VIII
6mm Ring Terminal

Oil Pressure Switch
4mm Ring Terminal
Flat Receptical: 999 652 106 02

Coolant temp. Switch
Larger Flat Receptical: 999 652 106 02
Smaller Flat Receptical: N 017 243 1

Altitude Switch
???

Codes Plug
???
(These two appear identical apart from color; one is white, one is black)

Knock Control Diagnostics Plug
Housing: 911 612 122 02 ?
Contacts: 999 652 371 12 ?

Temp Switch, Turbocharger
Housing: 999 653 002 90
Contact: 999 652 371 12
(Not exactly sure how this one comes apart)

DME Connection Plug
Housing: 911 612 121 01 ?
Contacts: 911 612 907 00 ?

If anyone can shed any light on this stuff let me know, it'd be awesome if there's a definitive reference for this stuff, mostly it's been careful guesswork.

JohnKoaWood

Sadly there is no definitive listing.. but you are off to a very good start!

Word of caution, be minfull of the wire color codes, and consider marking each wire if not adhering to the OE color coding! And don't overlook the pins in the DME connector...

I can double check my pin supply I have remaining from when I did the group buy... I will send you a PM this evening once I double check my supply and what kind of price deal I can make you (I am 99.9% sure I can do MUCH better than .70 a pin!)

flightline

Shameless self bump; anyone else have experience with doing this? I'm especially confused about the contacts for the 14-pin DME connector and the knock control diagnostics plug. In the parts catalog the only thing pictured that looks remotely like this is cryptically labelled as 'bush, $ 0,5 - 2,0 CUAG' and 'contact pin $ 0,5 - 2,0 CUAG'. Can anyone confirm that these are the correct parts? If I cant find these I may have to de-solder them from the donor harness, but I'd really rather not.

944CS

my advice - use adhesive heat shrink on the ends that are exposed, the cover with your sheathing (I recommend fiberglass based) and use regular heat shrick to secure the sheathing in place. Also for your grounds, use heat shrink terminals.

flightline

Ok, so I've got most of the pins worked out (thanks John), any word on getting hold of the connector boots? kayjayco has them, but at $19.89 apiece for the 6-pin one, I'm thinking maybe not. 944online sells the entire connector, including boot and pins, for 16.95, which seems like a steal comparted to kayjayco. Anyone know of a better source?

Also still looking for pins for the other miscilaneous connectors if anyone can beat pelican.

JohnKoaWood

I will check my stock... email is quicker to get ahold of me than PMs, but either will work.

FWIW, Ian and I use the same supplier, If I dont have the bits in stock you need, I can put you in touch directly with him.

BTW, Your pins go out today!

gregeast

Watching 951 geeks at play makes me hot! Good work gents.