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How to Wire Plastic Automobile Connectors

Plastic automobile connectors, sometimes called Molex connectors, are ubiquitous in the auto industry. There is good reason for that: unplugging one or a few plugs with many connectors each simplifies and speeds up wired component replacement, as opposed to any other connection method. Every electric motor, sensor and factory-wired radio has them. After the initial installation, miswiring becomes a non-issue. There is a specific technique and tool set for the job. The socket connector holds the male pins, and the plug connector holds the female pins.

Instructions

1

Make a function chart of the wires you are connecting by color. Use that chart to mate the correct connections in the male and female plugs.

2

Plug the plastic plugs together before wiring to ascertain proper fit and test the locking/polarity mechanism.

3

Read the manufacturers recommended crimper size for your connector pins. Failure to use the proper size can break the pins or make a weak connection.

4

Strip an exact length of insulation off the end of each wire that will allow 1/16 inch of wire to protrude past the wire crimp section while the insulation end fits in the insulation crimp section. Twist the strands of each wire tightly.

5

Lay the wire into the pin and hold it in place. Lay the wire crimp section of the pin into the correctly-sized section of the crimper, round side down into the round side of the crimper. Bear down the W-shaped side of the crimper so the open wings of the pin bend in and down into the wire strand bundle.

6

Use the technique in the previous step to crimp the insulation crimp section into the wire insulation.

7

Slide each connected pin into its slot in the plastic housing until their tangs click into position, keeping them from backing out of the housing when you mate the plugs.