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View Full Version : Fitting new air boost sensor plug?


Mickyfin
09-29-2018, 03:37 PM
Van is a 2011 2.0TDi VW Crafter LWB Hightop. The below I believe also is true with the Mercedes socket, and fitment.

I had a broken socket that plugged into my air boost sensor (On the air box) I have now received the new air boost sensor pin bushing plug, and have trial fit it to my sensor, and it clicks onto there perfectly. Although the plug has Mercedes branding on it, so too does my old plug which is not surprising considering the Sprinter, and Crafter were assembled in the same German factory.

All I need to do now is transfer the three wires from the currently fitted plug with its broken retainer clip across to the new plug. Looking at the new plug, it looks like the plug is comprised of two parts, back plastic housing and a grey plastic inner which looking closely has some clips.

Does anyone know how this plug comes apart so I can extract the wires, with their pins so I can fit them into the new plug?

Here's what the old plug looks like....

https://farm2.staticflickr.com/1886/43872987234_122d99b2ac_b.jpg
https://farm2.staticflickr.com/1882/43872986474_79e34ba734_b.jpg
https://farm2.staticflickr.com/1866/42781409740_0c316eb1ec_b.jpg

And here's the new plug...

https://farm2.staticflickr.com/1980/31115213898_eec30243a0_b.jpg
https://farm2.staticflickr.com/1938/44987844801_11d435903d_b.jpg

I did purchase some recommended tools specifically designs for VW and Mercedes connectors, but as mentioned earlier, this looks like the plug has an opening position to extract, and to fit the old/new wiring and pins.

Any help, and guidance would be greatly appreciated.

Mickyfin
09-30-2018, 03:37 AM
Part number of the socket if it helps is 2105402181

Mickyfin
09-30-2018, 05:45 AM
Possibly the same plug is used on various other areas of a VW/Mercedes, come across a reverse sensor being the same type, exact part number.

I have exhausted youtube looking for assistance, all on there are pigtail type, this one I have is slightly different, and there's no videos or help anywhere on how this socket/terminal is taken apart.

Mickyfin
09-30-2018, 06:06 AM
I figured it out, but at the cost of the connector, so had to purchase a second terminal. Basically, the grey coloured plastic is the locking mechanism, and needs lifting around 1mm inside the terminal, and then whilst holding in place with a small screwdriver, you need to use another screwdriver to lift the releasing pin for the internal three socket housing. Should anyone be interested I will shoot a video of the process when the new socket/terminal arrives.

https://farm2.staticflickr.com/1975/44952960272_67bc32845a_b.jpg

manwithgun
09-30-2018, 08:11 AM
Your specific connector is quite different than the standard 2/3 pin connectors throughout the sprinter sensor web. I recently went through this and had to self-learn how to de-pin the main wire harness to ECM connector, as well as the regular 2/3 pin sensor plugs. I plan to do a write up, but a quick summary involves first removing the primary plastic retaining device using a small flat blade screwdriver, then releasing the actual integrated barb on the terminal with the appropriate tool. I managed to get by with a single .8mm Wiha screwdriver for the single barb terminals (top only) in the main harness, and then used a massaged set of micro-tweezers for the 2-barb terminals (top and bottom) on the 2-3 pin sensors. I'll post some pics once I'm on the phone that contains them. In my research I stumbled across this video that gives specific dimensions for 2 common de-pinning tools and how to make them. I just went by feel and logic. As already mentioned, your connecter is a bit unique with multiple pin dimensions so my post may not apply, but it may help someone down the road....

ACTUAL TOOL SPECS AND DIMENSIONS @ 8:20

https://www.youtube.com/watch?v=bbW9Yc36RPE

Mickyfin
09-30-2018, 08:20 AM
Thanks, I did come across that video, but dismissed it initially thinking it was a promotional video. Will check again.

manwithgun
09-30-2018, 08:25 AM
Pics from de-pinning a 3-wire sensor. Semi related to the OP. NOTE: Barbs must be bent back to the “catch” position before re-insertion after being released by a tool. For questionable terminal continuity, I advise also adding tension to the actual contact surfaces as well.

manwithgun
09-30-2018, 08:29 AM
Tweezer hack for 2 barb terminals.

manwithgun
09-30-2018, 08:48 AM
Thanks, I did come across that video, but dismissed it initially thinking it was a promotional video. Will check again.

Yeah, I searched everywhere for this information and came up empty. Took pics so that I could add to the the database. Main wire-harness has a removable back cover, a white plastic primary locking device that slides out, then a single barb on the actual terminal that must be released.

NOTE: I hope you don’t mind the slight derail, but there’s so little info on Sprinter wiring, I see this as an opportunity to spread some around...

Mickyfin
09-30-2018, 09:17 AM
Thanks again, thats fine my friend. I'm guessing those tweezers are 5 (fine)?

lindenengineering
09-30-2018, 01:22 PM
This is what the trade uses:-
https://www.summitracing.com/parts/wmr-w89732?seid=srese1&cm_mmc=pla-google-_-shopping-_-srese1-_-performance-tool&gclid=EAIaIQobChMItp_vyuji3QIVBihpCh3qQAv5EAQYBCAB EgJ5EvD_

A two minute job to separate the connector.
Dennis

Mickyfin
09-30-2018, 02:28 PM
Thanks for that, I will check it out.

Mickyfin
09-30-2018, 02:30 PM
Found the same kit but much cheaper shipped within EU :)

https://www.ebay.co.uk/itm/23-PIECE-TERMINAL-RELEASE-REMOVAL-TOOL-SET-CONNECTOR-UNLOCK-TERMINAL-SERVICE-KIT/362422243798?hash=item54620c91d6:g:N7wAAOSw-zNbgpNq