This image below shows the BDM with the connector correctly installed. Note position of red striped wire and index arrow on connector. It also shows the wire numbering. The red striped wire is pin 1.
The BDM comes with an ~7 inch ribbon cable with connectors so if you purchased a Cable16/32 your already half the way there and can skip ahead to installing the pins on the other end. If you need to make your own cable from scratch buy or scroung 9" of 10 conductor flat ribbon cable and a 10 pin IDC (Insulation Displacement Connector) female connector . (DigiKey# HSR10H-ND)
Insert the cable into the connector so the end is flush with one side of the connector. Notice the relation of the index groove on the connector and the red stripe on the ribbon cable.
Use a pair of channel locks or a vise and carefully squeeze the connector together. The little teeth inside will "displace the insulation" and make contact with the wire.
It should look like this when your done.
Now to add a strain relief that prevents the cable from seperating when pulling on the wire bend the cable over the top and snap on the strain relief.
Flip the connector over and use a permenant marker to mark pin 1 index on the connector.
The cable properly connected to the CABLE 16/32 BDM Interface looks as follows...
Crimping on the pins:
Because the ECU is a single row header you will need to use the kind of connector that uses crimp on pins. First seperate the individual ribbon cable wires from each other back about an inch. Then cut off wires 1,2, and 5 (Red stripe is 1). After that carefully strip off about an 1/8 inch of insulation off the end of each wire. It should look something like this.
The crimp on pins have two sesctions to crimp. The larger section at the rear goes around the insulation and the smaller inside section crimps down on the wire.
Place the pin in the special crimp tool you bought at Radio Shack. You can use a pair of needle nose pliers if your desperate. Make sure to place the pin with the large end in the correct half of the tool.
Insert the wire into the crimp. Make sure the insulation stays in the rear half and the wire makes it into the other half. SQUEEZE
A correctly crimped pin should look something like this. Crimp the other 6
Once they are all crimped insert them into the correct slot on the connector. As shown below pin 1 of the connector is at the far right. The crimp show is being inserted into position 6.
What it should look like when your done. Pin 1 of the connector is at the top of the photo. Don't be confused by the red stripe. While the redstripe does mark the postion 1 on the ribbon cable coming from the BDM is doesn't indicate which side of this connector is pin 1.
Properly installed in the matching ECU connector. Pin 1 is to the left
While all the parts you need to manufacture this cable are readily available you may find buying them in small quantities difficult. Most online suppliers will require a minimum order of $25.00
Here are the parts we use from Digikey.
Part NumDescriptionQtyunit costNote
1 - 609-2415-ND - CONN HEADER 8 POS SGL PCB GOLD - $ 1.42
1 - 609-2400-ND - CONN HOUSING 8 POS .1 SINGLE - $ 1.41
10 - 609-2306-ND - CONN SOCKET 28-32AWG GOLD CRIMP - $0.165 (Only 7 reguired. Extras just in case you mess up)
1 - HSR10H-ND - CONN SOCKET IDC 10 POS W/STR GOLD - $ .705
1 - MC10G-5-ND CABLE 10 COND 5FT FLAT, GRAY - $ 1.63 (5 feet is the smallest length they sell it. You'll only need 9 inches)
BTW I do sell these cables for $20US. Email me if your interested.