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Thread: Wiring harness refurbishing

  1. #1
    Van Fan
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    Wiring harness refurbishing

    Hey whats up,

    I decided to make a post on DIY refurbishing your wire Harness because we know that electronical is a big issue for us and there is no post on this subject.
    (If one there on the forum, show me)

    I plan to refurbishing my wiring harness on my van since the engine is rebuild. Do anybody can help me on how to do that on can show me a post already did on it (excepting the one of tim about the new harness for easy acess to the injector)

    This is the tool that I found on internet that I think I will need to do the job.

    - Wire striper :
    https://www.amazon.ca/Irwin-Industrial-207830…/…/ref=sr_1_1…

    - Shrink tubing:
    https://www.amazon.ca/SummitLink%C2%AE-Assort…/…/ref=sr_1_4…

    - Solder gun
    https://www.amazon.ca/Portasol-010589330-Supe…/…/ref=sr_1_1…

    - Helping hand
    https://www.amazon.ca/Neiko-Hiltex-0190…/…/ref=sr_1_fkmr0_1…

    -Dielectric lubricant
    https://www.amazon.ca/3M-08946-Clear-Silicone…/…/ref=sr_1_1…

    - Rosin paste
    https://www.amazon.com/…/product/B008ZIV85A/ref=as_li_ss_tl…

    - Electrical tape ( if you have better quality one, show us)
    https://www.amazon.com/…/product/B016ZMXLEI/ref=as_li_ss_tl…
    - 60/40 rosin core solder
    https://www.amazon.com/…/product/B016ZMXLEI/ref=as_li_ss_tl…
    - Wiring diagram book 1989 toyota van


    Im looking for a High quality loom and shrink. Can anybody refer me to good one?
    Do I miss someting about tools and stuff/parts to do the job?
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  2. 03-14-2018, 03:59 AM

  3. #2
    Van Obsessed
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    Re: Wiring harness refurbishing

    That is a daunting task, I don't envy you, you may find its better to just target the most problematic circuits

    I found that the wiring available today is no where near the quality of what went into the vans.
    The van wiring is very fine copper threads, replacement is much thicker like on the order of 10-1, makes soldering connections loads of fun.
    And because the strands are thicker, the wire isn't as flexible as OE, makes all those tight corners extremely difficult.
    Choice of colour codes is poor too, I made do with what was available but wish I had made notes on what I put where, future diagnosis will not be possible by following wire colour.

    Personally, I would only chase the heavy power wires - Battery to FL 125 to pos post, and of course the alternator harness.
    I was gonna skip that alt harness as it all "looked" good but cutting back insulation showed otherwise.
    That portion can be separated out from the rest of the harness with reasonable ease. (I opted to keep it separate)
    90% of my issues were in that portion of the harness and factory splices made up most of the rest.
    I did replace a bunch of secondary wiring but that was just my OCD taking over.

    What I found during interrogation, wiring that looked off-colour (brownish tinge) or was uncommonly stiff was a sure sign of failure within the wire, when you cut the insulation open at that point, you'll find that the copper isn't shiny and bright.

  4. #3
    Van Fan
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    Re: Wiring harness refurbishing

    I would also really appreciate some expert advice, I could see what I did wrong.

    When soldering to the existing wiring harness wire, I found that it helped to use the Rosin Paste, lots of it. The rosin core was not enough to clean up the old wire. Heat up the old wire with the paste to clean it before starting to add the solder.
    .
    I bought a bunch of tools to remove the pins from the existing plugs. I needed to occasionally fix a wire, right at the spot where it entered a plug that I could not replace. With lots of hassle and fussing I managed to take some plugs apart, solder a new wire to the pin, replace. VSV's for example.

    The silicone coated wire is very flexible, I used it but don't think its necessary.

    I used Heat shield with shrink tube at the ends to protect the wire. Its a black fiber glass weave tubing that comes in lots of diameters and seems to work ok.

  5. #4
    Van Fan
    My Van(s):
    1989 toyota vanwagon 4x4 5 speeds manual. Engine blow. Try to replace the engine..
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    Re: Wiring harness refurbishing

    Can you link some tools that you used to do the job?

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