AC Compressor Clutch Connector

[StickMon]

I was poking around under the hood today and noticed a couple of problems with the wire to my A/C compressor clutch.
1) It comes from the harness under the Vanos solenoid and runs too close to the exhaust. The plastic corrugated cover shrunk up like a shrinky-dink and cracked up where it passed closest to the #1 exhaust. Unplugged it from the tubular connector on the compressor body, put new tubing over it, and routed it around the front side of the Vanos accumulator line and AC lines, away from the exhaust.
2) The wire from the other end of the tubular connector twists around, goes through what might be another in-line connection, and then to a white plastic connector on the compressor clutch. The insulation has cracked off the first 1/2" of it, and the bare wire just missed shorting to the compressor bracket.

Others might want to inspect theirs.

Bought the replacement cable #2 below.
Does anybody know how that rectangular connector attaches to the clutch?
Hopefully it doesn't require removing the compressor.

[StickMon]

Talking to myself again. Nothing new.

This all started when I noticed the plastic corrugated cover on the wire to the AC compressor had shrinky-dinked. I dressed it into a better location and put some 3/8" over it, because it was the smallest I.D. I had.

Went to PepBoys to get some 1/4" I.D. but no joy. The smallest they have is 3/8".

Got the manufacturer off their website and checked with them. Smallest they make is 3/8". Even RealOEM, under "Harness Fixin's" doesn't have the OEM tubing.

After lots of Googling found some small I.D. tubing. High temp nylon.
The bad news is it only comes in 100' boxes. That's 2 lifetimes worth.
The good news is that it's $12 a box !!

[StickMon]

So here's what you get for part #2 (64526912400) above.
Luckily, that's the part where the insulation smoked off.
The ribbed bit is indeed an inline connector.
The rectangular connector is apparently an integral part of the A/C compressor clutch. The wire on that is OK. Must be higher temp rated wire.
I'm going to pull off the smaller connector on the right and slip some high temp Teflon tubing over the wire.
Can't replace the wire. The larger connector on the left is molded on.

[StickMon]

[Finnegan]

Great information and detail as always.

[maupineda]

I am having this issue, and cannot manage to disconnect the jumper, to avoid screwing the compressor side I am going to retap the jumper and add 1/4 convolute to protect it further.

I wish I could disconnect it to replace it with a fresh jumper.

******* Update *******

So I have completed the overhaul of my AC Compressor jumper, I tried to take enough photos to document what did, which was not much and is easy, but requires patience and small hands

First, please note the condition of the jumper wire, with the rubber protector completely worn out in three sections, basically in middle, and at both ends.



The next photo shows the jumper wire wrapped with electrical tape, I tried to wrap it as tight as I could but is difficult due to the location



After the tape was applied, I used 1/4 convolute wiring cover for additional protection





Finally, I routed it in a way that allowed the wire to bend long and smooth