2001 T5 exhaust VVT solenoid wiring diameter?

[hiroku]

Good evening everyone, I hope you are all well.

I'm currently replacing the connector for the VVT solenoid on my 2001 T5 (exhaust-only).

Because this part of the wiring was already repaired before and I don't really trust any previous work on this car, I was looking to cut it off upstream of the old repair and splice a new section of wiring into the OEM harness.

I measured the diameter of the original wires so I could use the same in the repair. Both wires come out around 1.9mm in diameter.

I ordered a new connector off MaxxECU, but the terminals and seals are clearly way too small for a wire of this diameter. I cannot bend the wings properly around the copper, the seals will stretch too much and tear, and the terminals won't click into place inside the connector housing.

Testing with some spare automotive wiring, they look a lot more like they want to accept a wire that's around 1.5mm or even 1.2mm in diameter.

Anyone know what gauge this wiring is supposed to be? The wiring on the car now does look OEM and the colors are correct as far as I can tell (red/yellow and green/gray).
Have I got the wrong connector?
Am I supposed to splice in wires with a smaller cross section?

Any advice is appreciated.

Thanks!

[dikidera]

Technically if we measure the solenoid's resistance and multiply by voltage, we yield something to the tune of 38-40 amps. But the signal is PWM, so perhaps the actual amp is lower than that. Just make it thick and I dont think you will notice any issues.