TD5 Replacement connector for Crank Position Sensor

Si Click · Oct 9, 2019

Have just replaced the CPS on my son's TD5 D90 and in doing so have discovered that the issue was not a faulty sensor, but that one of the wires to the socket has broken where it enters the socket.
The bullet-type connector that goes into the green part of the socket is still in there and the wire has broken immediately behind.
With patience and the possible dislocation of one hand, I can just about strip some wire back and fit another bullet type connector, remove the old one from the socket and refit.

However, what are those bullet type connectors called, where do I get some and are they crimped on or soldered ('cos I'm pretty sure soldering would be next to impossible)?

Discodevon · Oct 10, 2019

You’d be better buying the plug mate and joining it that way, you can buy it with wire for peanuts, then just connect it up and shrink wrap

bankz5152 · Oct 10, 2019

Fit a new connector.

anitarrc · Oct 10, 2019

Buying the plug is not possible here so a while ago I bought a pack of 10 round pins on fleabay and had them sent out with other stuff from Europe.
It helps to warm them slightly and put some resin behind them when you are done.
Donut yourself repair for the shield is aluminium foil or recuperate some antenna cable.

Si Click · Oct 10, 2019

Discodevon said:
You’d be better buying the plug mate and joining it that way, you can buy it with wire for peanuts, then just connect it up and shrink wrap

Thanks, I have come to the same conclusion. However, I am having problems finding one for peanuts or otherwise. I have ordered one of these and will post here if it fits.
https://www.ebay.co.uk/itm/2-Way-Female-Econoseal-Electrical-Wiring-Multi-Connector-Genuine-AMP-Product/131030682284?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649

As my chances of wiring in a new plug in situ are zero, I have also ordered some screened wire. https://www.efi-parts.co.uk/index.php?productID=324

Si Click · Oct 12, 2019

So on the upside, the connector above seems identical to the original.
On the downside the original wiring just fell apart when I tried to splice to it. Too old, too corroded - which is why we had a problem in the first place.
So now I need new wiring all the way to the ECU. Not a problem and I bought enough wire as this was always a possibility, but before I go digging does anyone happen to know which pins on the ECU I need to replace? It's on a 1999 TD5 Defender 10p engine. The colours at the connector are white and sort of orange with a band.

Si Click · Oct 12, 2019

So this is what RAVE says;
Inputs / Outputs
The two pins of the CKP sensor (C1068-1 & C1068-2) are both outputs. The ECM (C0158-13 & C0158-36)
processes the outputs of the sensor. To protect the integrity of the CKP sensor signal, an earth screen is used.
The ECM measures the outputs from the CKP sensor. The ECM (C0158-13) measures a positive signal on a
pink/black wire, and a negative signal (C0158-36) on a white/blue wire. The earth path for the sensor is via the
ECM (C0158-16).

So am I right in thinking that the screening in the wire needs to be connected into C0158-16? Is this just to dissipate induced current in the cable from interference, or does it need to be connected to the CKP sensor in some way I cannot see?

TD5 Replacement connector for Crank Position Sensor

Si Click

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Discodevon

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bankz5152

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anitarrc

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Si Click

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Si Click

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Si Click

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