Harvey Racing has ceased operations, but you can still make a harness just like Andrew by following this DIY guide. Thank you so much for your business over the last 10 years!
Here are instructions for making an adapter harness just like Andrew. If you want to do it differently, that’s totally up to you. You may save this info for your personal use, but please don’t copy & paste any of it for commercial purposes. If you want to sell harnesses then please create your own instructions from scratch. See this Wikipedia article about plagiarism: https://en.wikipedia.org/wiki/Wikipedia:Plagiarism An exception is if you want to quote something here and then cite this thread and Andrew as the author. That’s totally fine!
The first step is figuring out your workspace. It may work for you to work on a very large desk that is near chest height so that you can stand, or you may find it convenient to work on the floor. For your desk perhaps you could get a full-size piece of plywood at a builder’s supply store along with a couple saw horses and nail it together. For the floor you can get a floor chair. If you’re in Japan then you probably already have one. If not, then you can make one. Go to Ikea and choose a chair you like. Buy it without the legs. Make feet for it using little wood blocks and screw them to the bottom. Put a seat pillow on it to make it more comfy. This will be your home for many hours. :)
The second step is gathering up the tools you’ll need. Buy these tools:
Engineer PA-09 crimper for small terminals: https://www.amazon.com/Engineers-Pre...dp/B002AVVO7K/
Engineer PAD-13 crimper for medium terminals: https://www.amazon.com/Engineer-PAD-...dp/B00IWD9XKU/
A hydraulic crimper for large terminals: https://www.amazon.com/gp/product/B09Y5XLDS9/
A simple crimper & stripper tool: https://www.amazon.com/Gardner-Bende...dp/B00164C0KW/ or https://www.crutchfield.com/S-56dHN7...-Tool-Set.html
A metric wire stripper tool (must be metric, not AWG): https://www.amazon.com/Katapult-Metr.../dp/B079TPXDDY or https://www.amazon.com/KNIPEX-Tools-...dp/B005EXNX1Q/
A wire cutter: https://www.amazon.com/Cutter-Lightw...dp/B000GTMZHG/ or https://www.amazon.com/Creativity-Cu...dp/B087BL2KGM/
A set of pin eject tools (I have some genuine ones, but I found these cheap Chinese ones work just fine. What it’s missing are the ones for the square C101, but those are obscure parts so no surprise there.): https://www.amazon.com/gp/product/B09YPRFRCN/
Some small screwdrivers for pushing in pins and seals. You can shop around on Amazon or wherever. I don’t have this one, but something like that: https://www.amazon.com/WORKPRO-10-Pi...dp/B091C32HLX/
A tape measure, like this, you can shop around: https://www.amazon.com/Lufkin-Self-C...dp/B0C754QG56/ or https://www.amazon.com/Lufkin-PHV103...dp/B01N3BYK61/
A pair of scissors, pretty much any are fine, something like this: https://www.amazon.com/Westcott-1390...dp/B000P0LNRE/
A heat gun (I’ve tried several and this one works): https://www.amazon.com/PORTER-CABLE-...dp/B004Q04X44/
A cigarette lighter, such as standard Bic.
A digital multimeter with audible continuity checker (the 9V battery in mine still works since 2015!): https://www.amazon.com/Fluke-113-Tru...dp/B004Q05ODI/
A soldering station: https://www.amazon.com/Hakko-FX888D-...dp/B00ANZRT4M/
A flat piece of wood about 1/4” thick and 7 to 8” x 3 to 4” for soldering on (just cut one from scrap wood).
An air purifier (for sucking up nasty fumes you shouldn’t breathe): https://www.costco.com/winix-true-he...000093012.html
Now buy the supplies you need:
Kester lead-free silver alloy solder (don’t cheap out on solder, you’ll regret it. Buy the good stuff once and don’t think about it.): https://www.amazon.com/KESTER-SOLDER...dp/B00H2AFXS0/ If you must cheap out at least get the name brand leaded stuff (check eBay for deals on the other before buying this): https://www.amazon.com/Kester-24-633...dp/B0149K4JTY/
Electrical tape (if you want cloth tape, go for it. I never bothered.): https://www.harborfreight.com/electr...ack-63312.html
For the wire, fuse holders, braided sleeving, pins, etc. you’ll need to request to open an account with Transfer Multisort Elektronik at tme.com. After a day or two your account will be ready and you can start ordering. Keep each order under 5 kg to save on shipping. If it goes over just split it up into another order. Everything ships super fast from Poland. These people are totally awesome, but if you screw up there isn’t much you can do. Just have to suck it up because their return policy is pretty much non-existent. They primarily deal with businesses, not end-users, just like most of these suppliers.
Now order wire in the FLRYW-B spec in these sizes (the W is for high-temp insulation) in 100 meter rolls:
0.35 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
0.5 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
0.75 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
1.0 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
1.5 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
2.5 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
6.0 mm2 (order it in red color): https://www.tme.com/ux/en-us/details...bles/bq-cable/
Now order braided sleeving in these sizes (1 box each is fine for 1 or 2 harnesses):
4mm: https://www.tme.com/ux/en-us/details.../cyg-pet4-box/
6mm: https://www.tme.com/ux/en-us/details.../cyg-pet6-box/
12mm: https://www.tme.com/ux/en-us/details.../cyg-pet6-box/
Now order heat shrink tubing in these sizes (black for ground, red for positive):
3mm black: https://www.tme.com/ux/en-us/details...-connectivity/
6mm black: https://www.tme.com/ux/en-us/details...-connectivity/
9mm black: https://www.tme.com/ux/en-us/details...-connectivity/
12mm black: https://www.tme.com/ux/en-us/details...-connectivity/
6mm red: https://www.tme.com/ux/en-us/details...-connectivity/ or https://www.tme.com/ux/en-us/details...3m/7000099250/
Now order ring terminals in these sizes (10 each is fine):
M6 for 0.25 to 1.5 mm2 wire: https://www.tme.com/ux/en-us/details...roup/bm-01131/
M6 for 1.5 to 2.5 mm2 wire: https://www.tme.com/ux/en-us/details...roup/bm-01131/
M6 for 6mm2 wire: https://www.tme.com/ux/en-us/details...roup/bm-01331/
M10 for 0.25 to 1.5 mm2 wire (For S54 starter field terminal or omit for non-M starter that has a terminal 30h): https://www.tme.com/ux/en-us/details...roup/bm-01143/
Fuse holders (3 per harness): https://www.tme.com/ux/en-us/details...s/mta/3050153/
5 amp fuses (2 per harness): https://www.tme.com/ux/en-us/details...es/littelfuse/
7.5 amp fuses (1 per harness): https://www.tme.com/ux/en-us/details...es/littelfuse/
For E30 oil level light off 1K ohm resistor: https://www.tme.com/ux/en-us/details...f0207fte52-1k/ or https://www.tme.com/ux/en-us/details...f006ff1001a50/
Momentary on switch for sport mode: https://www.tme.com/ux/en-us/details...hes/marquardt/ or https://www.tme.com/ux/en-us/details...i/r13-516a-02/
If you want a switch for oil service and inspection reset order an on/off rocker switch: such as https://www.tme.com/ux/en-us/details...hes/marquardt/
Now you need connector pins. Order these:
4.8mmx0.8 tab for switches: https://www.tme.com/ux/en-us/details...erminals/vogt/
Now here’s the part numbers for the connectors and pins. I’m just pasting it here from a document I created. Go over it to figure out what you need. For the BMW part numbers you can order them from a BMW dealer. For TE/AMP and Kostal part numbers you can order them from TME, Mouser, Newark, etc. Search octopart.com for the best prices.
X60004: Covering cap 40 POL. : 12521744629 (967286-1)
-Socket housing 20 POL, pins 1-20: 12521744631 (965489-1)
-Socket housing 20 POL, pins 21-40: 12521744630 (965489-2)
-Terminal socket MQS ELA 0.75 MM²/SN: 61138366260
-Terminal socket MQS ELA 0.2-0.5 MM² SN: 61131393704
-Terminal socket MQS ELA 0.25-0.35mm: TE Part #: 963726-1 (loose piece) 928999-1 (Sn) (reel), 928999-5 (Ag), 928999-6 (Au)
0.5-0.75mm: 963729-1 (loose piece), 963715-1 (Sn), 963715-5 (Au), 963715-6 (Ag)
MQS crimp tool: 539682-1 (handle 539635-1) (die set 539682-2)
X64101/X64102: 61138373609
-Little connector that plugs into X64101/X64102 connector: 61138377082
-Double leaf spring contact 2,5-4,0MM²: 61131370693<-NLA!
This one->4.0-6.0mm2: 61138377734 -> Standard Timer, 4.0-6.0mm TE #: 963714-1 or 963709-1, 144433-1. 4,0MM² 927829-1
E46 X6021: 61136901729 / 61136901731 -> superseded to 61132360044 (includes pins)
-Pin-contact ELO-Power 2,8 x 0,63 0,35-0,5MM²: 61138373293
-Pin-contact ELO-Power 2,8 x 0,63 0,5-1,0MM²: 61138364833
-Pin-contact ELO-Power 2,8 x 0,63 1,0-2,5MM²: 61138364835
E46 X6011: 61136905995 / 61136905999
-Pin-contact ELO-Power 2,8 x 0,63 0,35-0,5MM²: 61138373293
-Pin-contact ELO-Power 2,8 x 0,63 0,5-1,0MM²: 61138364833
-Pin-contact ELO-Power 2,8 x 0,63 1,0-2,5MM²: 61138364835
E39 X6011: 61131378137. Uses male C101 pins.
OBD2 cover:
-Cover with frame OBD socket SCHWARZ: 61138373323
OBD2 connector: Plug housing 16 POL.: 61138380698
-Flat spring contact 0,35-0,5MM²/AU: 61138366598
0.5-1 TE #: 964263-2, 964264-2, 964261, 962876-1 (tme.eu) 1241732-2, 969005-2 or 969019-2 or 1241860-2
E30 coolant temperature sensor connector & E30 M3 oil temperature sensor:
- Socket housing 2 POL.: 12521427615
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN: 12521427608 (?->Kostal 22140492060050-L)
-Single conductor seal 0,25-1,0MM² (5.2mm blue): 12521748973 (Kostal 10800444522091) or TE 828904-1 (828905-1 for larger wire)
-Cavity plug: TE 828922-1
-PROTECTION CAP 2 POL.: 12521732694
Accelerator pedal connector: Socket housing 6 POL.: 61138383300
-Terminal socket MQS ELA 0.2-0.5 MM² SN: 61130005199
-Terminal socket MQS ELA 0,35-0,5 MM²: 61136901726
-AMP terminal socket: 0.25-0.35mm: TE Part #: 963727-1 (loose piece) or 962885-1 (reel) (Die set for MQS crimp tool 539685-2)
-Rubber grommet 0.2MM²: 61138366247 TE#: 967067-2
C101: Plug housing 20POL: 12521707283
-0.2-0.4mm: TE 962970-1 or 929966-1 (reel)
-Circular contact 2.5 0,5-1,5MM²: 61131376191. TE Part #: 962971-1 or 929967-1
Wire seal: 828920-1
-Circular contact 2.5 1,0-2,5MM²: 61131376193 superseded to 61130007452 (with wire). TE #:929968-1 or 962972-1
Wire seal: 828921-1
-Circular contact 2.5 2,5-4,0MM²: 61131376195.
Cavity plug: 963531-1
-Protection cap: 12521707302 -> use X20 version instead -> stretches easier: 12521719733
Relays:
Relay for fuel pump, cycled (USA S54): 61357892976
Standard relay for Euro S54, and also M54 & M52TU: 61368373700
Base for relay: 61131389114 (black top) or 61131389111 (white top) or 61131389113
Contacts:
Junior timer, 0.22-0.5mm: 964280
Junior timer, 0.5-1mm: TE Part #: 964284 or 964286-2
Junior timer, 1.5-2.5mm: 965999 or 964273 or 241872 or 964273-2
Standard timer 0.2-0.5mm: 927839 or 928990-2
Standard timer 0.5-1mm: TE Part #: 927827
Standard timer, 1-2.5mm, TE Part #: 927833-1, 927837-2 (tme.eu) or 927837 (mouser.com)
E36 Dual Coolant Temperature Sensor Connector:
-Pins (KOSTAL LKS 1,5 ELA): 12521436205 or 12521744075 (Kostal 22124444630060-L, 22140444630-L)
-Wire seal (5.2mm blue): 12521748973 (Kostal 10800444522091, 10800444522)
-Protection cap: 12521703593
NLA -> Z3M S54 X6011 chassis side connector 2 POL.: 61138352331
-Circular contact 2.5 0,5-1,5MM²: 61131376191. TE Part #: 929967-1
-Circular contact 2.5 1,0-2,5MM²: 61131376193 superseded to 61130007452 (with wire). TE #:929968-1 or 962972-1
Z3M S54 X6021 engine harness side connector 8 pol: 61131378118 -> 61138352322
Chassis side: 61131378116 -> 61138352323
Male E46 X6011 connector to replace Z3 connector on engine harness: 12527505477
-Socket contact SLK 2,8 1,0-2,5 MM²/AG: 12527502933 (Kostal 22124492070050-L)
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN 12521427608
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² AG 12521427612
-Socket terminal SLK 2.8 ELA 1,0-2,5MM² /SN 12521433216 (Kostal 22140492070050)
-Socket terminal SLK 2.8 ELA 4,0 MM² 12527505636 (Kostal 22124499720030)
Male E46 X6021 connector to replace Z3 M54 and M52TU connector on oxygen sensor/transmission harness: 12527505269
-Socket contact SLK 2,8 1,0-2,5 MM²/AG: 12527502933
Female X20 connector for E36 M54/S54 harness:
TE:
0.2-0.4: 929973-1
0.50-1.00: 962981-1 or 929974-1
1.00-2.50: 962978-1 or 929975-1 or 962982-1
For M50/S50 adapter:
Male X20 connector: 61131387109
Use C101 pins.
E34 M50 oil level sensor connector:
-Socket housing: 12521427222
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN: 12521427608
-Single conductor seal 0,25-1,0MM² (5.2mm blue): 12521748973 (Kostal 10800444522091)
-PROTECTION CAP 3 POL. : 12521732634 (alternate: 3 pol. Snap close protection cap: 12521707749)
For M52/S52 adapter:
Male X6031 connector: 61131383589 (internal number/NLA)
-Protection cap: 12521427316 (internal number/NLA)
Use C101 pins.
Female X6031 connector: 61131388862 (looks to be available from European suppliers)
-Protection cap: 12521427316 (internal number/NLA)
-Uses female 2.5 circular pins.
E30 C104 3-pin connector (for 87 and older): 1369123
Male C101 plug that goes to fuse box: 12521707284 (NLA)
TE: 0.50-1.00: 962981-1
1.00-2.50: 962978-1
Z3M S54 main engine harness: 12517831637
E46 M52TU X6011, also E30/E36 evap temp sensor: 61131378106 = car side. Male C101 pins.
61131378108 = engine side. Female C101 pins.
E46 M52TU X6021: 61131378132, superseded to 61138352311 = car side. Male C101 pins.
61131378134 = engine side. Female C101 pins.
Z3 M52TU X6011: Engine side = 61138352330
Chassis side = 61138352331
Z3 M52TU X6021: Engine side = 61131378134
Chassis side = 61138352311
Z3 M54 X2499 engine harness side connector 8 pol: 61131378118 -> 61138352322
Chassis side: 61131378116 -> 61138352323
Z3 M54 X6021: Engine side = 61131378134
Chassis side = 61131378132 -> 61138352311
E36 D100 Data Link Connector (Diagnosis plug):
-Housing: 12521711218
-Female C101 pins
-Protection cap: 12521719733 (straight version is 12521309527)
-Bracket: 61131388867
-Nut for bracket: 12521711219
-Cover (cap): 12521703202 (12521724690 is OBD1 version)
E36 dual coolant temperature sensor: 13621703993, MEK100160
Brown E30 coolant temperature sensor: 12621710512 or 12621710511 (Genuine is black)
E30 M3 and 95 and older E36 oil temperature sensor: 12611309193
S50b32 oil temperature sensor: 12611404699
-Connector housing 2 pol.: 12521427787
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN: 12521427608 (?->Kostal 22140492060050-L)
-Single conductor seal 0,25-1,0MM²: 12521748973
-PROTECTION CAP 2 POL.: 12521732694
E30 M3 firewall engine harness cover kit:
21 TRIM PANEL WIRE HARNES ENGINE 1 51711380392
22 COVERING WIRE HARNES ENGINE 1 51711380391
23 SUPPORT WIRE HARNES ENGINE 1 51711380390
E24 & E28 C101 connector housing: 12521273189
85 and older E30 & E23 C101 connector housing: 12521277533 ->NLA
Small pins: unknown (1.5 mm) (NOT 61131368621 or 61131373820) could be 61131353260 -> O2 sensor pins work.
Large pins: CABLE SOCKET ROUND FEMALE D3,5 61131359289
Secondary air pump connector: 61138352552
-Terminal socket 2.5 2,5-4,0 MM²: 61138352926
-Grommet: 61138352924
Secondary air pump relay: 12631742690
Splice, 4-6 mm²: 61136931481
Splice, .2-.5 mm²: 61138353746
Splice, 1.0-0.75 mm²: 61138353747
Splice, 1.5-2.5 mm²: 61138353748
Parts for MS42, MS43, MSS54, & MSS52 ECU bench flashing harness:
X60001: Covering cap: 12527502456 (TE 3-965487 or 1-965487-1 or 2-965487-1)
Socket housing 9 POL. /A1 12521744624 (TE 1-965486-1 or 2-965486-1)
Junior timer pins:
Junior timer, 0.22-0.5mm: 964280
Junior timer, 0.5-1mm: TE Part #: 964284 or 964286-2
OBD2 connector: Plug housing 16 POL.: 61138380698
-Flat spring contact 0,35-0,5MM²/AU: 61138366598
Micro Timer III @ TE: 1241732-2, 969005-2
Parts for MS41 ECU bench flashing harness:
X6000 ECU connector: Plug terminal control unit DDE/EGS 88 POL: 12521724131 (Bosch 1928401587)
-Takes junior timer and micro timer 1 pins.
-Micro timer 1: 0.35-0.75 mm2: 928939-1 (reel/cut strip) or 929927-1 (loose piece) (alliedelec.com has some). 0.2-0.5 mm2: 929950-1 (reel/cut strip) or 929951-1 (loose piece).
OBD2 connector: Plug housing 16 POL.: 61138380698
-Flat spring contact 0,35-0,5MM²/AU: 61138366598
Micro Timer III @ TE: 1241732-2, 969005-2
E38 10-pin X69 connector housing (Kostal) (also for M52TU throttle motor): 12521744870
-Pins: 0,5-1,0MM²: 12521744075. 1,0-2,5MM²: 12521744076.
-Sealing grommet: 12521703522
Z3, Freelander, E38, E39, pedal potentiometer connector (chassis side) 8-pin: 61131378972 (AMP/TE 1-828737-2) -> 61138352323
E39 X6021 26-pin:
Chassis side:
Housing: 61138352517 (AMP/TE 1-965056-1) Alternative: 61138352519, TE 953736
End cover: 61138352530 (AMP/TE 965057-1)
Slide thingy (secures end cover): AMP/TE 962112-3)
Pins (male MQS): 0.2-0.5: 1-928918-2 (strip) 19963725-1 (loose), 0.5-0.75: 963716-1 (strip) 963730-1 (loose)
Engine side:
Exterior housing: 61138373602 (Siemens B1026-Y240) Alternative:61136913644
Interior housing: 61138373618 (Siemens B1026-Y220) Alternatives: 61136913626, TE 144935-1
Pins MQS female
E39 unknown 18-pin:
Chassis side:
Housing: 61138364645 (TE 1-968152-1)
End cover: 61138364655 (TE 968153-1)
Pins (male MQS): 0.2-0.5: 1-928918-2 (strip) 19963725-1 (loose), 0.5-0.75: 963716-1 (strip) 963730-1 (loose)
Engine side:
Exterior housing: 61138364662, TE 1-967416-1 and 1-965777-1 Alternative: TE 1379100
Interior housing: 61138364666, TE 965778-1 Alternative: TE 1379102-1
Pins MQS female
E39 unknown 10-pin:
Chassis side: 61138364675 (new part number)
Housing: 61131383873 (TE 1-962110-3)
End cover: 61131383864 (TE 1-962109-3)
Slide thingy (secures end cover): AMP/TE 962112-3)
Pins (male MQS): 0.2-0.5: 1-928918-2 (strip) 19963725-1 (loose), 0.5-0.75: 963716-1 (strip) 963730-1 (loose)
Engine side: 61136909008 (new part number) (61131383840 & 61131383570 combined)
Exterior housing: 61131383840, (TE 1-962113-3)
Interior housing: 61131383570, (TE 962016-3
Slide thingy (secures end cover): AMP/TE 962112-3)
Pins MQS female
E39 X6011 engine side: 61131378139. Uses female C101 pins.
Male 2-pin connector that connects to E30 coolant temp sensor connector: Bosch 1928402448, VW/Audi 8D0971946
-Rubber boot: 1280703026
-Terminals: TE: 0.2-0.5: 965982 or 965983, 0.5–1.0 962915 or 963748, 1.5–2.5: 962916 or 963749, 4.0: 968947 or 968966
-Wire seal: TE: 0.35–1.00: 828904, 1.5-2.5: 828905, 2.5–4.0: 828985
-Sealing Plug: TE: 5.6mm diameter: 828922, 7.2mm diameter: 828986
E31 840Ci X20 connector, engine side (E36 X69 chassis side): 61131387115
-Uses male 2.5mm circular pins
E31 840Ci X20 connector, chassis side (E36 X69 harness side): 61131387116
-Uses female 2.5mm circular pins
Z3 EWS 3.D module connector: 61131382567
-Uses female 2.5mm pins
Z3 evaporator controller connector: 61131378123 -> 61138352316
E36 / Z3 instrument cluster connectors:
X16 26 pin white (Siemens): covering cap: 61138365376 (NLA), socket housing: 61131383810 -> 61138373618 (TE), pins for TE socket housing: 61130008998
X17 26 pin blue (Siemens): covering cap: 61138373606 (NLA), socket housing: 61131383810 -> 61138373618 (TE), pins for TE socket housing: 61130008998
X271 12 pin black (TE/AMP): covering cap: 61138364646 -> 61138364652 -> 61132471237 (comes with socket housing), socket housing: 61131383736. Takes MQS pins.
BMW Leakage Diagnosis Pump (DMTL) connector, 2002+: 61138365356
-Takes sealed female MQS pins like accelerator pedal connector.
BMW E31 X25 4-pin connector (engine side): 12521718057
Harness lengths (many based off of stock E30 M42 harness):
E30:
ECU to C101 = 60”
ECU to throttle pedal = 80” (I cut them 2” longer so 82”) (36” for RHD)
ECU to sport button = 60”
ECU to ground = 39.5”
ECU to B+ junction = 32”
ECU to C136 = 17”
ECU to OBD2 connector: 100” for driver’s kick panel area, 18” for glovebox (or 24” or whatever you want.)
C101 to coolant temp sensor = 70” (for upper radiator hose, maybe 60” for behind thermostat housing. You can measure. I made it long just in case.)
C101 to oil level sensor (only for M54/M50/S50/S52, not S54 or S62): 60”
C101 to fuel pump relay = 18” (for M3/318is harness cover on firewall). 10” to harness junction from C101 and 7” to harness junction from fuel pump relay.
C101 to ground = 60”
C101 to starter terminal 30h = 37”
C101 to D100 (20-pin diagnostic port) = 21”. 14” to harness junction.
Fuel pump relay to B+ junction = 30” (for M3/318is harness cover on firewall)
Fuel pump relay to ground = 30” (for M3/318is harness cover on firewall)
Fuel pump relay to X6021 = 62”
D100 to B+ junction = 40”. 9.5” to harness junction.
D100 to ground = 40”. 9.5” to harness junction.
E36:
ECU to X20 = 70” (82” for Z3)
ECU to throttle pedal = 80”
ECU to sport button = 60”
ECU to ground = 42”
ECU to B+ junction = 43”
ECU to OBD2 connector: 100” for driver’s kick panel area, 18” for glovebox (or 24” or whatever you want.)
ECU to SAP = 52”
SAP to ground = 12”
X20 to E36 dual coolant temp sensor = 60” (omit for CAN bus version)
X20 to fuel pump relay = 18”
X20 to starter terminal 30h = 50”
X20 to X6031 = 18” (OBD2)
Fuel pump relay to B+ = 18”
Fuel pump relay to ground = 24”
Wiring:
For a basic E30 S54 adapter harness without 20-pin diagnostic port:
Alternator charge indicator: C101 pin 1 to X60004 pin 1 = 0.5 mm2 wire
Starter terminal 30h: C101 15 = 0.75 mm2 wire (omit for 87 and older E30)
Starter terminal 50h: C101 pin 18 to X6011 pin 1 = 2.5 mm2 wire
->Also wire to 5 amp fuse and to X60004 pin 6 with 0.5mm2 wire (double up wires on X6011 pin 1)
Oil pressure light: C101 pin 5 to X60004 pin 11 = 0.5 mm2 wire
Engine speed (tachometer): C101 pin 9 to X60004 pin 17 = 0.5 mm2 wire (87 and older E30 is C104 pin 1 in glovebox instead of C101)
Vehicle speed input: C101 pin 14 to X60004 pin 22 = 0.5 mm2 wire
Terminal 15 (ignition switched power): C101 pin 6 to X60004 pin 26 = 0.75 mm2 wire
Coolant temp sensor pin 1 to C101 pin 4 = 0.5 mm2 wire
Fuel pump relay pin 2 to C101 pin 13 = 2.5 mm2 wire
Ignition switched power C101 pin 7 to 7.5 amp fuse to X6011 pin 2 = 1.0 mm2 wire
1990+ ABS power C101 pin 20 to X6021 pin 2 = 0.75 mm2 wire (doubled up with fuel pump relay pin 8 wire)
E30 M3 oil temp sensor pin 1 to C101 pin 19 = 0.5 mm2 wire
Oil service & inspection reset: C101 pin 11 to switch = 0.5 mm2 wire (other side of switch is ground)
Check control oil level off: C101 pin 2 to ground and pin 10 to 1K ohm resistor and then to ground (double up resistor and ground wire on pin 2 and put pin 10 on other side of resistor) = 0.5mm2 wire
Fuel pump relay activation: Euro pin 4 to X60004 pin 10 or USA pin 1 to X6021 pin 1 = 0.5 mm2 wire
Fuel pump relay trigger power: pin 8 to X6021 pin 2 = 1.5 mm2 wire
Fuel pump relay power: pin 6 to B+ junction = 2.5 mm2 wire
USA fuel pump relay ground: pin 7 (omit for Euro)
Power adapter cable: X64101/X64102 pin 1 to B+ junction = 6.0 mm2 red wire
All connections that are B+ junction or ground are a ring terminal. Starter terminal 30h is also a ring terminal (use 10mm hole size for that one).
Harness construction:
Start by cutting the 6.0 mm2 power adapter cable to 32”. Cut a 1” piece of red 6mm heat shrink tubing and put it over the wire. Strip 1/4” of insulation off the end and crimp a standard power timer on the X64101/X64102 connector side, but don’t crimp the insulation tabs yet. Turn on your soldering station and set it to 350 degrees C for lead-free solder or 300 degrees C for leaded solder. Now add a little solder to the crimp joint you made, just enough to cover the bare wire in the joint. This will help prevent it from coming loose and seals it from moisture. Now wait for it to cool and then lightly crimp the insulation tabs. Then insert the pin into pin 1 on the little connector that goes into the X64101/X64102 connector. Strip 1/2” of insulation off the end and crimp a ring terminal on it. Solder and then position the piece of red 6mm heat shrink tubing over the crimped area and use the heat gun to shrink it.
Start by cutting all the wires that go to the C101 connector to the correct lengths. Add 7” to the wire length for wires that go to X6011 or a fuse from the C101. So pins 1, 5, 9, and 6 are 60” and pins 18, 7, and 20 (90+) are 67”. Pin 15 is 37” and pin 13 is 18”. Pin 15 wire goes in it’s own sleeve. Pin 4 is 70” (or whatever you measured) and goes in it’s own sleeve.
Then cut the 12mm braided sleeving they will go in. Cut it to 54” and cauterize the ends with the cigarette lighter. Then if you are installing the fuel pump relay in the M3 cover then cut 10” off the end. Cut 3 1” pieces of 12mm heat shrink tubing and put 1 pice on the 10” sleeve and 2 pieces on the 44” sleeve. Put the 10” sleeve through the rubber boot for the C101 connector.
Then put the 18” long wire for the fuel pump relay pin 2 through the sleeve. Strip 1/4” of insulation off the end and crimp a standard power timer on the fuel pump relay side, but don’t crimp the insulation tabs yet (solder, wait to cool, crimp insulation as before). Then insert the pin into pin 2 on the fuel pump relay base. Do the same thing on the other side of the wire, but this time use a male C101 (2.5 mm system) pin and then insert it into the C101 housing in pin 13.
Now cut a piece of 4 mm sleeving to 67” (or 3” less than the wire size you want for the coolant temp sensor wire) and cauterize the ends with the cigarette lighter.. Put the coolant temp sensor wire through it. Then put it through the rubber boot for the C101 connector. Crimp a male C101 pin on the C101 side (solder, wait to cool, crimp insulation) and insert into pin 4 on the C101. Then put the other end through the rubber boot for the coolant temp sensor connector. Then strip 1/4” of insulation off the end and put a wire seal on the end to match up with the end of the insulation so that 1/4” bare wire sticks out. Now crimp an SLK 2.8 ELA pin onto it (solder, wait to cool, crimp insulation) and insert into pin 1. Put a sealing grommet into pin 2. Then put the rubber boot over the end.
Just like for the coolant temp sensor do the same thing for the pin 15 starter terminal 30h wire, but make the sleeving only 2” shorter, so 35” for the 37” wire, and cauterize the ends with the cigarette lighter. Cut 1 piece of 6mm heat shrink tubing and put it over the sleeving and the wire. Put the 10mm hole ring terminal on the starter end. Strip 1/2” of insulation off the wire, crimp, and solder it. Then position the heat shrink tubing over the crimped part of the ring terminal and the end of the sleeving. Use the heat gun to shrink the heat shrink tubing. Be careful not to heat the braided sleeving or it will melt and come apart.
Bunch up all the wires that go in the main 44” sleeve. Tape the ends together. Now slide them in. Then slide them through the 10 sleeve that the fuel pump relay wire is in that goes through the C101 rubber boot. Once you worked them through with about 2” of wire sticking out take the tape off the end. Now crimp C101 pins on them (solder, wait to cool, crimp insulation).
Now strip 1/8” of insulation off the end of the X60004 wires and crimp MQS pins onto them. Do not solder the little MQS pins. They are too small and solder could get stuck inside the pin holes. Just crimp them good. Also make sure the ends of the wire do not stick past the crimp area at all. There’s a ridge in the X60004 connector housing that will push them together and cause problems!
Now double up the terminal 50, C101 pin 18, wire with small section of 0.5 mm2 wire (about 12”) and crimp an ELO-Power 2,8 pin onto both wires (solder, wait to cool, crimp insulation). Insert it into X6011 pin 1. Wire the 0.5 mm2 wire to a fuse holder and cut another piece of 0.5 mm2 wire from the fuse holder to the X60004 pin 6 (just run the wire length down to measure it and cut it). Then crimp an MQS pin for pin 6 and stick it in. Install a 5 amp fuse in the fuse holder.
Now wire the wire from C101 pin 7 to a fuse holder and other end of the fuse holder to X6011 pin 2 (solder, wait to cool, crimp insulation).
Now trace the distance with a piece of wire from the position of X6011 and the fuse holders to the fuel pump relay and cut a 1.5 mm2 wire (and 0.5 mm2 wire for USA relay). For Euro relay trace the distance for the 0.5 mm2 wire from the X60004 to the fuel pump relay. Feed both wires through the main 44” sleeve to the fuel pump relay and wire both ends. The 1.5 mm2 wire goes to pin 8 on the fuel pump relay to X6021 pin 2 (and the 0.75 mm2 wire from pin 20 if the E30 is 90+ also goes to X6021 pin 2 doubled up like X6011 pin 1). For USA relay the 0.5 mm2 wire goes to X6021 pin 1 and pin 1 on the relay base. For Euro relay the 0.5 mm2 wire goes to X60004 pin 10 and pin 4 on the relay base. Wire pin 6 on the relay with a standard power terminal to the B+ junction with a ring terminal and a 1” piece of red 6 mm heat shrink tubing.
Now get your multimeter and set it to the audible continuity settings. Use it to tell which wires are which that go to the C101, X60004, X6011, and X6021 connectors. Insert them into the correct pin positions.
Now wire the sport mode switch. One 0.5 mm2 wire goes from X60004 pin 15 to the switch and the other 0.5 mm2 wire goes to ground. Feed both wires through some 4 mm sleeving. Use the 4.8mm x 0.8 pins for the switch. Solder those like the ring terminals, but put a 1/2” piece of 3 mm heat shrink tubing over each one. Put 2 pieces of 1” 6mm black heat shrink tubing over the ends of the sleeving and shrink them with the heat gun.
Now wire the OBD2 port. Pins 4 and 5 are ground. If you are installing the OBD2 port at the driver’s kick panel area then cut 2 pieces of 0.5 mm2 wire to 36” and wire those with Micro Timer II pins to the OBD2 port, through a piece of 4mm sleeving with 6 mm black heat shrink tubing, and to a ring terminal. Cut the wires for pins 7 and 16, both 0.5 mm2. Pin 7 goes the X60004 pin 32 with an MQS pin. Pin 16 goes to a 5 amp fuse in a fuse holder and then to the B+ junction. Cut the pin 7 wire to 100” and the pin 16 wire to 107”. You can wire the pin 16 wire directly to the B+ junction with its own ring terminal or you can crimp a standard power timer to the wire on the other side of the fuse holder and insert it into pin 2 on the X64101/X64102 connector with the 6 mm2 power adapter cable.
Now wire the throttle pedal. Cut a piece of 6 mm sleeving to 76” and then cut 6 pieces of 0.35 mm2 wire to 82” each. Tape the ends together and feed them through. Now take the tape off. Then strip 1/8” of insulation off the ends of wires on both sides. Put wire seals on one side, but not the other. Crimp sealing MQS pins on the wire seal side and regular non-sealing ones on the other side. Now get your multimeter again to tell the wires apart. Put one side through your toes until your ready to put it into the connector. Pin 1 on the throttle pedal connector goes to pin 7 on the X60004. Pin 4 goes to X60004 pin 8. Pin 5 goes to X60004 pin 9. Pin 2 goes to X60004 pin 12. Pin 6 goes to X60004 pin 13. Pin 3 goes to X60004 pin 14. Note: This is for the E46 pedal. If you have the Z3M potentiometer unit the wiring is different. In that case look at the 2001 Z3M ETM. That connector uses C101 pins (2.5 mm system) instead of MQS pins.
Now put the two X60004 connector inserts into the main housing and tape the wires behind it to look neat. You can label the connectors if you are giving the harness to someone else to install or if you think you’ll forget what they are later.
You’re done! You did it! Congratulations!
Examples of the adapter harnesses I used to make:
S54 for E30 (this updated version puts fuel pump relay in stock location under M3 harness cover):
S62 for E30 M3:
S54 for OBD2 E36 with wires to connect to Z3M instrument cluster (this updated version puts fuel pump relay mounted in stock location on side of fuse box):
Here are instructions for making an adapter harness just like Andrew. If you want to do it differently, that’s totally up to you. You may save this info for your personal use, but please don’t copy & paste any of it for commercial purposes. If you want to sell harnesses then please create your own instructions from scratch. See this Wikipedia article about plagiarism: https://en.wikipedia.org/wiki/Wikipedia:Plagiarism An exception is if you want to quote something here and then cite this thread and Andrew as the author. That’s totally fine!
The first step is figuring out your workspace. It may work for you to work on a very large desk that is near chest height so that you can stand, or you may find it convenient to work on the floor. For your desk perhaps you could get a full-size piece of plywood at a builder’s supply store along with a couple saw horses and nail it together. For the floor you can get a floor chair. If you’re in Japan then you probably already have one. If not, then you can make one. Go to Ikea and choose a chair you like. Buy it without the legs. Make feet for it using little wood blocks and screw them to the bottom. Put a seat pillow on it to make it more comfy. This will be your home for many hours. :)
The second step is gathering up the tools you’ll need. Buy these tools:
Engineer PA-09 crimper for small terminals: https://www.amazon.com/Engineers-Pre...dp/B002AVVO7K/
Engineer PAD-13 crimper for medium terminals: https://www.amazon.com/Engineer-PAD-...dp/B00IWD9XKU/
A hydraulic crimper for large terminals: https://www.amazon.com/gp/product/B09Y5XLDS9/
A simple crimper & stripper tool: https://www.amazon.com/Gardner-Bende...dp/B00164C0KW/ or https://www.crutchfield.com/S-56dHN7...-Tool-Set.html
A metric wire stripper tool (must be metric, not AWG): https://www.amazon.com/Katapult-Metr.../dp/B079TPXDDY or https://www.amazon.com/KNIPEX-Tools-...dp/B005EXNX1Q/
A wire cutter: https://www.amazon.com/Cutter-Lightw...dp/B000GTMZHG/ or https://www.amazon.com/Creativity-Cu...dp/B087BL2KGM/
A set of pin eject tools (I have some genuine ones, but I found these cheap Chinese ones work just fine. What it’s missing are the ones for the square C101, but those are obscure parts so no surprise there.): https://www.amazon.com/gp/product/B09YPRFRCN/
Some small screwdrivers for pushing in pins and seals. You can shop around on Amazon or wherever. I don’t have this one, but something like that: https://www.amazon.com/WORKPRO-10-Pi...dp/B091C32HLX/
A tape measure, like this, you can shop around: https://www.amazon.com/Lufkin-Self-C...dp/B0C754QG56/ or https://www.amazon.com/Lufkin-PHV103...dp/B01N3BYK61/
A pair of scissors, pretty much any are fine, something like this: https://www.amazon.com/Westcott-1390...dp/B000P0LNRE/
A heat gun (I’ve tried several and this one works): https://www.amazon.com/PORTER-CABLE-...dp/B004Q04X44/
A cigarette lighter, such as standard Bic.
A digital multimeter with audible continuity checker (the 9V battery in mine still works since 2015!): https://www.amazon.com/Fluke-113-Tru...dp/B004Q05ODI/
A soldering station: https://www.amazon.com/Hakko-FX888D-...dp/B00ANZRT4M/
A flat piece of wood about 1/4” thick and 7 to 8” x 3 to 4” for soldering on (just cut one from scrap wood).
An air purifier (for sucking up nasty fumes you shouldn’t breathe): https://www.costco.com/winix-true-he...000093012.html
Now buy the supplies you need:
Kester lead-free silver alloy solder (don’t cheap out on solder, you’ll regret it. Buy the good stuff once and don’t think about it.): https://www.amazon.com/KESTER-SOLDER...dp/B00H2AFXS0/ If you must cheap out at least get the name brand leaded stuff (check eBay for deals on the other before buying this): https://www.amazon.com/Kester-24-633...dp/B0149K4JTY/
Electrical tape (if you want cloth tape, go for it. I never bothered.): https://www.harborfreight.com/electr...ack-63312.html
For the wire, fuse holders, braided sleeving, pins, etc. you’ll need to request to open an account with Transfer Multisort Elektronik at tme.com. After a day or two your account will be ready and you can start ordering. Keep each order under 5 kg to save on shipping. If it goes over just split it up into another order. Everything ships super fast from Poland. These people are totally awesome, but if you screw up there isn’t much you can do. Just have to suck it up because their return policy is pretty much non-existent. They primarily deal with businesses, not end-users, just like most of these suppliers.
Now order wire in the FLRYW-B spec in these sizes (the W is for high-temp insulation) in 100 meter rolls:
0.35 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
0.5 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
0.75 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
1.0 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
1.5 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
2.5 mm2: https://www.tme.com/ux/en-us/details...bles/bq-cable/
6.0 mm2 (order it in red color): https://www.tme.com/ux/en-us/details...bles/bq-cable/
Now order braided sleeving in these sizes (1 box each is fine for 1 or 2 harnesses):
4mm: https://www.tme.com/ux/en-us/details.../cyg-pet4-box/
6mm: https://www.tme.com/ux/en-us/details.../cyg-pet6-box/
12mm: https://www.tme.com/ux/en-us/details.../cyg-pet6-box/
Now order heat shrink tubing in these sizes (black for ground, red for positive):
3mm black: https://www.tme.com/ux/en-us/details...-connectivity/
6mm black: https://www.tme.com/ux/en-us/details...-connectivity/
9mm black: https://www.tme.com/ux/en-us/details...-connectivity/
12mm black: https://www.tme.com/ux/en-us/details...-connectivity/
6mm red: https://www.tme.com/ux/en-us/details...-connectivity/ or https://www.tme.com/ux/en-us/details...3m/7000099250/
Now order ring terminals in these sizes (10 each is fine):
M6 for 0.25 to 1.5 mm2 wire: https://www.tme.com/ux/en-us/details...roup/bm-01131/
M6 for 1.5 to 2.5 mm2 wire: https://www.tme.com/ux/en-us/details...roup/bm-01131/
M6 for 6mm2 wire: https://www.tme.com/ux/en-us/details...roup/bm-01331/
M10 for 0.25 to 1.5 mm2 wire (For S54 starter field terminal or omit for non-M starter that has a terminal 30h): https://www.tme.com/ux/en-us/details...roup/bm-01143/
Fuse holders (3 per harness): https://www.tme.com/ux/en-us/details...s/mta/3050153/
5 amp fuses (2 per harness): https://www.tme.com/ux/en-us/details...es/littelfuse/
7.5 amp fuses (1 per harness): https://www.tme.com/ux/en-us/details...es/littelfuse/
For E30 oil level light off 1K ohm resistor: https://www.tme.com/ux/en-us/details...f0207fte52-1k/ or https://www.tme.com/ux/en-us/details...f006ff1001a50/
Momentary on switch for sport mode: https://www.tme.com/ux/en-us/details...hes/marquardt/ or https://www.tme.com/ux/en-us/details...i/r13-516a-02/
If you want a switch for oil service and inspection reset order an on/off rocker switch: such as https://www.tme.com/ux/en-us/details...hes/marquardt/
Now you need connector pins. Order these:
4.8mmx0.8 tab for switches: https://www.tme.com/ux/en-us/details...erminals/vogt/
Now here’s the part numbers for the connectors and pins. I’m just pasting it here from a document I created. Go over it to figure out what you need. For the BMW part numbers you can order them from a BMW dealer. For TE/AMP and Kostal part numbers you can order them from TME, Mouser, Newark, etc. Search octopart.com for the best prices.
X60004: Covering cap 40 POL. : 12521744629 (967286-1)
-Socket housing 20 POL, pins 1-20: 12521744631 (965489-1)
-Socket housing 20 POL, pins 21-40: 12521744630 (965489-2)
-Terminal socket MQS ELA 0.75 MM²/SN: 61138366260
-Terminal socket MQS ELA 0.2-0.5 MM² SN: 61131393704
-Terminal socket MQS ELA 0.25-0.35mm: TE Part #: 963726-1 (loose piece) 928999-1 (Sn) (reel), 928999-5 (Ag), 928999-6 (Au)
0.5-0.75mm: 963729-1 (loose piece), 963715-1 (Sn), 963715-5 (Au), 963715-6 (Ag)
MQS crimp tool: 539682-1 (handle 539635-1) (die set 539682-2)
X64101/X64102: 61138373609
-Little connector that plugs into X64101/X64102 connector: 61138377082
-Double leaf spring contact 2,5-4,0MM²: 61131370693<-NLA!
This one->4.0-6.0mm2: 61138377734 -> Standard Timer, 4.0-6.0mm TE #: 963714-1 or 963709-1, 144433-1. 4,0MM² 927829-1
E46 X6021: 61136901729 / 61136901731 -> superseded to 61132360044 (includes pins)
-Pin-contact ELO-Power 2,8 x 0,63 0,35-0,5MM²: 61138373293
-Pin-contact ELO-Power 2,8 x 0,63 0,5-1,0MM²: 61138364833
-Pin-contact ELO-Power 2,8 x 0,63 1,0-2,5MM²: 61138364835
E46 X6011: 61136905995 / 61136905999
-Pin-contact ELO-Power 2,8 x 0,63 0,35-0,5MM²: 61138373293
-Pin-contact ELO-Power 2,8 x 0,63 0,5-1,0MM²: 61138364833
-Pin-contact ELO-Power 2,8 x 0,63 1,0-2,5MM²: 61138364835
E39 X6011: 61131378137. Uses male C101 pins.
OBD2 cover:
-Cover with frame OBD socket SCHWARZ: 61138373323
OBD2 connector: Plug housing 16 POL.: 61138380698
-Flat spring contact 0,35-0,5MM²/AU: 61138366598
0.5-1 TE #: 964263-2, 964264-2, 964261, 962876-1 (tme.eu) 1241732-2, 969005-2 or 969019-2 or 1241860-2
E30 coolant temperature sensor connector & E30 M3 oil temperature sensor:
- Socket housing 2 POL.: 12521427615
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN: 12521427608 (?->Kostal 22140492060050-L)
-Single conductor seal 0,25-1,0MM² (5.2mm blue): 12521748973 (Kostal 10800444522091) or TE 828904-1 (828905-1 for larger wire)
-Cavity plug: TE 828922-1
-PROTECTION CAP 2 POL.: 12521732694
Accelerator pedal connector: Socket housing 6 POL.: 61138383300
-Terminal socket MQS ELA 0.2-0.5 MM² SN: 61130005199
-Terminal socket MQS ELA 0,35-0,5 MM²: 61136901726
-AMP terminal socket: 0.25-0.35mm: TE Part #: 963727-1 (loose piece) or 962885-1 (reel) (Die set for MQS crimp tool 539685-2)
-Rubber grommet 0.2MM²: 61138366247 TE#: 967067-2
C101: Plug housing 20POL: 12521707283
-0.2-0.4mm: TE 962970-1 or 929966-1 (reel)
-Circular contact 2.5 0,5-1,5MM²: 61131376191. TE Part #: 962971-1 or 929967-1
Wire seal: 828920-1
-Circular contact 2.5 1,0-2,5MM²: 61131376193 superseded to 61130007452 (with wire). TE #:929968-1 or 962972-1
Wire seal: 828921-1
-Circular contact 2.5 2,5-4,0MM²: 61131376195.
Cavity plug: 963531-1
-Protection cap: 12521707302 -> use X20 version instead -> stretches easier: 12521719733
Relays:
Relay for fuel pump, cycled (USA S54): 61357892976
Standard relay for Euro S54, and also M54 & M52TU: 61368373700
Base for relay: 61131389114 (black top) or 61131389111 (white top) or 61131389113
Contacts:
Junior timer, 0.22-0.5mm: 964280
Junior timer, 0.5-1mm: TE Part #: 964284 or 964286-2
Junior timer, 1.5-2.5mm: 965999 or 964273 or 241872 or 964273-2
Standard timer 0.2-0.5mm: 927839 or 928990-2
Standard timer 0.5-1mm: TE Part #: 927827
Standard timer, 1-2.5mm, TE Part #: 927833-1, 927837-2 (tme.eu) or 927837 (mouser.com)
E36 Dual Coolant Temperature Sensor Connector:
-Pins (KOSTAL LKS 1,5 ELA): 12521436205 or 12521744075 (Kostal 22124444630060-L, 22140444630-L)
-Wire seal (5.2mm blue): 12521748973 (Kostal 10800444522091, 10800444522)
-Protection cap: 12521703593
NLA -> Z3M S54 X6011 chassis side connector 2 POL.: 61138352331
-Circular contact 2.5 0,5-1,5MM²: 61131376191. TE Part #: 929967-1
-Circular contact 2.5 1,0-2,5MM²: 61131376193 superseded to 61130007452 (with wire). TE #:929968-1 or 962972-1
Z3M S54 X6021 engine harness side connector 8 pol: 61131378118 -> 61138352322
Chassis side: 61131378116 -> 61138352323
Male E46 X6011 connector to replace Z3 connector on engine harness: 12527505477
-Socket contact SLK 2,8 1,0-2,5 MM²/AG: 12527502933 (Kostal 22124492070050-L)
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN 12521427608
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² AG 12521427612
-Socket terminal SLK 2.8 ELA 1,0-2,5MM² /SN 12521433216 (Kostal 22140492070050)
-Socket terminal SLK 2.8 ELA 4,0 MM² 12527505636 (Kostal 22124499720030)
Male E46 X6021 connector to replace Z3 M54 and M52TU connector on oxygen sensor/transmission harness: 12527505269
-Socket contact SLK 2,8 1,0-2,5 MM²/AG: 12527502933
Female X20 connector for E36 M54/S54 harness:
TE:
0.2-0.4: 929973-1
0.50-1.00: 962981-1 or 929974-1
1.00-2.50: 962978-1 or 929975-1 or 962982-1
For M50/S50 adapter:
Male X20 connector: 61131387109
Use C101 pins.
E34 M50 oil level sensor connector:
-Socket housing: 12521427222
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN: 12521427608
-Single conductor seal 0,25-1,0MM² (5.2mm blue): 12521748973 (Kostal 10800444522091)
-PROTECTION CAP 3 POL. : 12521732634 (alternate: 3 pol. Snap close protection cap: 12521707749)
For M52/S52 adapter:
Male X6031 connector: 61131383589 (internal number/NLA)
-Protection cap: 12521427316 (internal number/NLA)
Use C101 pins.
Female X6031 connector: 61131388862 (looks to be available from European suppliers)
-Protection cap: 12521427316 (internal number/NLA)
-Uses female 2.5 circular pins.
E30 C104 3-pin connector (for 87 and older): 1369123
Male C101 plug that goes to fuse box: 12521707284 (NLA)
TE: 0.50-1.00: 962981-1
1.00-2.50: 962978-1
Z3M S54 main engine harness: 12517831637
E46 M52TU X6011, also E30/E36 evap temp sensor: 61131378106 = car side. Male C101 pins.
61131378108 = engine side. Female C101 pins.
E46 M52TU X6021: 61131378132, superseded to 61138352311 = car side. Male C101 pins.
61131378134 = engine side. Female C101 pins.
Z3 M52TU X6011: Engine side = 61138352330
Chassis side = 61138352331
Z3 M52TU X6021: Engine side = 61131378134
Chassis side = 61138352311
Z3 M54 X2499 engine harness side connector 8 pol: 61131378118 -> 61138352322
Chassis side: 61131378116 -> 61138352323
Z3 M54 X6021: Engine side = 61131378134
Chassis side = 61131378132 -> 61138352311
E36 D100 Data Link Connector (Diagnosis plug):
-Housing: 12521711218
-Female C101 pins
-Protection cap: 12521719733 (straight version is 12521309527)
-Bracket: 61131388867
-Nut for bracket: 12521711219
-Cover (cap): 12521703202 (12521724690 is OBD1 version)
E36 dual coolant temperature sensor: 13621703993, MEK100160
Brown E30 coolant temperature sensor: 12621710512 or 12621710511 (Genuine is black)
E30 M3 and 95 and older E36 oil temperature sensor: 12611309193
S50b32 oil temperature sensor: 12611404699
-Connector housing 2 pol.: 12521427787
-Socket terminal SLK 2.8 ELA 0,22-0,5MM² SN: 12521427608 (?->Kostal 22140492060050-L)
-Single conductor seal 0,25-1,0MM²: 12521748973
-PROTECTION CAP 2 POL.: 12521732694
E30 M3 firewall engine harness cover kit:
21 TRIM PANEL WIRE HARNES ENGINE 1 51711380392
22 COVERING WIRE HARNES ENGINE 1 51711380391
23 SUPPORT WIRE HARNES ENGINE 1 51711380390
E24 & E28 C101 connector housing: 12521273189
85 and older E30 & E23 C101 connector housing: 12521277533 ->NLA
Small pins: unknown (1.5 mm) (NOT 61131368621 or 61131373820) could be 61131353260 -> O2 sensor pins work.
Large pins: CABLE SOCKET ROUND FEMALE D3,5 61131359289
Secondary air pump connector: 61138352552
-Terminal socket 2.5 2,5-4,0 MM²: 61138352926
-Grommet: 61138352924
Secondary air pump relay: 12631742690
Splice, 4-6 mm²: 61136931481
Splice, .2-.5 mm²: 61138353746
Splice, 1.0-0.75 mm²: 61138353747
Splice, 1.5-2.5 mm²: 61138353748
Parts for MS42, MS43, MSS54, & MSS52 ECU bench flashing harness:
X60001: Covering cap: 12527502456 (TE 3-965487 or 1-965487-1 or 2-965487-1)
Socket housing 9 POL. /A1 12521744624 (TE 1-965486-1 or 2-965486-1)
Junior timer pins:
Junior timer, 0.22-0.5mm: 964280
Junior timer, 0.5-1mm: TE Part #: 964284 or 964286-2
OBD2 connector: Plug housing 16 POL.: 61138380698
-Flat spring contact 0,35-0,5MM²/AU: 61138366598
Micro Timer III @ TE: 1241732-2, 969005-2
Parts for MS41 ECU bench flashing harness:
X6000 ECU connector: Plug terminal control unit DDE/EGS 88 POL: 12521724131 (Bosch 1928401587)
-Takes junior timer and micro timer 1 pins.
-Micro timer 1: 0.35-0.75 mm2: 928939-1 (reel/cut strip) or 929927-1 (loose piece) (alliedelec.com has some). 0.2-0.5 mm2: 929950-1 (reel/cut strip) or 929951-1 (loose piece).
OBD2 connector: Plug housing 16 POL.: 61138380698
-Flat spring contact 0,35-0,5MM²/AU: 61138366598
Micro Timer III @ TE: 1241732-2, 969005-2
E38 10-pin X69 connector housing (Kostal) (also for M52TU throttle motor): 12521744870
-Pins: 0,5-1,0MM²: 12521744075. 1,0-2,5MM²: 12521744076.
-Sealing grommet: 12521703522
Z3, Freelander, E38, E39, pedal potentiometer connector (chassis side) 8-pin: 61131378972 (AMP/TE 1-828737-2) -> 61138352323
E39 X6021 26-pin:
Chassis side:
Housing: 61138352517 (AMP/TE 1-965056-1) Alternative: 61138352519, TE 953736
End cover: 61138352530 (AMP/TE 965057-1)
Slide thingy (secures end cover): AMP/TE 962112-3)
Pins (male MQS): 0.2-0.5: 1-928918-2 (strip) 19963725-1 (loose), 0.5-0.75: 963716-1 (strip) 963730-1 (loose)
Engine side:
Exterior housing: 61138373602 (Siemens B1026-Y240) Alternative:61136913644
Interior housing: 61138373618 (Siemens B1026-Y220) Alternatives: 61136913626, TE 144935-1
Pins MQS female
E39 unknown 18-pin:
Chassis side:
Housing: 61138364645 (TE 1-968152-1)
End cover: 61138364655 (TE 968153-1)
Pins (male MQS): 0.2-0.5: 1-928918-2 (strip) 19963725-1 (loose), 0.5-0.75: 963716-1 (strip) 963730-1 (loose)
Engine side:
Exterior housing: 61138364662, TE 1-967416-1 and 1-965777-1 Alternative: TE 1379100
Interior housing: 61138364666, TE 965778-1 Alternative: TE 1379102-1
Pins MQS female
E39 unknown 10-pin:
Chassis side: 61138364675 (new part number)
Housing: 61131383873 (TE 1-962110-3)
End cover: 61131383864 (TE 1-962109-3)
Slide thingy (secures end cover): AMP/TE 962112-3)
Pins (male MQS): 0.2-0.5: 1-928918-2 (strip) 19963725-1 (loose), 0.5-0.75: 963716-1 (strip) 963730-1 (loose)
Engine side: 61136909008 (new part number) (61131383840 & 61131383570 combined)
Exterior housing: 61131383840, (TE 1-962113-3)
Interior housing: 61131383570, (TE 962016-3
Slide thingy (secures end cover): AMP/TE 962112-3)
Pins MQS female
E39 X6011 engine side: 61131378139. Uses female C101 pins.
Male 2-pin connector that connects to E30 coolant temp sensor connector: Bosch 1928402448, VW/Audi 8D0971946
-Rubber boot: 1280703026
-Terminals: TE: 0.2-0.5: 965982 or 965983, 0.5–1.0 962915 or 963748, 1.5–2.5: 962916 or 963749, 4.0: 968947 or 968966
-Wire seal: TE: 0.35–1.00: 828904, 1.5-2.5: 828905, 2.5–4.0: 828985
-Sealing Plug: TE: 5.6mm diameter: 828922, 7.2mm diameter: 828986
E31 840Ci X20 connector, engine side (E36 X69 chassis side): 61131387115
-Uses male 2.5mm circular pins
E31 840Ci X20 connector, chassis side (E36 X69 harness side): 61131387116
-Uses female 2.5mm circular pins
Z3 EWS 3.D module connector: 61131382567
-Uses female 2.5mm pins
Z3 evaporator controller connector: 61131378123 -> 61138352316
E36 / Z3 instrument cluster connectors:
X16 26 pin white (Siemens): covering cap: 61138365376 (NLA), socket housing: 61131383810 -> 61138373618 (TE), pins for TE socket housing: 61130008998
X17 26 pin blue (Siemens): covering cap: 61138373606 (NLA), socket housing: 61131383810 -> 61138373618 (TE), pins for TE socket housing: 61130008998
X271 12 pin black (TE/AMP): covering cap: 61138364646 -> 61138364652 -> 61132471237 (comes with socket housing), socket housing: 61131383736. Takes MQS pins.
BMW Leakage Diagnosis Pump (DMTL) connector, 2002+: 61138365356
-Takes sealed female MQS pins like accelerator pedal connector.
BMW E31 X25 4-pin connector (engine side): 12521718057
Harness lengths (many based off of stock E30 M42 harness):
E30:
ECU to C101 = 60”
ECU to throttle pedal = 80” (I cut them 2” longer so 82”) (36” for RHD)
ECU to sport button = 60”
ECU to ground = 39.5”
ECU to B+ junction = 32”
ECU to C136 = 17”
ECU to OBD2 connector: 100” for driver’s kick panel area, 18” for glovebox (or 24” or whatever you want.)
C101 to coolant temp sensor = 70” (for upper radiator hose, maybe 60” for behind thermostat housing. You can measure. I made it long just in case.)
C101 to oil level sensor (only for M54/M50/S50/S52, not S54 or S62): 60”
C101 to fuel pump relay = 18” (for M3/318is harness cover on firewall). 10” to harness junction from C101 and 7” to harness junction from fuel pump relay.
C101 to ground = 60”
C101 to starter terminal 30h = 37”
C101 to D100 (20-pin diagnostic port) = 21”. 14” to harness junction.
Fuel pump relay to B+ junction = 30” (for M3/318is harness cover on firewall)
Fuel pump relay to ground = 30” (for M3/318is harness cover on firewall)
Fuel pump relay to X6021 = 62”
D100 to B+ junction = 40”. 9.5” to harness junction.
D100 to ground = 40”. 9.5” to harness junction.
E36:
ECU to X20 = 70” (82” for Z3)
ECU to throttle pedal = 80”
ECU to sport button = 60”
ECU to ground = 42”
ECU to B+ junction = 43”
ECU to OBD2 connector: 100” for driver’s kick panel area, 18” for glovebox (or 24” or whatever you want.)
ECU to SAP = 52”
SAP to ground = 12”
X20 to E36 dual coolant temp sensor = 60” (omit for CAN bus version)
X20 to fuel pump relay = 18”
X20 to starter terminal 30h = 50”
X20 to X6031 = 18” (OBD2)
Fuel pump relay to B+ = 18”
Fuel pump relay to ground = 24”
Wiring:
For a basic E30 S54 adapter harness without 20-pin diagnostic port:
Alternator charge indicator: C101 pin 1 to X60004 pin 1 = 0.5 mm2 wire
Starter terminal 30h: C101 15 = 0.75 mm2 wire (omit for 87 and older E30)
Starter terminal 50h: C101 pin 18 to X6011 pin 1 = 2.5 mm2 wire
->Also wire to 5 amp fuse and to X60004 pin 6 with 0.5mm2 wire (double up wires on X6011 pin 1)
Oil pressure light: C101 pin 5 to X60004 pin 11 = 0.5 mm2 wire
Engine speed (tachometer): C101 pin 9 to X60004 pin 17 = 0.5 mm2 wire (87 and older E30 is C104 pin 1 in glovebox instead of C101)
Vehicle speed input: C101 pin 14 to X60004 pin 22 = 0.5 mm2 wire
Terminal 15 (ignition switched power): C101 pin 6 to X60004 pin 26 = 0.75 mm2 wire
Coolant temp sensor pin 1 to C101 pin 4 = 0.5 mm2 wire
Fuel pump relay pin 2 to C101 pin 13 = 2.5 mm2 wire
Ignition switched power C101 pin 7 to 7.5 amp fuse to X6011 pin 2 = 1.0 mm2 wire
1990+ ABS power C101 pin 20 to X6021 pin 2 = 0.75 mm2 wire (doubled up with fuel pump relay pin 8 wire)
E30 M3 oil temp sensor pin 1 to C101 pin 19 = 0.5 mm2 wire
Oil service & inspection reset: C101 pin 11 to switch = 0.5 mm2 wire (other side of switch is ground)
Check control oil level off: C101 pin 2 to ground and pin 10 to 1K ohm resistor and then to ground (double up resistor and ground wire on pin 2 and put pin 10 on other side of resistor) = 0.5mm2 wire
Fuel pump relay activation: Euro pin 4 to X60004 pin 10 or USA pin 1 to X6021 pin 1 = 0.5 mm2 wire
Fuel pump relay trigger power: pin 8 to X6021 pin 2 = 1.5 mm2 wire
Fuel pump relay power: pin 6 to B+ junction = 2.5 mm2 wire
USA fuel pump relay ground: pin 7 (omit for Euro)
Power adapter cable: X64101/X64102 pin 1 to B+ junction = 6.0 mm2 red wire
All connections that are B+ junction or ground are a ring terminal. Starter terminal 30h is also a ring terminal (use 10mm hole size for that one).
Harness construction:
Start by cutting the 6.0 mm2 power adapter cable to 32”. Cut a 1” piece of red 6mm heat shrink tubing and put it over the wire. Strip 1/4” of insulation off the end and crimp a standard power timer on the X64101/X64102 connector side, but don’t crimp the insulation tabs yet. Turn on your soldering station and set it to 350 degrees C for lead-free solder or 300 degrees C for leaded solder. Now add a little solder to the crimp joint you made, just enough to cover the bare wire in the joint. This will help prevent it from coming loose and seals it from moisture. Now wait for it to cool and then lightly crimp the insulation tabs. Then insert the pin into pin 1 on the little connector that goes into the X64101/X64102 connector. Strip 1/2” of insulation off the end and crimp a ring terminal on it. Solder and then position the piece of red 6mm heat shrink tubing over the crimped area and use the heat gun to shrink it.
Start by cutting all the wires that go to the C101 connector to the correct lengths. Add 7” to the wire length for wires that go to X6011 or a fuse from the C101. So pins 1, 5, 9, and 6 are 60” and pins 18, 7, and 20 (90+) are 67”. Pin 15 is 37” and pin 13 is 18”. Pin 15 wire goes in it’s own sleeve. Pin 4 is 70” (or whatever you measured) and goes in it’s own sleeve.
Then cut the 12mm braided sleeving they will go in. Cut it to 54” and cauterize the ends with the cigarette lighter. Then if you are installing the fuel pump relay in the M3 cover then cut 10” off the end. Cut 3 1” pieces of 12mm heat shrink tubing and put 1 pice on the 10” sleeve and 2 pieces on the 44” sleeve. Put the 10” sleeve through the rubber boot for the C101 connector.
Then put the 18” long wire for the fuel pump relay pin 2 through the sleeve. Strip 1/4” of insulation off the end and crimp a standard power timer on the fuel pump relay side, but don’t crimp the insulation tabs yet (solder, wait to cool, crimp insulation as before). Then insert the pin into pin 2 on the fuel pump relay base. Do the same thing on the other side of the wire, but this time use a male C101 (2.5 mm system) pin and then insert it into the C101 housing in pin 13.
Now cut a piece of 4 mm sleeving to 67” (or 3” less than the wire size you want for the coolant temp sensor wire) and cauterize the ends with the cigarette lighter.. Put the coolant temp sensor wire through it. Then put it through the rubber boot for the C101 connector. Crimp a male C101 pin on the C101 side (solder, wait to cool, crimp insulation) and insert into pin 4 on the C101. Then put the other end through the rubber boot for the coolant temp sensor connector. Then strip 1/4” of insulation off the end and put a wire seal on the end to match up with the end of the insulation so that 1/4” bare wire sticks out. Now crimp an SLK 2.8 ELA pin onto it (solder, wait to cool, crimp insulation) and insert into pin 1. Put a sealing grommet into pin 2. Then put the rubber boot over the end.
Just like for the coolant temp sensor do the same thing for the pin 15 starter terminal 30h wire, but make the sleeving only 2” shorter, so 35” for the 37” wire, and cauterize the ends with the cigarette lighter. Cut 1 piece of 6mm heat shrink tubing and put it over the sleeving and the wire. Put the 10mm hole ring terminal on the starter end. Strip 1/2” of insulation off the wire, crimp, and solder it. Then position the heat shrink tubing over the crimped part of the ring terminal and the end of the sleeving. Use the heat gun to shrink the heat shrink tubing. Be careful not to heat the braided sleeving or it will melt and come apart.
Bunch up all the wires that go in the main 44” sleeve. Tape the ends together. Now slide them in. Then slide them through the 10 sleeve that the fuel pump relay wire is in that goes through the C101 rubber boot. Once you worked them through with about 2” of wire sticking out take the tape off the end. Now crimp C101 pins on them (solder, wait to cool, crimp insulation).
Now strip 1/8” of insulation off the end of the X60004 wires and crimp MQS pins onto them. Do not solder the little MQS pins. They are too small and solder could get stuck inside the pin holes. Just crimp them good. Also make sure the ends of the wire do not stick past the crimp area at all. There’s a ridge in the X60004 connector housing that will push them together and cause problems!
Now double up the terminal 50, C101 pin 18, wire with small section of 0.5 mm2 wire (about 12”) and crimp an ELO-Power 2,8 pin onto both wires (solder, wait to cool, crimp insulation). Insert it into X6011 pin 1. Wire the 0.5 mm2 wire to a fuse holder and cut another piece of 0.5 mm2 wire from the fuse holder to the X60004 pin 6 (just run the wire length down to measure it and cut it). Then crimp an MQS pin for pin 6 and stick it in. Install a 5 amp fuse in the fuse holder.
Now wire the wire from C101 pin 7 to a fuse holder and other end of the fuse holder to X6011 pin 2 (solder, wait to cool, crimp insulation).
Now trace the distance with a piece of wire from the position of X6011 and the fuse holders to the fuel pump relay and cut a 1.5 mm2 wire (and 0.5 mm2 wire for USA relay). For Euro relay trace the distance for the 0.5 mm2 wire from the X60004 to the fuel pump relay. Feed both wires through the main 44” sleeve to the fuel pump relay and wire both ends. The 1.5 mm2 wire goes to pin 8 on the fuel pump relay to X6021 pin 2 (and the 0.75 mm2 wire from pin 20 if the E30 is 90+ also goes to X6021 pin 2 doubled up like X6011 pin 1). For USA relay the 0.5 mm2 wire goes to X6021 pin 1 and pin 1 on the relay base. For Euro relay the 0.5 mm2 wire goes to X60004 pin 10 and pin 4 on the relay base. Wire pin 6 on the relay with a standard power terminal to the B+ junction with a ring terminal and a 1” piece of red 6 mm heat shrink tubing.
Now get your multimeter and set it to the audible continuity settings. Use it to tell which wires are which that go to the C101, X60004, X6011, and X6021 connectors. Insert them into the correct pin positions.
Now wire the sport mode switch. One 0.5 mm2 wire goes from X60004 pin 15 to the switch and the other 0.5 mm2 wire goes to ground. Feed both wires through some 4 mm sleeving. Use the 4.8mm x 0.8 pins for the switch. Solder those like the ring terminals, but put a 1/2” piece of 3 mm heat shrink tubing over each one. Put 2 pieces of 1” 6mm black heat shrink tubing over the ends of the sleeving and shrink them with the heat gun.
Now wire the OBD2 port. Pins 4 and 5 are ground. If you are installing the OBD2 port at the driver’s kick panel area then cut 2 pieces of 0.5 mm2 wire to 36” and wire those with Micro Timer II pins to the OBD2 port, through a piece of 4mm sleeving with 6 mm black heat shrink tubing, and to a ring terminal. Cut the wires for pins 7 and 16, both 0.5 mm2. Pin 7 goes the X60004 pin 32 with an MQS pin. Pin 16 goes to a 5 amp fuse in a fuse holder and then to the B+ junction. Cut the pin 7 wire to 100” and the pin 16 wire to 107”. You can wire the pin 16 wire directly to the B+ junction with its own ring terminal or you can crimp a standard power timer to the wire on the other side of the fuse holder and insert it into pin 2 on the X64101/X64102 connector with the 6 mm2 power adapter cable.
Now wire the throttle pedal. Cut a piece of 6 mm sleeving to 76” and then cut 6 pieces of 0.35 mm2 wire to 82” each. Tape the ends together and feed them through. Now take the tape off. Then strip 1/8” of insulation off the ends of wires on both sides. Put wire seals on one side, but not the other. Crimp sealing MQS pins on the wire seal side and regular non-sealing ones on the other side. Now get your multimeter again to tell the wires apart. Put one side through your toes until your ready to put it into the connector. Pin 1 on the throttle pedal connector goes to pin 7 on the X60004. Pin 4 goes to X60004 pin 8. Pin 5 goes to X60004 pin 9. Pin 2 goes to X60004 pin 12. Pin 6 goes to X60004 pin 13. Pin 3 goes to X60004 pin 14. Note: This is for the E46 pedal. If you have the Z3M potentiometer unit the wiring is different. In that case look at the 2001 Z3M ETM. That connector uses C101 pins (2.5 mm system) instead of MQS pins.
Now put the two X60004 connector inserts into the main housing and tape the wires behind it to look neat. You can label the connectors if you are giving the harness to someone else to install or if you think you’ll forget what they are later.
You’re done! You did it! Congratulations!
Examples of the adapter harnesses I used to make:
S54 for E30 (this updated version puts fuel pump relay in stock location under M3 harness cover):
S62 for E30 M3:
S54 for OBD2 E36 with wires to connect to Z3M instrument cluster (this updated version puts fuel pump relay mounted in stock location on side of fuse box):
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