How best to replace a wire in the harness?

[PonchoCatalina]

I feel this is kind of a dumb question, but that's never stopped me before. I have discovered that the wire that goes from the idle air control solenoid to the ECU on my 91 Loyale does not have continuity. I would like to simply run a new wire between the IAC and the ECU's yellow connector, but I'm not sure what the best way is to do so. Should I: (A) just cut off the existing wire leaving an inch or two at each connector, then splice in with butt connectors or similar, or ( try to remove the wire completely at both connectors and make a "factory" connection? If I go with B, how should i go about removing the existing wire from the IAC's round connector and the ECU's yellow connector (do the wires just pull out, or do you have to insert something to release the wire, etc.?). As always, your advice is welcomed! Thanks.

[ninjaben43]

go with a

[ninjaben43]

but leave more tha an inch, leave at least 6-8

[ninjaben43]

but, you usually can stick a small screwdriver into the hole with the wire, and pull it out, but it sometimes breaks the little plastic tab that holds the wire in, and then you can never trust it again. so unless cutting into the wire is going to change the reading from the sensor, id leave the plug alone.

[daeron]

the best way is a solder joint, because butt crimp connectors arent very well sealed, and if this wire gets mad contacts at the butt connectors, you are back to where you stand now. at least use some shrink tubing.

[mikeshoup]

Cut it at each connector, leaving an inch or two, just enough to solder on to. Then run your new wire through the routing you want. Cut to length, and solder it with some heat shrink tubing. Crimp butt connectors work, but they're not the best for the job as they can vibrate loose. A solder joint done properly will not fall apart.

 

Here's a good website describing wrong and right ways to splice wire together:

http://www.mmxpress.com/technical/connections.htm

 

The site says to use a torch or heat gun to shrink the tubing. You don't need that. I usually just use the cooler part of the soldering iron tip and run it lengthwise against the tubing, and it shrinks right up. You can also use a lighter if your a pyro.

[stephenw22]

A crimped connection will hold up better under vibration than a soldered connection. A crimped butt splice is the best way to go for longevity. Just make sure you have the right crimp tool.

 

If dirt/dust is a concern, you can get watertight splices from any water pump shop. It's a bare metal butt splice with a special heat shrink sleeve. The heat shrink has a hot glue layer in it that will seal the heat shrink on watertight. Just remember to check resistance on the lead after you splice, but before you shrink the sleeves on.