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Aircooler Engine Harness Rebuild
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82WestyMan
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PostPosted: Wed Jan 14, 2009 6:07 pm    Post subject: Aircooler Engine Harness Rebuild Reply with quote

Last time I was in the salvage yard, I ran across a Engine Harness that looked in better shape than the one I currently am running
When checked it out, it turned out the #1 injector wasn't firing and some of the other AMP connectors had some pretty sorry connectors in them.
Since I already had a working Engine Harness, I thought I'd take a stab at rebuilding with 4 new connectors at the injectors and using the best of those to replace a couple of the ones at the Thermo Time Switch / Cold Start Valve / Aux Air Regulator.
Along the way I did put 'zip-ties' to 'clean-up' the wiring inside the cover

Once I cut away all the brittle and old cover, this is what I had to work with
Image may have been reduced in size. Click image to view fullscreen.


As you can see, some of the AMP connectors were "less than stellar"
Image may have been reduced in size. Click image to view fullscreen.


After some research, the best bet for true replacements looked like this option, since it came with your choice of boot type / lengths
http://store.yahoo.com/eagleday/electrical.html

This is what the replacements I ordered looked like unassembled
(I supplied the 18 gauge wire and shrink-wrap
Image may have been reduced in size. Click image to view fullscreen.


I decided to solder all the connections
Image may have been reduced in size. Click image to view fullscreen.
Image may have been reduced in size. Click image to view fullscreen.


Actually assembling the connectors was pretty easy
Image may have been reduced in size. Click image to view fullscreen.
Image may have been reduced in size. Click image to view fullscreen.


I decided to added a little more length to each injector wire (about 1.5 in)

Cyl's 1 & 2
Image may have been reduced in size. Click image to view fullscreen.


Cyl's 3 & 4
Image may have been reduced in size. Click image to view fullscreen.


This is what it looked like finished, waiting on some wire loom to cover it
I did bring the coil wire thru the harness to clean up my engine compartment, used some of the better 'replaced' connectors to replace and added some length to Therm/Cold-Start/Aux-Air connecters
Image may have been reduced in size. Click image to view fullscreen.


I still have to run thru all the connections with my multimeter but I'm hoping it will put to rest any possible problems in the harness in the future and clean up my engine compartment all in one fell swoop

I'll let you know how it works when I get the wire loom on it and installed
_________________
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82 Westfalia - w/ a Raby 'Camper Special' engine
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Vanagon Nut
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PostPosted: Wed Jan 14, 2009 8:11 pm    Post subject: Reply with quote

Lookin' good.

I wish I had taken more pics of my Vanagon/Jetta harness during my conversion. I wanted to make more notes too of little details I learned about. (the hard way in some cases! Rolling Eyes Smile )

The devil is in the detail for sure. These wires: (hard to see, but 3 casings were cracked)

Image may have been reduced in size. Click image to view fullscreen.


were twisted together (factory) and were likely shorting out. (of course they went to the CMP connector on the dizzy!) Engine heat does some crazy stuff to harnesses I'm learning.

Image may have been reduced in size. Click image to view fullscreen.


FWIW, to prevent this (partially removed cuz i missed a ground)

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.



if possible/safe, hook up and run the engine before looming the harness. I recall having to unwrap my work to get at that dang missed ground. Yeesh!

You will be totally happy with a nice clean engine bay and refurbed harness!

Neil.
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deprivation
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PostPosted: Thu Jan 15, 2009 6:02 pm    Post subject: Reply with quote

Way to go! I have a used harness that I have been re-doing ever-so-slowly for about a year now. Your post gave me a little kick in the pants to get moving on that again.
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82WestyMan
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PostPosted: Thu Jan 22, 2009 2:09 pm    Post subject: Reply with quote

Though I'd a few final thoughts & pictures
After I got all the new connectors and all done, I did a final fit and test on the engine.
It worked great but a few of my connectors were not quite the right length
So after marking and correcting those, I wrapped the whole thing up in black wire loom
I used 1/4", 1/2" and 3/4". I started by installing the smallest size first and worked my way back up to the main bundle that used the 3/4".
I had a 5 ft piece of 3/4" and it fit perfectly from the ECM connectior to the double relay plugs

Here's what it looked like before being installed
Image may have been reduced in size. Click image to view fullscreen.


And here's what it looks like in the engine compartment
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Overall, the project wasn't that hard
My only recommendation to anyone else is to start with a fairly good used harness (I had 2) so you're not working on your 'known good' one
The only parts I really go new were the 4 injector connectors and the wire loom (if you discount some 18 gauge white wire, shrink-tubing and solder)
Sure beats laying out $350 and I got exactly what I had in mind and with the exact fit
_________________
"The floggings will continue until morale improves"
"I never did give anybody hell. I just told the truth and they thought it was hell" - Harry S. Truman
82 Westfalia - w/ a Raby 'Camper Special' engine
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ftp2leta
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PostPosted: Thu Jan 22, 2009 3:41 pm    Post subject: Reply with quote

82WestyMan wrote:
Though I'd a few final thoughts & pictures
After I got all the new connectors and all done, I did a final fit and test on the engine.
It worked great but a few of my connectors were not quite the right length
So after marking and correcting those, I wrapped the whole thing up in black wire loom
I used 1/4", 1/2" and 3/4". I started by installing the smallest size first and worked my way back up to the main bundle that used the 3/4".
I had a 5 ft piece of 3/4" and it fit perfectly from the ECM connectior to the double relay plugs

Here's what it looked like before being installed

Image may have been reduced in size. Click image to view fullscreen.


Overall, the project wasn't that hard
My only recommendation to anyone else is to start with a fairly good used harness (I had 2) so you're not working on your 'known good' one
The only parts I really go new were the 4 injector connectors and the wire loom (if you discount some 18 gauge white wire, shrink-tubing and solder)
Sure beats laying out $350 and I got exactly what I had in mind and with the exact fit


Beautiful job men, BEAUTIFUL!!!

Ben
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airkooledchris
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PostPosted: Thu Jan 22, 2009 3:50 pm    Post subject: Reply with quote

that is the best looking AC Vanagon motor compartment ive ever seen.

nice work, again.
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82WestyMan
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PostPosted: Thu Jan 22, 2009 4:48 pm    Post subject: Reply with quote

thanx for the compliments
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"The floggings will continue until morale improves"
"I never did give anybody hell. I just told the truth and they thought it was hell" - Harry S. Truman
82 Westfalia - w/ a Raby 'Camper Special' engine
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tencentlife
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PostPosted: Thu Jan 22, 2009 7:54 pm    Post subject: Reply with quote

Very nice! Makes me want to get out my spare harness and do it up.

Yeah, sure, someday....
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daroota
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PostPosted: Tue Apr 12, 2016 11:42 am    Post subject: Re: Aircooler Engine Harness Rebuild Reply with quote

Thanks for this!!

I'm working on making a harness for myself. 82 Air cooled Federal.

I've found a computer pigtail off a old 84 Golf (it will have to be repinned of course)

Digikey parts list:
USD http://www.digikey.com/short/38vvz3

CAD http://www.digikey.ca/short/38vtc8

I've ordered some SXL grade wire, heat shrink wrap so far. I'm still waiting to order the rest from digikey because I'm trying to source a few more parts. Hopefully with some help, and from Digikey, I can find the rest.


German supply seems to have the connectors for the Double relay, but is there a equal from Digikey that anyone knows? (I'll need 2)
http://www.germansupply.com/home/customer/product.php?productid=17593

Looking for the boot for the AFM connector.

And looking for information for the Coldstart injector connector (I don't think it's the same as the regular injectors) and I don't have my van with me at the moment (it's getting touched up at the paint shop)

Anyone point me to the correct digikey parts?

BTW, new ECU pigtail is: http://www.digikey.ca/product-search/en?keywords=963318-2
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gatorjos
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PostPosted: Tue Aug 21, 2018 5:38 pm    Post subject: Re: Aircooler Engine Harness Rebuild Reply with quote

daroota wrote:


Looking for the boot for the AFM connector.


This one:
http://eagleday.stores.yahoo.net/bofor7feampj.html

I'm not positive the vanagon AFM is 7 position Junior Timer connector, but here's the boot. I'm guessing the OP already found by now, but just capturing since I'm cruising various threads
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daroota
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PostPosted: Tue Aug 21, 2018 6:13 pm    Post subject: Re: Aircooler Engine Harness Rebuild Reply with quote

Thats where i bought my 7pin boot and plug.
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