Wingnut
Top Post Dawg
With Red Rotors (Marc) increasing sales of complete Bosch .205 injectors, there are many asking how to plug them in to the OEM plug. Since his injectors come from a 2003 car, anyone who has a 2K3 has no worries. If you are a 2002 or older owner, then the plugs are not compatable and must be changed. It is a simple procedure and can be done with simple tools & materials. And the plug is only a few $ from the dealer, so no worries about cutting & splicing.
First step is to make yourself a pin extractor tool. You need:
1 medium sized paper clip
1 hammer
1 pair of pliers.
1 new style plug (part # 1J0 973 722)
Take your paperclip & use the pliers to straighten it out. Cut it to 3 or 4". Then shape it into a tweezer shape as follows:
In order to get the ends of the tool to fit into the end of the plugs, you have to use a hammer & make the tips flat:
Now, find the plug in question. It is attached to a bracket under the vacuum reservoir (black ball):
Insert the pin removal tool into the end of the plug like this:
You should hear or feel a slight click as it pushes in the barbs that hold the pins in place. You may have to push the tool in further if the pins will not release. Another tip that Lito has suggested is to bend the tips of the tool inward. This helps in releasing the locks. Once you have released them, the wires just pull out:
Now that you have the old plug off, here it is compared to the new style plug:
If you look closely, you will see the numbers on each plug. The grey wire goes in slot 1 & the blue wire goes in slot 2 (just remember that 2 & blue ryme, so you won't forget):
Now, just insert the wires into the new plug & you are done. Just make sure that the locking tab inside the new plug is not locked or the pins will not fit. Here is the locking tab (purple thing) in the unlocked position:
Here it is once it is locked. You can use a small flat screwdriver to slide it in & out or any small, sharp object. Note that when you buy it from the dealer, it should be in the unlocked position already.
The new plug will fit into the existing bracket, so everything still looks OEM & no worries about tie wrapping it somewhere:
So now you have successfully swapped the injector plugs. You can now continue on with the rest of the instalation. I do recommend trying the connector swap before taking anything else apart in case you have a problem and have to put the old injectors back in.
For those of you who do not want to bother with making a pin removal tool, you can buy one from many auto parts stores for around $15. Just look at the 'Electrical pin removal tool' thread.
Good luck to all & I hope you enjoy your new injectors /images/graemlins/grin.gif
EDIT: This writeup was done before the popularity of the .216's. The procedure is the same, but the connectors are different. The .205's have a new style connector, and the .216's have the old style connector.
So to summarize:
2003 cars can install .205's with no modification.
2002 and older cars can install .216's with no modification.
2003 cars need an old style plug (037 906 240) to install the .216's
2002 and older cars need the new style plug (1J0 973 722) to install the .205's.
Hope this helps to clarify things.
First step is to make yourself a pin extractor tool. You need:
1 medium sized paper clip
1 hammer
1 pair of pliers.
1 new style plug (part # 1J0 973 722)
Take your paperclip & use the pliers to straighten it out. Cut it to 3 or 4". Then shape it into a tweezer shape as follows:



In order to get the ends of the tool to fit into the end of the plugs, you have to use a hammer & make the tips flat:

Now, find the plug in question. It is attached to a bracket under the vacuum reservoir (black ball):

Insert the pin removal tool into the end of the plug like this:

You should hear or feel a slight click as it pushes in the barbs that hold the pins in place. You may have to push the tool in further if the pins will not release. Another tip that Lito has suggested is to bend the tips of the tool inward. This helps in releasing the locks. Once you have released them, the wires just pull out:

Now that you have the old plug off, here it is compared to the new style plug:

If you look closely, you will see the numbers on each plug. The grey wire goes in slot 1 & the blue wire goes in slot 2 (just remember that 2 & blue ryme, so you won't forget):

Now, just insert the wires into the new plug & you are done. Just make sure that the locking tab inside the new plug is not locked or the pins will not fit. Here is the locking tab (purple thing) in the unlocked position:

Here it is once it is locked. You can use a small flat screwdriver to slide it in & out or any small, sharp object. Note that when you buy it from the dealer, it should be in the unlocked position already.

The new plug will fit into the existing bracket, so everything still looks OEM & no worries about tie wrapping it somewhere:

So now you have successfully swapped the injector plugs. You can now continue on with the rest of the instalation. I do recommend trying the connector swap before taking anything else apart in case you have a problem and have to put the old injectors back in.
For those of you who do not want to bother with making a pin removal tool, you can buy one from many auto parts stores for around $15. Just look at the 'Electrical pin removal tool' thread.
Good luck to all & I hope you enjoy your new injectors /images/graemlins/grin.gif
EDIT: This writeup was done before the popularity of the .216's. The procedure is the same, but the connectors are different. The .205's have a new style connector, and the .216's have the old style connector.
So to summarize:
2003 cars can install .205's with no modification.
2002 and older cars can install .216's with no modification.
2003 cars need an old style plug (037 906 240) to install the .216's
2002 and older cars need the new style plug (1J0 973 722) to install the .205's.
Hope this helps to clarify things.