Ghibli II wiring harness

[dt95aac]

A question for all you wiring experts out there

My Ghibli, needs a new engine wiring harness, as the old one is full of cracked connectors and aged wires, which keep causing intermittent faults.

These are now out of production, so i'm considering making one on my own.

I already have the a full harness out of a car, mounted on a board with all the connections marked.

I have some experience of doing wiring, but never undertaken anything so major.

I have been able to source most of the connectors from various online sources.

My question are the following:

1. Based on people's experiences, what are the things I need to be careful of?
2. Which are the reputable vendors to source all the connectors, wires and shielding?
3. How do I determine the gauge and type of wires I need?
4. Any other tips and tricks?

 

[Wally]

you can find many connectors here: www.rdae.nl But... you need to have some knowledge of the type of connectors. (think you can send him pictures of what you are looking for) Also many connectors to be found on Ebay.

 

[Phil H]

A question for all you wiring experts out there
I already have the a full harness out of a car, mounted on a board with all the connections marked.

Do you mean that you already removed your harness, or do you have another for reference?

PH

 

[dickyb]

1). Remaking wiring looms is fairly simple as long as you have some basic knowledge and have the original to work from. Be methodical and check and re-check everything as you go. If you don't have one already I would recommend you buy a wire crimping tool, pliers don't really work very well when crimping connectors as they don't bend them in the correct way. A set of terminal extractor tools are also useful for removing the spade connectors from plastic terminals.

2). I've only used UK suppliers but can recommend www.autosparks.co.uk and www.autoelectricsupplies.co.uk. As Wally says, most electrical connectors are fairly universal and easily available from the previously mentioned suppliers, or via ebay.

3). This guide should help you to ascertain which wiring gauges you need, you can measure your existing wires with a micrometer and then order the same gauges that you need:

https://www.autoelectricsupplies.co.uk/product/66/category/11

4). Try to avoid soldering any joints, if you crimp everything correctly there should be no need for solder and you will achieve a much stronger mechanical and electrical connection. Make sure you have all the terminals in the correct parts of the plastic connector blocks, its easy to get them mixed up or in the wrong part of the block.

 

[Oneball]

Echoing what Dickyb crimping tools are worth their weight in gold, but pay a fair bit for a decent one some of the Chinese stuff is ****.

 

[dt95aac]

you can find many connectors here: www.rdae.nl But... you need to have some knowledge of the type of connectors. (think you can send him pictures of what you are looking for) Also many connectors to be found on Ebay.

Thanks, but it's a bit Dutch for me

 

[dt95aac]

Do you mean that you already removed your harness, or do you have another for reference?

PH

Already have a spare one mounted on a board ready to be copied.

 

[dt95aac]

1). Remaking wiring looms is fairly simple as long as you have some basic knowledge and have the original to work from. Be methodical and check and re-check everything as you go. If you don't have one already I would recommend you buy a wire crimping tool, pliers don't really work very well when crimping connectors as they don't bend them in the correct way. A set of terminal extractor tools are also useful for removing the spade connectors from plastic terminals.

2). I've only used UK suppliers but can recommend www.autosparks.co.uk and www.autoelectricsupplies.co.uk. As Wally says, most electrical connectors are fairly universal and easily available from the previously mentioned suppliers, or via ebay.

3). This guide should help you to ascertain which wiring gauges you need, you can measure your existing wires with a micrometer and then order the same gauges that you need:

https://www.autoelectricsupplies.co.uk/product/66/category/11

4). Try to avoid soldering any joints, if you crimp everything correctly there should be no need for solder and you will achieve a much stronger mechanical and electrical connection. Make sure you have all the terminals in the correct parts of the plastic connector blocks, its easy to get them mixed up or in the wrong part of the block.

Thank you for these, all good comments.

I knew I had to invest in a crimping tool, just wasn't sure it needed to be one of the expensive ones.

 

[Oneball]

Thank you for these, all good comments.

I knew I had to invest in a crimping tool, just wasn't sure it needed to be one of the expensive ones.

The machining of the jaws on the £10 ones don’t line up very well. I’d just buy a branded one for a bit more.

 

[Phil H]

Good advice there from Dickyb and Oneball. Decent wire strippers and crimp tools are half the battle, as you will only want to do the job once and it’s not worth the risk of using cheap tools.

The following are general comments for harness replacement and not Ghibli specific.

Before you remove the existing harness take a few pics of the routings, connector locations, and fixing points.

Check also for any bits of the harness which show evidence of heat exposure, chafing, water ingress, corrosion, or other damage so that you can add protection on the new harness if needs be.

Note the locations of earth points and ensure that they are clean prior to installation. Use new bolts/screws/washers for earthing.

NOTE: Before you make the new harness ensure that your pattern one is exactly the same as that currently fitted (connector sizes, plug/socket orientations and keys, colour codes, etc), as manufacturers do change specs during production.

It helps to match the existing colour codes, but if you can’t then make a record of which substitute colours you use in which position/service; it may not matter for now, but it might if trouble-shooting sometime on the future.

When making the new harness it’s better to have it a little too long than a little too short! (Don’t overdo it though.)

Do a light tug test on each pin when assembling the connectors, as a loose crimp during assembly can become a real pain once in the car. If you have to solder wires, clean off any flux residue.

Don’t forget to do an end-to-end con check on the new harness prior to installation, and take the opportunity to inspect the mating connectors on the car before connecting up.

WRT wire types and applications, there is a wealth of info and plenty of suppliers on the web, and you might also find the following pages helpful as they give typical applications for different wire gauges:

https://www.autoserviceprofessional.com/article/95608/electrical-wiring-basics

https://www.autoelectricalspares.co.uk/standard-pvc-single-core-111-c.asp

Harnessing shouldn’t be too difficult, and if you are methodical and have reasonable access on the car you should be fine, just don’t be tempted to cut corners as it can be a pita to resolve issues once the new harness is installed.

Good luck

PH

 

[dt95aac]

Thank you Phil H.

Any suggestions on a good crimping tool for Junior Power Timer terminals?

 

[Phil H]

Google throws up a number of sources, typically at around £40-50 which should get a decent ratchet version. Don't forget to check pin size and compatibility before buying.

PH

 

[safrane]

No doubt you will be aware of this but warm up the looms prior to fitting as it makes the wire nice and flexible.

 

[spacecadet]

If you are also doing the accessory loom, I've just rewrapped mine using Techflex heat resistant sleeving. There are distributors in Germany and in the Netherlands too.

 

[dt95aac]

Thanks, will look into it

 

[ZAM400209]

nice bit of work there, Spacecadet