In the process of installing my 300 degree fuel rails, I came to the task I was most dreading: splicing in the new style injector connectors. I suck at soldering (took wood shop in high school) but after a couple of failed attempts, I went online and found a technique that worked quite well.
Switching the old style connector (left) for the new style (right)
Step 1: Cut the old connector, leaving at least two inches of wire extending from the harness. Its tricky on the rear ones, but can be done.
Step 2: Peel back the hard black insulation to get to the wires, cut one wire about 1/2" shorter than the other one. Strip the wire ends, exposing about 1/2" of wire on each one.
Step 3: Trim the wires on the new connector you're installing so that the staggered lengths of wire match the two lengths you cut on the harness wires. Match thin wire to thin, thick wire to thick. The purpose of this is so that the the splices will not be next to each other.
Step 4: Cut 2 1" lengths of 1/4" heatshrink tubing and slide them onto the new connector wires. Secure the tubing from sliding down the wire into your splice with a tiny piece of electrical tape.
Step 5: Now you're ready to splice the new connector wires. Push the stripped ends together on the two wires, don't twist them, just have them mesh together, like you're trying to shuffle a deck of cards.
Wires meshed together
You can pinch them with your fingers and try to balance the harness and connector so that the wires stay meshed, but basically keep them straight, don't worry if they spread out a little as they press together.
Step 6: From one of your cut ends of wire, pull out a single strand of copper wire, at least 2" long, and use it to wrap around the spliced wires. Start in the middle, get the first loop done, and holding the centre loop with one hand, tightly wrap one side of the splice working out towards the end. Any spread out wires will now start to be pulled in with the wrap.
Wrap started from the centre outwards
Finish the other side of the wire wrap, careful that you don't knock the splice apart. If you do, start again, it will take a couple of tries to get the wrapping technique down. Finish wrapping the other side and tuck in any stray wire bits.
Completed wrap
Step 7: Get your (pre-heated) soldering iron and get a layer of solder flowing over the splice.
Top of splice soldered
Once it is cooled a bit, Flip the splice over and do the same to the bottom. If there are any solder 'bumps', heat them until they flow into the splice. Let the splice cool a minute.
Bottom of splice soldered
Step 8: Remove the tape bit from the heatshrink and slide it over the splice and shrink it down. Finished result:
Heat shrink over splice
This is probably pretty basic for some of you, but I was from the school of 'twist together & solder', not an elegant solution for an injector harness. This looks much better and is stronger.
Regards,
My Zs are hybrid vehicles, they run on gasoline and money
times change, people change, but the Z32 still kicks ass. - apudapus 16:46:02 06/15/07
I was more wondering how you set your climate control to 22* lol, it would be that fastest freezer on wheels! - Briscoe'sZ32 (NJ) 23:15:44 02/05/07
You have *got* to be getting a cut from B&B :D - SeedyROM 15:24:29 08/16/06 What do you think B&B stands for? - YugoBernie (NoVA) 15:57:09 08/16/06
Injector connector splicing technique - 
