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Adding an electrical connection through the front door connectors

Discussion in 'Do It Yourself' started by pdydeva, Oct 10, 2013.

  1. pdydeva

    pdydeva Regolare

    Messages:
    442
    India
    @Vijay_khasa: any idea how to pull out a wire from this connector? Are they kind of self locking?

    Edit: figured out:) Had to remove other side of the connector in yellow color to push the pin out.

    Sent from my GT-I9100 using Tapatalk now Free
    Last edited: Oct 12, 2013
  2. pdydeva

    pdydeva Regolare

    Messages:
    442
    India
    pictures of the pins used

    Attaching the pins of the door connectors

    Male pins crimped to wires in the body side connector

    IMG_20131012_120327.jpg

    IMG_20131012_120358.jpg

    IMG_20131012_120819.jpg

    IMG_20131012_120853.jpg

    Female pins crimped to wires in the door side connector

    IMG_20131012_113211.jpg

    IMG_20131012_113306.jpg

    IMG_20131012_113347.jpg

    IMG_20131012_113417.jpg

    IMG_20131012_113457.jpg
    1 person likes this.
  3. PatchyBoy

    PatchyBoy Esperto

    Messages:
    2,438
    Bangalore
    Were you able to see any specifications on those pins? Also, still waiting on your step-by-step to remove those connectors :D

    Rajan
  4. pdydeva

    pdydeva Regolare

    Messages:
    442
    India
    The female pin had an inscription as FD 125.

    Approximate dimensions:

    Male pin:
    total length (end to end) - 3 cm
    actual contact length - 1.2 cm
    thickness - 1 mm

    Female pin:
    total length (end to end) - 2 cm
    actual contact length - 1.3 cm

    Regarding the step by step guide, I'll try to do it in a couple of days. Busy with Ayudha pooja ;)
  5. pdydeva

    pdydeva Regolare

    Messages:
    442
    India
    steps to remove the door connectors

    Following are the steps to remove the door connector in order to add custom pin contacts:

    Disclaimer: http://www.teamfiat.co.in/do-yourself/8263-***-important-instructions-diy-threads-***.html

    You don't need any sophisticated tools other than a screw driver with both regular and Phillips screw head.

    I. Removing the door side connector

    Remove the door side connector by pulling down the grey colored tab downward IMG_20131014_123313.jpg

    IMG_20131014_123422.jpg

    Once down as shown above, the connector will automatically pop-out. Pull it away from the body side connector.
    IMG_20131014_123640.jpg

    Remove the rubber boot from the connector by sliding it backwards.
    IMG_20131014_123720.jpg

    Remove the green colored dummy plastics in place of empty holes. The blue colored plastic which keep the wires in position needs to be moved away by pulling the locks outward.
    IMG_20131014_123720.jpg

    IMG_20131014_124002.jpg

    Use a flat screw driver and remove the orange colored grommet kind of rubber. Insert the screw driver between the rubber and the plastic body and pull the rubber out.
    IMG_20131014_124046.jpg

    Similarly, pull out the yellow colored plastic. Insert the flat screw driver under the yellow plastic and pull outward.
    IMG_20131014_124150.jpg

    Once the yellow plastic comes out, the female pins are accessible
    IMG_20131014_124229.jpg

    Choose some object (like a torx screw driver head) and push the female pin so that it pops out from the other side as shown
    IMG_20131014_124518.jpg

    IMG_20131014_124538.jpg
    6 people like this.
  6. Parantap Chatterjee

    Parantap Chatterjee Regolare

    Messages:
    250
    Gurgaon
    Gurgaon
    Linea T-Jet
    Many thanks for posting :) . I had a question though - whats happening on the body side of the connectors ? How would you access the male pins (??) on that side ?

    EDIT - Never mind , I saw that you posted pictures of the male pins in the first post. Thanks.
    Last edited: Oct 14, 2013
  7. pdydeva

    pdydeva Regolare

    Messages:
    442
    India
    door connector removal contd...

    II. Removing the body side connector

    Bonnet opening lever and the plastic panel which connects to the door sill should be removed by unscrewing the shown screws.

    IMG_20131014_124909.jpg

    IMG_20131014_124950.jpg

    IMG_20131014_125029.jpg

    Remove the plastic door sill plate by unscrewing the screw shown in 1st pic below. Once unscrewed, lift the door sill plate by prying it upwards to gain access to the other screw (as shown in the 2nd pic below) for completely removing the plastic panel mentioned in previous step.

    IMG_20131014_125058.jpg

    IMG_20131014_140751.jpg

    Once the plastic panels are removed, a grommet like the one below should be seen at the point where the wires emerge toward the connector. Pull it out from the body panel.
    IMG_20131014_141121.jpg

    Now comes the most trickier part. The external side of the body connector (containing the male pins) needs to be pushed inward and taken out through the hole from where the grommet was removed. In order to do this, push the locking tab (using a flat screw driver) shown in the picture below. There are 2 such locking tabs. I have shown the 1st one and the 2nd is exactly opposite to the 1st. Once the 1st lock is pushed down, the connector goes in partially. You need to struggle a bit with the 2nd invisible locking tab to push the connector inside. Follow the wire and try to pull out the complete connector through the hole inside.

    IMG_20131014_141050.jpg

    Once the connector is out, procedure for removing the pins are exactly the same as shown in door side connector.

    PS: I know there are people who have already removed these connectors. Suggestion are welcome for refining this process.
    Last edited: Oct 14, 2013
    4 people like this.
  8. PatchyBoy

    PatchyBoy Esperto

    Messages:
    2,438
    Bangalore
    Thank you very much. Much appreciated.

    Rajan
    1 person likes this.
  9. pdydeva

    pdydeva Regolare

    Messages:
    442
    India
    Inspired by you :)
  10. pdydeva

    pdydeva Regolare

    Messages:
    442
    India
    I need help in pulling out the front wiper arms. I have removed the nut from the wiper arm but unable to pull out the arm from the spindle. From what I could see, there are splines in the spindle which is kind of locking the arms. Any suggestion how to get these out?

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