How to Replace Broken Wire Harness Clips/Connectors Audi/VW DIY

Broken wire harness connectors

In all my DIY's I always stress the need to be gentle when removing these clip and sure enough when I went to take pictures for my temp sensor DIY I got a little to eager and broke the clip right off. I had also broke one of the coil clips many years ago but the wire harness stayed on just fine so I never worried about it. This time I was not so lucky. (If you do have a broken clip on the coil connection and do not feel like wasting $30 and doing this repair you can always use a zip tie to keep it in place).

This DIY covers how to replace the connection housings from the wires to the sensor/coil or what ever one you happened to break off. The part number should be the same for MKIV and the newer MKV jetta, GTI ect, models as well as Audi's and passats. As always make sure you verify the part number with your local dealership before you buy the part.

I will be doing the repair on a Temperature sensor plug but it will be the same operation for the other connections as well. If I ever break down and buy a new coil connection I will upload pictures for that connector too.

See all 9 photos

Tools Needed for the Job

This DIY can be done with house hold items but if you plan on going all out you can buy a specialty tool called a "Terminal Release Tool". The tool can cost anywhere between $70-$110 and has the same affect as using a standard paper clip.

Large Paper Clip
Hammer/Vise-Grips
Needle nose pliers (optional)
Small flathead screw driver
Replacement part

Depending on which clip you broke the most common housings are part #4B0-973-724 and part 4B0-973-712. 4B0-973-724 is the connection for the Maf, coils and the like plugs and runs around $30 each from the local dealership. 4B0-973-712 is the smaller plug used for the Temperature sensor, AIT sensor, Throttle Body and like connections. That part will run about $12 at the dealership. They can also be ordered online from ECS Tuning for about $18 and $9.

Lets Get MacGyver on this B!!

Yea, welcome back to the 80's. If you decided against the hundred dollar tool then it's time to make your own out of a paperclip.

For the larger connections (maf/coil) use a large paperclip, for the smaller (temp sensor) type connections use a small paper clip. Start by flattening the ends with a hammer or vise-grips. Then curve it around till the two ends are a few mm apart. Look at the "tools" picture for reference. Yes, that's it. So save your pen and rubberband for another day my fellow MacGyver fans.

On with the Procedure

To be honest this is a quick and simple DIY, but it is a pain in the blank the first time you do it. If you are changing the larger (maf/coil) connection it should be a little easier.

Step 1) The first thing you want to do is remove the pink/purple clip inside of the harness. It slides out very easy so use very little pressure. It also helps to place some newspaper under whatever connector your working on so you don't drop these little pieces into the engine bay.
Step 2) The black hose that covers all the wires has a little clamp on it to keep it tight. It really helps later on to take this off and pull out the wires. You can remove it easily with your finger nail or a small screwdriver. Pic 2 & 3
Step 3) Take your homemade tool and wedge it in on both sides of the connection pin (picture 4). The trick is to get it in deep enough to bend down the little tabs that are holding it in place. I'd estimate about a half centimeter in.
Step 4) With your tool in place pull on the wire from the back side till it releases. It will take a little persuasion but don't rip it out with all your force (see diagram below for a better example of how the wire connections look). You're trying to release it, not break off the tabs. You can also use your needle nose pliers to get a good elongated grip on the wire.
Once all two or four wires have been released (depending on the plug) you can slightly bend back the tabs so the wire will hold firm in your new connector. The best would be to use a pen knife to slightly bend them out. The last picture shows the tabs but the resolution is not that great.
Step 5) Push the pins back into your new plug with yours fingers or pliers if that helps. Make sure you write down which color wires come out of each hole. The plug harness will be labeled with 1,2,3,4.

Wire prong diagram

Temperature sensor wire colors

Maf/coil diagram

Wire Harness Diagrams

These are some drawings that should help with keeping the wires in proper order and a little diagram of what the pin connector looks like. Click on the pictures for a larger view of the diagrams.

The tabs/prongs in the first diagram are there to hold the wire in place. These are the tabs you are trying to slightly push/bend down so the wire can be released from the harness. These are the little taps that can be carefully opened back up with a pen (small swiss army) knife before they are re-inserted in to the new harness. Don't bend them to much as they are thin metal and like to break easy like everything else VW/Audi makes. If you do break the tab off of one side don't be overly concerned it will still stay in place once inserted into the harness.

For the Temp sensor the colors are:

1) Purple
2) Brown/White stripe
3) Green/Yellow stripe
4)Brown/Blue stripe

Coils: Even on my own car I have different colors going to the 1,2,3,4 points so make sure you write down what color is going to what connection before you pull out the wires.