6th Gen ('00-'05): Butt Connectors on the PCM Harness
IMO you are 'borrowing trouble by using crimp connectors for your repairs. You have already discovered that they are prone to creating problems, so why repeat the mistake? The wires should be soldered and protected with shrink tube. Not only will this deter/prevent resistance in the circuits (which will alter the sensor signal to the PCM)' but it is a repair that will last for years. It won't be long until oxidation and vibration cause your electrical gremlins to return.
Using the butt connectors wasn't the problem. The problem was that they didn't push the wires all the way in and the only crimped the plastic. I pushed the wires all the way in and did 3crimps. One on each end, on the merely and then on the center to ensure a good connection. If done right, crimping is fine. And if your budget is low it's the better than just Twisting the wires together. As with any repair work, the repair is only as the job you do!
In certain situations, crimp connectors are perfectly acceptable. I just don't think that the hostile environment under hood is one of them. Heat, cold, moisture and vibration (not to mention the normal oxidation process that occurs between dissimilar metals) will take their toll on the crimp connectors and they will fail. The resistance introduced by the weakening connections will skew the signals being sent from the sensors to the PCM. Then the mysterious electrical gremlins will return. I have seen this scenario play out numerous times over the last 30+ years being an ASE certified mechanic. To each their own, but with JC's intention of keeping the car for a while it just seems to me a more permanent repair would prevent future headaches and the need to revisit the same problem(s) when they pop up again.
In certain situations, crimp connectors are perfectly acceptable. I just don't think that the hostile environment under hood is one of them. Heat, cold, moisture and vibration (not to mention the normal oxidation process that occurs between dissimilar metals) will take their toll on the crimp connectors and they will fail. The resistance introduced by the weakening connections will skew the signals being sent from the sensors to the PCM. Then the mysterious electrical gremlins will return. I have seen this scenario play out numerous times over the last 30+ years being an ASE certified mechanic. To each their own, but with JC's intention of keeping the car for a while it just seems to me a more permanent repair would prevent future headaches and the need to revisit the same problem(s) when they pop up again.
My best solution is to completely replace the harness. But I can't do a Junkyard Day until the spring. The closest Big ones are in Pa. They would be my most likely source for a complete wire harness for an Old2 Monte.
Last edited by JC Colon; Oct 23, 2013 at 11:20 AM.
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