Engine Bay Connector Bracket

thingiverse

I designed this bracket for my Audi A4 (B6). A similar bracket is used on vehicles with factory Bixenon headlights. It moves the fan module connector up out of the way because the headlight housings are thicker. The bracket for cars with halogen and single xenon headlights holds the connectors lower and will interfere with the headlights if you retrofit the Bixenon housings. You can see in the images how close the back of the new headlights are. Many parts websites show the correct bracket (PN: 8E0971845AB) as being available, but I tried ordering from two different sites and they said it was either unavailable or would have to be special ordered from Germany. Instead of waiting, I decided to use my original bracket (PN: 4B0971845S) for initial measurements to design from and also using reference photos online, I was able to design my own version. Some pictures show V1 of my design which printed the clips and bracket together, I found they would snap off easily. My version is comprised of multiple pieces since the layer orientation of a single piece would make the clips very weak. Printing the clips separately gives them better strength. To assemble your own bracket you will need: 2 Stronger Clips 1 of each Connector Clip 1 Connector Bracket 4 M3 Heat Set Inserts 1 M5 Heat Set Insert 4 M3x8mm Button Head Screws 1 M5x16mm Button Head Screw 2 M2.5x8mm Screws (I used ones designed for threading into plastic, McMaster-Carr PN: 96817A894) Print the bracket with supports for the slots that the clips go into. Print all the clips on their sides. Install the heat set inserts. Fasten the clips to the bracket as shown in the pictures. I would recommend using ABS at least. PLA will not hold up to engine bay temperatures for long. I chose to print mine with NylonX from Matterhackers for durability.