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Fri Jun 07, 2013 6:01 pm

So if there is something that I wont need/use should I remove it from the harness? I just don't want to have a code pop up in diagnostics for something not connected or "failed".

I think I will mostly focus on the radiator this weekend but I will try to figure out the best way to get the main harness into the Beetle.
Ill have to play with the harness a bit because I want to have the OBD II up front with the dash (to use my HUD unit.)

Sat Jun 08, 2013 7:36 am

Just wait til you pull it. There are 50 to 60 plugs or more and you only use 14 or less.

There will be a whole lot that is cut and removed, actually more is removed than what stays. It is integrated with all the dash wiring.

Your only at the tip of the iceberg right now. Wait till it is laying on the floor in front of you. If you don't love wiring, that is a stopping point for a lot of people.

I don't think it would be possible to just wing it, it is hard enough when you buy the instructions.

Not trying to scare you off but you need to know what you are in for.

With Bug conversions Joel is probably one of the most knowledgeable and by far the most helpful one out there. Take any advise you can get from him, it will make your life a lot easier.

I saw another post about coolant lines and the use of copper. I would think you wouldn't really want to enter another type of metal into the system if you don't have to.

I'm anxious to see your progress, my Bug project got put on the back burner til I get some other projects done.

PLEASE!!!! Lots of pics and posts!!!!!

Jeff

Sat Jun 08, 2013 8:29 am

Ill take pictures today but I have about everything needed for the wiring already out. The whole dash/engine wires/consoles/AC box/heater box/fan/etc. Pretty much the whole front end was stripped and now it just needs sorted lol

I don't mind doing the wiring as it isn't hard for me. I just don't want to mess with something till I know exactly what is what. I thought about having it done for me but then I figured it would be better to do it myself for better understanding of what is going on in my car and what to fix (if needed.)

Sat Jun 08, 2013 10:12 am

well here you go :)

Sat Jun 08, 2013 10:45 am

I don't know if the wiring harness is the same as yours... If it is this will probably help. I was gonna use this when I did mine. The guy makes it look simple. http://www.shoptalkforums.com/viewtopic.php?f=19&t=136053

Sat Jun 08, 2013 12:10 pm

I'm not sure either but I'm sure it is close enough to get a basic understanding. Thanks :)

here's more :shock:

What do you guys think about the tank in the bay? :)

driver side rear fender

Passenger side rear fender. Damn foam rusting out my beetle :'(
I'm removing it and making drains for the water.

Old speedometer with 63,742 miles (102582.81km for you Euro folks. I prefer metrics lol.)
The VW engine only had 35,000 with a brand new carb :)

The only problem so far is the plugs. I can remove the wires but I wont be able to get to the plugs :/

More to come :lol:

Sat Jun 08, 2013 3:34 pm

There's a lot to look at but I want to get you guys involved in this as well so you can see what I am doing :)

The last time this trunk will be original lol

Made in Germany :)

Sat Jun 08, 2013 6:24 pm

jrobewesty wrote: With Bug conversions Joel is probably one of the most knowledgeable and by far the most helpful one out there. Take any advise you can get from him, it will make your life a lot easier.

Thanks for the kind words Jeff, it was actually a lot of yours and Chesters posts that helped me out with my conversion all those years ago.

Brett, I had all these plans of using the Subi dash cluster and climate control in mine too, however there just isn't enough room with the Super Beetle dash to neatly intergrate it while looking tidy and not taking up too much room

I still havent hooked my heater up but I reckon the best way to do it is mount the heater core under the backseat and duct it into the stock Beetle heater channels so the heat still works like stock on the windscreen or footwell outlets.

Sat Jun 08, 2013 8:56 pm

Yeah I'm just holding on to everything that I like for the moment lol
I cut the excess electrical tape off the interior loom and some unnecessary components like hazards and cruise control switch. NO HAZARDS!?!? :shock:

I placed the majority of the loom under the driver side rear seat so the wires to the engine have a direct route through the now useless heater hose (they were looking pretty pathetic just dangling under the car.)
The ECU is close by and the main wiring with the fuse box is about where the driver seat would be. It's the rough test to see what is needed as far as wire length.

I just want the heat for the windshield defrost is all. Otherwise a coat and some gloves are all I need lol
Honestly I like the colder air anyways. Even in winter when its freezing :)

Here's a fun little side topic. I removed the speaker in the lower left of the dash in my beetle and found what might be a vintage speaker lol
It's a Boman Astrosonix. Probably about a 4 inch speaker in pretty good condition lol. Puts out a powerful 8 watts :lol:
I'll post a picture tomorrow along with others of whatever I happen to do :)

Sun Jun 09, 2013 5:58 am

The stock wire lengths on the OBD2 harnesses are at a pretty good length.

The O2 wires will be long but you can fold then back against themselves.

For the OBD2 connector I use to extended the wire to reach the dash, now I just buy a extension cable off ebay.

For fuses you need main battery power and key on and one for the radiator fan.

When you are done removing what is not needed it will look like this.
There is probably 30lbs of wire removed.

Sun Jun 09, 2013 9:11 am

wow, there's nothing left :lol:

If there is a plug I am using but a wire that I am not, would the best choice be to remove the end from inside the plug or cut it far enough inside that it cant short on anything? I just cut them for now since some aren't exactly easy to pop out by hand. I have to barrow a tool to pop them out nicely.

I'm going to work on the second loom today. The engine loom with the fuse box and all the other goodies lol

That tape is such a pain. The adhesive is so runny and messy -_-
might as well have dunked my hands in some honey.... :lol:

More pictures coming so hold on and expect a barrage :)

Sun Jun 09, 2013 2:15 pm

I would leave 3" or so just in case you end up needing it.

Much cleaner to ditch the whole fuse box. 99% of it you don't need.

The only wiring you really need off that part of the harness is the ALT and wires and plug and wire for the A/C.

Jeff

Sun Jun 09, 2013 7:55 pm

Yeah I basically just stripped it today and cut off the main things I don't need. I didn't have enough time to go through the whole fuse box to toss what isn't needed but that is next for the loom. I'll be working on that tomorrow after work :)

This is what I got done today. I have been keeping all the plastic tubing and the vinyl wrap as well just to clean up the harness after I get it all settled in :)

Here is that speaker that was attached to the dash for probably 40 years XD

Sat Jun 15, 2013 5:48 pm

Hey Brett, I forgot I had a vid on a EJ25 harness I did.

This might help ya,

Sun Jun 16, 2013 3:18 pm

so I got a little left on the harness to get rid of but I wanted to see if anything here was worth saving.

I see the few things that you talked about in your video. I just have a few boxes that don't have specific labels.

These go to the trans and I want to make sure they don't go to the speed sensors. Ill have to get those later as I don't have them yet.

The madness doesn't end -_-

I was thinking of running the wires through either of these (preferably the lower) to keep the wires from being exposed. Just a possible idea but I'm not sure.

Mon Jun 17, 2013 8:53 pm

Ditch the trans plugs, you will need an aftermarket speed sensor and then just find the speed sensor wire coming off the ecm.

Ditch the Subaru fuse box also.

All you need is what's on the vid.

Keep at it.

Jeff

Mon Jun 17, 2013 9:39 pm

Alright, thanks for the video. Really helped me with a better glimpse :)
I wasn't sure what those other boxes were such as the metal ECU look-a-like or the pther plastic boxes. Ill need to look around to find both the speed sensor and wires. Would there be a diagram explaining what each input is on the ECU? I wasn't sure aboit that spare wire in your video as the colors are different.

Tue Jun 18, 2013 5:07 am

Factory service manual for wiring diagrams.

The colors might be different because I extended the wires and made them the same color as the aftermarket speed sensor so the guy installing would have an easier time.

Jeff

Wed Jun 19, 2013 5:06 pm

Any recommendations for a speed sensor? does it have to be specifically for a Subaru?

Wed Jun 19, 2013 6:11 pm

For just a few dollars you can buy the entire factory service manuals including the wiring diagrams for your year model suby online. They will send it to you as an email link or a cd, worked well for me when I was trimming my wiring down.. I got mine from someone called [email protected]