Dear Forum,
I have a wire loose in my EGR Valve Connector. I read online that you can make a simple tool out of a paperclip which will enable you to insert the clip into the front of the connector and to push down the two 'lugs' that lock the connector (soldered onto the end of the wire) into the back of the female and therefore allow you to pull the wire with its connector out; however, since my wire has already been pulled out of its individual connector, I'm not sure whether this will be of any help to me?
Can I push the now 'wire-less' wire connector out of the back from through the front with a very small screwdriver? I presume I need to get this wire connector out of the body of the female connector in order to solder it back onto my loose wire? I cannot see me getting a soldering iron directly into the tiny hole the wire goes into without melting the lot!
As you can tell, I am not sure how to go about this and would appreciate anyone's advice?

If you are interested in this post, please link it to the following post and scroll down to #55

https://www.jaguarforums.com/forum/x...3/#post1811350

Thank you.
Ray

 

Can you not do as you suggested with the paperclip, even tho the wire is not connected, to push down the 'lugs' to push out the connector? Or even push it out the front rather that the rear?

 

Thanks John, I am going to try that and post the result.
Regards,
Ray

 

Just use needle-nose pliers to grip (gently) the rear portion of the contact, insert the paper clip to release the holding tang, and it should slide out the rear. The contact will not push forward out of the connector by design.

 

Sir Michael, I tried to very gently insert my paperclip, but unfortunately the entire plastic 'insulator' contents of pin 4 fell out in a crumbling heap!

Please scroll up to see the added link at the top of this post (#1)

Michael, this is so frustrating. I started out with 5 error messages and thanks to the fantastic help I have received from many people on this forum, I now only have this accursed P0405 left and it may well be as simple as a wire out of the connector!

Thank you.
Ray

 

That connector in your photo is pretty toasted. If not replaced you'll probably have intermittent connection issues. Do you have any junkyards you can go and cut the connector from another vehicle?

 

Final result:
I have had to do a bit of a (hopefully temporary) 'rabbit job' on my EGR Connector. The plastic 'insulating' the individual connector within the body of the female had crumbled, so I have pushed the wire from behind and out through the front and then soldered the connector to it, put a insulating sleeve over it and plugged it in to the male and then pushed the body of the connector over it and home.

Not sure how long this will last, but WITH THE MAGNIFICENT HELP OF MANY MEMBERS OF THIS FORUM I HAVE FINALLY GOT RID OF P0405!!!!!!!! It was obviously this loose wire in the loom connector.

 

I wish there was a junkyard near me as I would look for bits and pieces like that connector and keep as spares.

 

You and I both, John!!

As these beautiful cars age in combination with what is a very hot engine, these plastic connectors are going to be one of the biggest problems. I contacted Jaguar here in Dubai and they could only sell me a complete wire harness!!

 

They may also have a dealer kit with spares but they will not readily sell you one - and they're a fortune.

 

Go to a breakers and snip them off with a good tail - they will be worth good money before very long!

JagV8, I now have a Jaguar with NO DTC's for Christmas so I would like to thank you for all your help along the way!!

Have an enjoyable (but most importantly) relaxing Christmas and I will plague you with stupid questions again in the New Year......

 

Good to hear!

(Most breakers here don't let you wander around any more, sadly.)

 

https://www.ebay.com/itm/JAGUAR-X350...72.m2749.l2649

Just for spares I have started looking for cheap but good wiring connectors. Bought the above the other day.

 

 

Lilfreddie, this is excellent - Thank you!
But I gotta ask!! I am assuming this Sumitomo Toyota connector is identical to our Jaguar EGR connector (it certainly looks it); how on earth did you know that it would be? I wouldn't have known where to begin looking?
Again, thank you for passing this on!

 

 

Lilfreddie, I am a big fan of the X350 XJ8L; to me, its extra length (and the benefits that go with that) hides its increased height (again, with the benefits that go with that)?
Nevertheless, that is one heck of a commitment you have shown!
As these over-engineered beauties age, their hot engines will ensure that the wiring looms and connecters will become weak points - Well done for starting a process of sourcing new connectors - We will all be at it before long!