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     UPDATED: March 7, 2019                       CONTACT       
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Crimping Open Barrel Terminals
Assembling EFI Crimp Connectors

Crimping Large Battery Cable Lugs

Crimping Open Barrel Terminals
Here's a good crimping guide for beginners: http://www.xj4ever.com/crimping my style.pdf
What is an OPEN BARREL terminal? 
<<< It's a NON-INSULATED terminal with open "wings" as shown to the left. Those wings are crimped over the wire. 

<<< PROPER CRIMP tools are important.  Try not to use a cheap stamped metal crimping tool.  Buy yourself something at least as good as this one to start off.   For those of you who are curious about what crimper I use, this is it for 90% of my crimps for non-insulated open barrel terminals and also many insulated terminals.  This is the Thomas & Betts model WT 112M. It runs about $40. I've had this one for 25 plus years. 

<<< Here's a close copy of that crimper, which is available at Harbor Feight. 
With some practice, this simple tool above can create nice crimps on open barrel terminals just like a fancy crimping tool, although a fancy tool may take less time and may be a better answer if you're crimping a lot of terminals.
Check out my video below.

<<< Here's an expensive MSD ratcheting crimper I own and have used for a number of years when I need a fancy crimper.  It was pretty expensive (close to $100), but back when I bought it there were not many cheap tool options like there are now. So shop around.
<<< THIS CRIMPER: MSD crimper with ignition dies: https://www.summitracing.com/parts/msd-35051/overview/ and optional open barrel dies: https://www.summitracing.com/parts/msd-3506/overview/
Here's a very highly rated copy of my expensive crimper for a fraction of the price.
<<< When shopping around for a crimper, try to find one that will do open barrel F type terminals.  You can spend a lot of money on one of these tools or kits, but it you hunt carefully, you can find cheap ones that will work pretty well.  This one pictured is under $30 for the crimper and it comes with extra crimping dies and a wire stripper.  Sometimes you get what you pay for when buying CHEAP tools, so shop carefully and read reviews if they exist.

<<< Looking at this photo, the style of crimping die normally used for open barrel terminals that I offer in my pages is the one on the right in this photo. It's most similar to the ABOVE larger photo on my expensive MSD crimper.  The other dies might come in handy, so they would be a bonus.  I don't own this particular crimper.  This one is cheap and might be worth the cost, or it might explode!  You can never really tell until it's in your hands.

HERE: https://www.amazon.com/IWISS-Crimping-different-terminals-interchangeable/dp/B0195VXA10/
Here's a short, but decent video showing close-up crimping action for an open barrel terminal.

Assembling Typical EFI Crimp Connectors
These style connectors and terminals are available in Dave's Volvo Page: https://www.240turbo.com/blackvinyl.html#EFIplugs
<<< Here's a typical sealed connector housing found in many different Bosch style fuel injection systems.  This one has 6 poles and is most often used for a MAF (mass air flow) sensor. 

This connector housing uses a FEMALE crmp terminal, so this housing is known as a FEMALE housing. Inserting or removing a crimp terminal from one of these housings is easy, but if you're never done this before, this page will show you how.

Fuel Injection
                              2-Pole Plug<<<  Connector housings like these come in a number of different configurations.  The most common one is a 2-pole connector shown here used for a Bosch style fuel injector. This style connector is also known as an EV-1 connector.  They all use the same style crimp terminals that are inserted into these housings from the rear after being crimped onto a wire.

<<< Here's a typical ratcheting terminal crimper that works well for these EFI terminals (same MSD crimper described above). 
The below video will offer a quick view of this type of crimping operation.
https://www.youtube.com/watch?v=LXDedfvmI_0   (length: 1:34)

The Terminals below are TYPE 1 EFI Terminals (Early type).
These terminals are most often found in Volvo engine harnesses up to approximately 1988.

<<< It may take some practice before your crimps come out just right.  The wire needs to be tightly crimped, so be sure to pull on the wire to test it.  It should not pull free.
<<< An EFI TYPE 1 terminal will have a single HOOK sticking out like that one on the underside. That hook will be what holds this terminal in place inside the connector housing. 
<<< As the TYPE 1 crimped terminal is inserted into the rear of the connector housing, that hook will click into place when it reaches the end and is fully inserted.

When fully inserted, you should hear the hook CLICK into place.

<<< Here's the backside of the EFI connector.  That hinged piece on the bottom is there to help lock in the wire or wire seals, if used. That hinged piece will not be present on all EFI connectors like this and there are plently of these connector without that part. Those work just as well.
<<< Here I'm inserting a crimped TYPE 1 terminal into the rear of the connector housing. It has a silicone wire seal installed on the wire before crimping the terminal. Some prefer crimping the seal onto the back of the terminal as you'll see below.

A wire seal like this is optional. If you decide to use a rubber boot on the back of this connector, a wire seal is not needed. 
<<<  Once the terminal is inserted, then the wire seal can be pushed up the wire and into the hole. 
<<< If your connector housing has the hinged piece, it can then be closed to lock in the wire and seal.  If your housing does not have it, you can certainly still insert a wire seal and it should stay in place without the need for a locking device, especially if you decide to crimp the wire seal onto the terminal as shown below.
<<< If you need to remove an EFI TYPE 1 terminal from a housing, a simple tool is used, which may be a sharp pick or even a micro screwdriver.  The pick is inserted into the front of the connector housing to reach that hook. The goal is to push that hook toward the terminal so it gets released from the housing and the terminal can then be pulled out the rear of the housing.

If you remove a terminal from a housing and intend to reuse or re-insert that terminal, first inspect the hook to make sure it's still sticking out. If you bent the hook inward, you may carefully re-bend it back outward so it'll click into place when inserted.

If you want to use a better tool, the Rennsteig tool in the Type 2 section below also works very well.

The Terminals below are TYPE 2 EFI Terminals (Later type).
These terminals are most often found in Volvo engine harnesses after 1988.
<<< An EFI TYPE 2 terminal will have TWO HOOKS sticking out like these on either side. These hooks will be what holds this terminal in place inside the connector housing.

In this photo a silicone wire seal has been added.  As mention above, this type of seal is optional.  It may be used instead of a rubber boot.  It you decide to use a rubber boot, then these seals are not needed.  This seal has been crimped onto the back of the terminal.  This is not required.  It's your preference.
<<< As the TYPE 2 crimped terminal is inserted into the rear of the connector housing, those two hooks will click into place when it reaches the end and is fully inserted.

When fully inserted, you should hear the hooks CLICK into place.
Since the TYPE 2 terminal has two hooks, it will be more difficult to release from the connector housing using a simple pick.  It's possible to use a pick as shown in the TYPE 1 section above, or possibly two picks, however the proper tool makes life so much easier for removing these terminals.
This one made by Rennsteig works exceptionally well.


This release tool also works quite well with Type 1 terminals also.
This tool is inserted as shown to depress the two hooks at the same time. Then the wire and terminal is pulled from the rear.

<<< Here we have a rubber boot that mates to the connector housing. If you're using a rubber boot, then using wire seals will not be necessary.
These connectors are available in Dave's Volvo Page: https://www.240turbo.com/blackvinyl.html#EFIplugs

Crimping Large Cable Battery Lugs.

<<< Lots of people have a tool like this one pictured.  This one is from 12 Volt Planet, but there are many other versions available everywhere.  This tool is designed to be hit with a hammer or squeezed in a vise.  I prefer using a vise.  This tool is functional and offers pretty good side support for the cable lug. There are better and much more expensive tools, but this one is pretty cheap and better than just smacking the lug with a punch or a screwdriver.  The BIG disadvantage to this tool and others that use a vise is it's hard to crimp a lug under your hood. 
<<< Lots of people have tube flaring tools laying around.  Here's a new use for half of your flaring tool in a vise that also offers good side support for a lug when crimping. This photo is from plan-to-build.com/making-lugs-for-3-0-cable-from-copper-pipe/.

<<< This inexpensive flaring kit from Harbor Freight will go up to 5/8 inch O.D.

Below video: https://www.youtube.com/watch?v=XkMdlPsBxkc
I'm have NOT normally been a fan of soldering when building an engine harness. Solder is fragile and tends to crack when subjected to vibration. if a harness connection cracks, it will lead to immense frustration in trying to find the connection problems. 
Soldering PLUS crimping can be done and can work well in a harness. 
It's obviously a lot more work than just crimping.  Here's a video below demonstrating the use of solder AFTER crimping a battery lug.

Large Crimping Tools
<<< If you will be doing frequent battery lug crimps or if you need to do crimps like this under your hood, you might want a large crimping tool.  These can be expensive, but if you're been looking on-line, you've probably seen something like this IWISS Terminal Crimping Tool on Amazon.  It advertises the ability to crimp a number of large METRIC sizes, but according to the below video it slightly misses the mark if you want perfect AWG size crimps.  But for the price (under $30) it might be good enough, especially if you have some tools to modify the crimping dies to better fit your needs.
Below video: https://www.youtube.com/watch?v=RuAg1Ong6lI


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