Coil Pack Connector DIY Replacement
Thread Starter
Joined: Jul 2012
Posts: 1,452
Likes: 23
Coil Pack Connector DIY Replacement
Writing this up in case any of you guys need to replace broken coil pack connectors (hint: this can be applied to most other parts of the wiring harness)
So my friend's car; heavily tracked for many years had the retention clips broken off from repeated exposure to heat and remove/install of coil pack connectors. Occasionally, the connector would wiggle loose and we would get a misfire code. Chances are if the retention clips are broken then their is a good chance the internal body of the harness is also deteriorating, too.
Connector Condition:
[attachment=79717:IMG_3458.JPG]
[attachment=79718:IMG_3457.JPG]
[attachment=79719:IMG_3456.JPG]
I bought the replacement harness clips from Cycle Terminal after and extensive search to find the original manufacturer:
http://www.cycleterminal.com/hx-series.html
Manufacturer: Sumitomo
part number: Female HX090-3 COP
[attachment=79720:Screen Shot 2015-05-21 at 11.32.12 AM.png]
Replacement Procedure
#1 Remove coil pack nuts (x4)
#2 Release coil pack from valve cover (x4)
#3 Release coil pack connector from coil pack (x4)
#4 Leave the coil pack in the spark plug tubes (this is to prevent plastic pieces from falling down the spark plug tubes if they are severely deteriorated)
#5 Take a coil connector, using a set of pliers squeeze the sides of the blue clip and pull the blue clip out (it's ok if destroy the blue clip; we are going to replace it but we don't want to damage the wiring pins)
[attachment=79721:IMG_3455.JPG]
#6 This exposes the black harness and pins (3); get your paper clip or (pin release tool) in the area above the pin hole, if the connector is still in tact then inside each pin slot is a clip that locks each pin in place. pry gently away from the pin and upwards while pulling gently to release each pin. There are individual retention clips for each individual pin.
[attachment=79722:IMG_3450.png]
#7 You will now have 3 pins removed. Don't worry about forgetting which wire goes where the order is (starting from the connector retention clip): Beige Trace; Black Trace; Black Yellow Trace
[attachment=79723:IMG_3451.JPG]
[attachment=79724:IMG_3452.JPG]
[attachment=79725:IMG_3453.JPG]
[attachment=79726:IMG_3454.JPG]
#8 Seat all 3 pins loosely into the connector in the proper order specified in #7. Press each pin in from the rubber seal till you hear them "click".
#9 Seat the blue retention clip back on the connector once all the pins are installed.
#10 Secure connector to coil pack and seat the coil packs firmly into the spark plug tubes.
#11 Torque securing bolts to 9 ft lbs
Coil Pack Connector Bare:
[attachment=79718:IMG_3457.JPG]
[attachment=79717:IMG_3458.JPG]
[attachment=79719:IMG_3456.JPG]
So my friend's car; heavily tracked for many years had the retention clips broken off from repeated exposure to heat and remove/install of coil pack connectors. Occasionally, the connector would wiggle loose and we would get a misfire code. Chances are if the retention clips are broken then their is a good chance the internal body of the harness is also deteriorating, too.
Connector Condition:
[attachment=79717:IMG_3458.JPG]
[attachment=79718:IMG_3457.JPG]
[attachment=79719:IMG_3456.JPG]
I bought the replacement harness clips from Cycle Terminal after and extensive search to find the original manufacturer:
http://www.cycleterminal.com/hx-series.html
Manufacturer: Sumitomo
part number: Female HX090-3 COP
[attachment=79720:Screen Shot 2015-05-21 at 11.32.12 AM.png]
Replacement Procedure
#1 Remove coil pack nuts (x4)
#2 Release coil pack from valve cover (x4)
#3 Release coil pack connector from coil pack (x4)
#4 Leave the coil pack in the spark plug tubes (this is to prevent plastic pieces from falling down the spark plug tubes if they are severely deteriorated)
#5 Take a coil connector, using a set of pliers squeeze the sides of the blue clip and pull the blue clip out (it's ok if destroy the blue clip; we are going to replace it but we don't want to damage the wiring pins)
[attachment=79721:IMG_3455.JPG]
#6 This exposes the black harness and pins (3); get your paper clip or (pin release tool) in the area above the pin hole, if the connector is still in tact then inside each pin slot is a clip that locks each pin in place. pry gently away from the pin and upwards while pulling gently to release each pin. There are individual retention clips for each individual pin.
[attachment=79722:IMG_3450.png]
#7 You will now have 3 pins removed. Don't worry about forgetting which wire goes where the order is (starting from the connector retention clip): Beige Trace; Black Trace; Black Yellow Trace
[attachment=79723:IMG_3451.JPG]
[attachment=79724:IMG_3452.JPG]
[attachment=79725:IMG_3453.JPG]
[attachment=79726:IMG_3454.JPG]
#8 Seat all 3 pins loosely into the connector in the proper order specified in #7. Press each pin in from the rubber seal till you hear them "click".
#9 Seat the blue retention clip back on the connector once all the pins are installed.
#10 Secure connector to coil pack and seat the coil packs firmly into the spark plug tubes.
#11 Torque securing bolts to 9 ft lbs
Coil Pack Connector Bare:
[attachment=79718:IMG_3457.JPG]
[attachment=79717:IMG_3458.JPG]
[attachment=79719:IMG_3456.JPG]
Joined: Jun 2010
Posts: 5,539
Likes: 6
From: McKinney, TX
Perfect..... now people have a much more affordable source for these connectors than the highway robbery price that (another company) has them listed at. 
I lost this site awhile back and have been trying to locate it again but have had trouble. 
I lost this site awhile back and have been trying to locate it again but have had trouble.
