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Engine fire and the wiring harness on a 72 Bug
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Rmvr53
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PostPosted: Sat Mar 29, 2025 7:43 am    Post subject: Engine fire and the wiring harness on a 72 Bug Reply with quote

Wasn't a bad fire but an engine fire none the less. Is there any way to just replace the rear/engine harness and not the whole thing? I an still working out "bugs" from a full harness replacement I had to do on my Wife's 68 5 years ago. I bought the car with the harness installed but it took me a month to finish it and the lights still don't work correctly. I REALLY don't want to do a full harness again just because of a engine fire

as a secondary question - is a "main" harness the engine to fuse block only? Worst case I'm going to have to buy that to cut/splice it in.


Last edited by Rmvr53 on Sat Mar 29, 2025 10:01 am; edited 2 times in total
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Cusser
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PostPosted: Sat Mar 29, 2025 8:11 am    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

Way back in 1974 I had to work on a VW with an engine fire. Yes, I unwrapped the harnesses and tapped into the good wires to get it running.

Is that VW still operational 51 years later? I don't know !
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baldessariclan
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PostPosted: Sat Mar 29, 2025 11:00 am    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

Rmvr53 wrote:
Is there any way to just replace the rear/engine harness and not the whole thing?

The only way I am aware of to accomplish something like that would be to cut and splice the individual wires in the engine compartment - there are no central splice/disconnect points for those wires that I am aware of (ref. factory wiring diagram here: https://www.thesamba.com/vw/archives/info/wiring/bug_6869.jpg ).

Those individual wires are bundled together with others for a lot of their length, and run through things like the “death foam” over the wheel well, under the carpeting along the edge of floor pan, etc. So not really any easy way to pull and install new ones along their entire length.
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cjsuner
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PostPosted: Sat Mar 29, 2025 11:26 am    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

I had a 74 catch fire 2 years ago,

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As you can see, it wasn't a awful fire, but it was enough to cook all of the wires.

Like you, I didn't want to do a full replacement, just for the few wires that are in the engine, so I cut it back until I had clean, not crispy wires, and spliced in new wires from there. Now, for me at the time, my buddy had a parts care, and I was able to take it's wiring loom out, and put wires into here, but I still ended up cutting and splicing the new wires on, instead of doing a full replacement harness.

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

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

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PostPosted: Sat Mar 29, 2025 1:27 pm    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

This would be an opportune time to install a terminal block with quick disconnect terminals something like this.

https://ceautoelectricsupply.com/product/terminal-...7Qvf3-aflk

A single location to disconnect all the engine wires when pulling the engine. Just be sure all the wires are tagged and/or colors match on both sides of the block.

Just a thought.
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Rmvr53
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PostPosted: Sat Mar 29, 2025 2:04 pm    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

Tom
close to what I was thinking. I was actually considering similar but using new "old style" clear 4 wire connectors so it kinda looked like it was supposed to be that way. '
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diamondblue1969
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PostPosted: Sat Mar 29, 2025 2:41 pm    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

They do make a repair harness

https://www.cip1.ca/c16-w-1001/
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Glenn Premium Member
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PostPosted: Sat Mar 29, 2025 2:58 pm    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

Let me guess, plastic fuel filter?

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PostPosted: Sat Mar 29, 2025 3:30 pm    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

Rmvr53 wrote:
I was actually considering similar but using new "old style" clear 4 wire connectors so it kinda looked like it was supposed to be that way.'


I don't think anyone sells a reproduction of the original 4 way connectors. These are in the Samba Classifieds and are probably as close as you'll get the original style. Cut to the number of attached connectors you want:

https://www.thesamba.com/vw/classifieds/detail.php?id=2696504
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cjsuner
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PostPosted: Sat Mar 29, 2025 7:34 pm    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

Glenn wrote:
Let me guess, plastic fuel filter?

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Lol NO.

Fuel line drip onto hot exhaust is our best guess as to what happened. New fuel line too, it was the maiden voyage of the car outside the neighborhood.
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Rmvr53
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PostPosted: Sat Mar 29, 2025 10:26 pm    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

OldSchoolVW's wrote:
Rmvr53 wrote:
I was actually considering similar but using new "old style" clear 4 wire connectors so it kinda looked like it was supposed to be that way.'


I don't think anyone sells a reproduction of the original 4 way connectors. These are in the Samba Classifieds and are probably as close as you'll get the original style. Cut to the number of attached connectors you want:

https://www.thesamba.com/vw/classifieds/detail.php?id=2696504


VWWerks does have them in sticks of 12. So I bought a stick. Quite reasonable on the price as well. Thanks for the lead. Now to buy the car or worst case (or best?) is to use them on my replicar if I don't get the 72. Thanks all for the ideas and directions
Bill
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Rome
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PostPosted: Sun Mar 30, 2025 8:27 am    Post subject: Re: Engine fire and the wiring harness on a 72 Bug Reply with quote

The stock-style connectors shown above would look best, but you still should solder on the wire "female" ends for optimal electrical connections. Another wiring connection possibility is this style, similar to VW's own black-colored terminals used thru '60. This style does not need the wire end have a female terminal, though for best connectity the wires' bare ends should be "tinned" with solder to keep all of the individual wire strands together.
Image may have been reduced in size. Click image to view fullscreen.

If you select this style, it'd be best to mount the strips vertically (wires come in from the sides) so that any water does not run into the wire chambers if the strips were mounted horizontally with the wires inserted vertically.

The now nearly defunct Radio Shack stores used to sell these terminal blocks with 2 hole sizes- the smaller ones for "thin to medium" wires such as up to 16 gauge, and a larger one for "larger" wires such as 12 gauge. So if you pursue one of the above blocks, make sure the chamber holes have large enough diameters for your car's thickest wires such as the B+ at the generator/alternator.
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