Just a small bit of advice: try to stagger your cable splices so you don't end up with a thick bundle of shrinksleeving all in one place, will make your wiring look a lot neater once wrapped.
Good tip. I almost always do that, especially on thicker wires and bigger bundles as there is much more to gain.
If you look closely, you'll see that I even did that here. No two joints are in exactly the same place. I chose to stagger only a small distance on most (usually the length of the solder joint itself). Reasoning was the fact that the way it was wired into the original loom meant I had to cut closer to the connector than I had liked and I wanted the flexibility at the connector end maintained as not to cause problems later. The area where joints are made (even when staggered) and shrink wrapped looses some flexibility. As these wires also were very thin and there were not too many bundled together I felt this would suffice. Some others are staggered the length of the shrink wrap as I had a bit more room to play. But adding equeal length shrink wrap distorts the visual effect a bit, as does the angle of photography. As you can see in the end result, the wrapped bundle is not very bulky at all.
In the full loom this only applies to a couple of connectors. All other wires are crimped with new pins at both ends.
Still spurred on by the imminent receipt of the pins and not wanting to overstay the looms welcome on the dinner table I had a small session last evening. Adding all but the final earth/ground connections. The list of wires shows more and more green (as in done). I hope to complete the last wires tonight or tomorrow. Unfortunately my time will be limited as one of the kids has asked for some help for a school project that needs doing by the end of the week. Anyway, I'm feeling happier about working on the loom at the moment so that must be a good thing...
Ohhh, the pins are in... and they seem to be just what I needed.
Too bad there are some other things to get out of the way first. Effectively I think I'll only have some time on Saturday this week, but I should be able to make a bit of a leap now. Don't think there's anything really stopping me from the material availability point of view.
I'll try not to set my expectations to high and just work away at it if and when I can. But the end is coming into view!
Well, with the pins finally in house, I really couldn’t have much reason not to make a push on the loom this weekend. So I tried… As expected with all that was planned I really only had part of the Saturday to work on it.
And so I did. I did underestimate how much time it would still take so obviously I didn’t quite get as far as I had liked. But the results so far are almost factory. I may sometimes have deviated from the original wire color in the diagrams (made note of that for future reference) but for look and feel with new pins on both sides of all the important bits I’m pretty happy.
First things first though, I wanted the two main connector wires separated into two bundles. From the ecu to the connector(s). By adding wire after wire to the loom they weren’t all running in an orderly fashion anymore. Some twists and crossovers made it a bit untidy. And as some wires split to go to more than one connector, they got a bit tangled. And I like things a bit more orderly. So each of the wires for these connectors were threaded back to the ecu and then ran back to the connector, much more orderly. In the end as both these bundles run in the same direction, they will probably end up wrapped as one for 85% of their length. But to make good decisions on the best way to wrap things I want to lay out all the wiring before wrapping. So in the mean time I try and hold its structure by using tie wraps.
Anyway next up was actually sizing up the wires as they were still a bit over in length and then crimping on the pins and threading them into the connector blocks. The crimping went very well, decent crimps on both the copper core as well as the insulation to keep it all in place. It wasn’t fast work though. Cut to length with one pair of pliers, another to strip the insulation exposing the core for 5mm and then using the crimping pliers to actually crimp on the pins. I used my excel registration to feed each wire to the right hole thereby at the same time checking my work. I also labelled all the power feeds I came into contact with so I can more easily combine the right wires to the 12 fuses I have available.
By end of work I had the two main connectors wired up. But there wasn’t more time to continue. And worse, I really should vacate the dining table with all my mess. So I tried to transport the loom as best as I could to my workbench in the cold of the garage. But the workbench is a bit short for it all. And at the moment it’s not a good working environment either. It’s cold for one, but it’s also too dark as last week first one light died, then later the other one as well. So apart from a meagre light source over my work bench I’m in the dark.
Also with these main connectors now wired up I feel like I’m at a point where I will have to put the loom in the car at least partially so I know where to cut the excess of some of the wires. Also, I used the wiring diagram to investigate the wiring to and from the fans and fan relay to make sure the way it was wired in before was correct (and it was) but as a result I held off running these wires and the best way to do that with minimal waste is in the car. And doing that requires access to the car from both sides which means putting it outside and it has been wet the last few days as well. Not the right circumstances for the jobs at hand.
So what do I do now? Well I think I’ll try and organize the other half of the loom from the ecu to its connector so the wires aren’t crossing. Probably determine from that where I need connectors splitting off the main loom and how to bundle it to wrap it all. The goal is to have a short section from the ecu where it all is one bundle only to split off soon after that to the right places. It’s a bit busy, that first stretch, because of my opportunity to now relocate some control units and making wiring to length, a lot of the important connectors stay close to the ecu location. I’m sure in the end it will be nicer than it was before. Additionally there are some connectors I can start to add even now as their location is relatively known and it’s no big deal if a section is a few cm’s longer than strictly necessary. One of these is again one that needs to be soldered. So work will continue as and when I can.
Biggest hurdle: mentally getting myself to actually do it. It’s hard to choose a cold garage over the warm living room and a decent movie on the telly. On the other hand, when I do work on the loom I feel quite good about it. As every little thing you do gets you closer to the end. Or to put it simply, each connector switched over is one less to go.
Note: On this first wire I had to crimp the insulation twice to get a good grip on the insulation. Turned out to be due to the positioning of the pin in the pliers. Any I didn't like I gave a little extra crimp.
Wow, is it me or are the weeks just going by faster and faster with every passing one? This year has gone pretty fast in general, but the past months that I’ve been working on getting my loom fixed just seem to be nothing but a blur…
Anyway, I had set myself some goals, so let’s see how much of those I managed to achieve, or not…
It actually went wrong pretty quickly, when after having to put the loom back in the garage on the workbench, the sheer cold in there meant there was no way in hell I was going to work on it in there. This gave me some more motivation for later in the week. By work week end on Thursday afternoon I still felt good about the progress I was going to make on Friday. So I made sure I was good to go and left it at that. Spent some quality time with the wife and kids.
So Friday came and although it’s my day off, the dog(s) still wake me at 6:10 at the latest and the kids both had to go to school. One was gone before 8 the other before 9. The wifey would be gone from around 10 or so. So I was up early enough and still highly motivated by the idea of having a full day with no (well almost no) interruption. So I started prepping the theatre...
I laid out the loom, all tools required, all pins and other materials like wires, crimps and what not that I could fit and organized the lot. When the wife left I put on the stereo (I love my (vintage) home system and new speakers) and got to work.
The work consisted of organizing the loom and adding connectors. In general all wires were running in the right direction, but by adding one here one there in the process they had become somewhat entangled or crossed. So now I was prepping to add the connectors to each end of their respective sections I wanted all wires going to that connector to be bundled together from the beginning. I could then also choose if I wanted to make a central main section with split offs or wrap some wires separately from the start. This obviously meant pulling these wires back through the loom and running them back to the same location only without entanglements. Keeping the right wires together once I had cut the bindings off that kept them together at their ends was sometimes quite challenging. One tangle usually impacted other wires going to other connectors so it became quite the puzzle and I needed to keep focus. It took me several hours to get it all neat. Everything now bundled in little sections.
It was now time to add the first connectors. The goal for the day was adding all connectors to the wiring that was confirmed as the right length and around the ecu section so that first central bit of loom could be made up. I also wanted to label any power feeds I hadn’t already.
I documented the connectors in situ on the old loom for fallback purposes and de-pinned or cut the first few off the old loom. The first one I added was the MAF connector. I had new pins for this and new water proofing caps. The cap got away from me a little on the first one, but it was still secure. The others went better. It felt good having made a start on adding more connectors, combined with the musical backing meant I really had a good time doing this. Feeling sort of euphoric even! And that totally drug free, lol.
It was then I discovered a mistake. I had previously added the first two or so wires to the bus bar that was used by Ford. It was easiest for me to keep this in tact given the 7 wire join that was made through it. But I had used the 16 pin one that groups four pins together (times four). Damned! I should have used the 8 wire one that groups all together as one. Thankfully I was able to remove the pins from the wrong one and add them back in the right one. Throughout the bundling work I added these in one by one and it became my second connector of the day that was completed. I wrapped that little section and a little bit around it as a temporary way of keeping it all in place.
This connector was cleaned up a little on the plastic bits to ensure good contact.
Next up I cut the wires going to some dash LEDs and added connectors to them so they would not need removal from the dash if ever the loom has to come out again. It is now made to be fully detachable at the ecu location.
Then I went for one of the main dash connectors feeding gauges and power to certain systems. It was a bit of a mess originally as the connector was sort of repurposed to combine these functions in this one connector. A good idea but with solder joints, not the best execution. As I also had pins for these connectors I just fully re-pinned the wiring and seated them. Upon completion checking this against it’s counterpart to make sure all wires were where they should go. Keeping track of all I had done in my excel to be able to stop and continue as needed. Pleased with this section as well, I wrapped it to keep it secure and I wrapped the bit immediately after the ecu to fix the different split offs in place.
I did the AC clutch wiring and the AC dual pressure switch wiring which is only there in case I ever add in the ac I was planning at the time. Then it was time to do the ODB2 or diagnostics port. Again a system that is mounted to the dash so I split the wiring with a new connector to make future removal of the loom easier. The diagnostic port was one connector I couldn’t get new pins for (and I didn’t want to by a complete unit) so I was forced to use the end of the original wires. Although I generally try to avoid that, it simply wasn’t possible everywhere. But this is in car wiring, which means it has suffered much less so I had no problem using the last 10-15mm of it. I crimped these using the wire extension crimps you guys had pointed me to before. Made a nice and solid connection and all shrink wrapped all the way back tot the pin so the end bit of the wire gets extra protection and wrapped in tape to be nice and secure, yet somewhat flexible.
Next up was the gear shifter connector. This one is funny. It’s the same 16 pin design as the dash one. It has around 14 wires or so connected, but mainly in three pairs. A few wires go to one ground point, 4 others all join one feed wire, 3 others another. So it was nice to have the right crimps for this job as well again thanks to this board. Again all nicely shrink wrapped. I didn’t yet take a picture as this was the final connector I got to work on, but I still have the ground bit to do. In fact all I have to show that is left, is the end of play status before having to clear the theatre again and moving all stuff back to the garage (mental support dog photobombed the image).
Oh, and this is why you have to stay on top of your game... mistakes are easily made. In a moment of lapse of concentration I saw I had to bring this thin violet/black wire to three other pins. I forgot to notice one line down in my excel the same pins also getting a thicker violet yellow wire. So I should have crimped these other pins using the thicker wire and add this thin on in on the first pin. Ooops, wasted about 1,5 euro's in pins. Fortunately I think I bought enough of these to have some spares. But I can't afford too many of these mistakes...
So in the end I made a good spurt but didn’t quite get where I had hoped to be. The goal set should have left me in a place where I can do a final test fitting to ascertain which wires can be shortened and if all still goes to the right places. I didn’t get that far. I’m about one and a bit connector short. But none the less quite happy with the progress. I’m sure I’ll be able to get to that point during the week. Then it’s a matter of finding time during a dry spell to put it all in for a trial fit.
I need that trial fit to add the final circuit, which is for the fans, but as I haven’t bought overly much of that wire thickness I don’t want to make guesswork of that. Then I’ll need to finish the power feed and ground sections (which should mostly be checks but some wires for the fuel pump etc. will need to be added. This may require opening up and re-wrapping the currently wrapped bits of the loom. After that I should bundle the power feeds so I can crimp multiple ones to ringed crimps so I can get them to the right fuses and then I need to either remove the loom again and finish it or finish it in situ and do a test… Which is a big thing in my mind, because what if it won’t start/run? What if again there’s wire damage? I’ll have spent a medium fortune without any result. And given the fact both the engine loom itself as well as the ecu to engine loom has been changed there’s quite bit of potential for failure…
So plenty to do still. But getting closer. Not sure exactly what goal to set for this week. Verifying/completing the ground/earth connections and the three main relay connections as well as finishing that last 1,5 connectors so I can do the test fit would be a good start. But despite motivation, Monday evening came and went without anything done on the loom… I really should get a move on as I know this Friday I won’t be able to repeat last Friday’s massive push as the morning is taken by something that could prove exciting or a total bust…
I never seem to have the right tool to get a perfect crimp as every connector seems to be a little different!
In all honesty, that is true to an extent. I've bought a set with 5 dies or so to have options. But I quickly found that the indications on the dies were just that, indications. Not every crimp was as succesfull. In the end I bought an extra pair of pliers as finding a fitting die for the existing one proved impossible or more expensive. That extra pliers added just the variety I needed.
Many of the connectors that are supposedly crimped with the same type of die needed their own approach. In my experience the bit where the copper core of the wires is crimped is usually ok in the first go if you use the one belonging to the wire thickness. The bit that grabs the insulation as pull protection is most often the bit that needs an extra crimp. For good crimps I've regularly had to resort to crimping that bit one size smaller. So while some pins and wire thinesses matched perfectly and were a perfect crimp in one go others needed a second pass to be better. And I'm not taking any chances...
Variations in metal thicknes of the crimps and with that the stiffness as well as differences in length and width of dies themselves mean you usually have to do a couple of tests to see which combo works best, which is not necessarily in agreement with the indications on the dies.
Good work and I feel a bit familiar in most of your struggles. Especially correcting old shortcuts when adding stuff...
The EEC pin source sounds interesting, is that a place you could share? I have always had issues finding these pins.
On e-bay, several vendors claim to sell the pins for both EEC- IV and EEC-V, although the latter are harder to find. I got all of my pins form Germany, Kühn Messgeräte (contact Florian). He doesn't seem to have a website up currently. If you can't find an address for him with the company name, pm me and I'll forward his e-mail address. He was quite alright on price and made me decent deals. Others charged twice or thrice his prices (some fools even for used pins). He couldn't match all contacts to a new one in his portfolio though... But the ones that mattered most to me I managed to get new.
Hm, the after weekend update… What will I have to share today?
The good news is there at least is something to share… I did get some time on the loom again this weekend.
I started Friday morning, laying out the loom once again on the dinner table. First goals: finishing the last 3 pins on one connector and adding the last major one in that section. This section contains all wires that stay inside the cabin behind the dash. So finishing that would be a good start.
Finishing the first connector was easy enough. It was again on of those one wire feed three pins situations so I crimped that one wire to the three pins with lovely little arches between the pins. The final one turning out to be only just long enough. But hey, it al fit and was secure. One down in minutes.
The next one was more involved, this was another one with 12 or 14 wires or so, those very thin wires that I felt were better of soldered than crimped as they were so thin. Soldering takes more time so this was more time consuming. Staggering the joints randomly to avoid thick bits in the loom. I was on a roll when I found an error. I usually check if I have the same color wire more than once, but this time for this wire I hadn’t noticed. Turns out I had switched two of the same color so I had to redo one (at the time I found out the second one hadn’t been soldered yet). Glad I found that mistake now. Whenever I have two or more wires of the same color/thickness, I made it a point to label any second or third of that color with either the pin number to be or the source and destination pins. This made it a lot easier to do the connectors as with bits now wrapped, it’s not a given that one can trace any wire back to the source still.
With these two done, the morning was pretty much gone, although I didn’t have a real early start 9around 10-ish). Time for some lunch and a catch up with the wife who’d been gone for the morning.
After lunch I went on making sure I had the full loom complete bar the fan control circuit. This meant checking grounds, which it seems I now have all just the same as they were before. On to the three main relays then! Turns out the main relay was complete, the second relay for the fuel pump needed a power feed adding in and a note that one pin not only was connected to the ecu but also needed to continue on to the fuel pump itself. But this is more logical to run when the loom is finally installed. That left relay number three that I designate as engine control. It needed a power feed drawn as well. The feed from the engine loom was already there and the remaining two wires had to be added. One of these is an ignition fed 12v, the other I think fuel pump cutoff switch related. This is the one bit I have to be very careful with when fitting up, as my picture evidence is unclear on the exact number of wires. But fortunately there is not too much room for error. There’s really only two that could get switched up I think. Still This bit has me worried on and off for months now. These were the only wires that had to be cut for the removal as there was no connector to undo. I hope remaining wire lengths will help provide the right hookups. Nothing much more to do than just be careful.
With that the loom was complete! Well apart form the one section I wasn’t sure of how to proceed with. Separate or included in the loom and that I felt I needed to wire up with the loom in the car. But, with that playtime was also over for the day. The kids needed gifts for various occasions and one had decided he needed to visit a shop in the city center (where we hardly ever go as we have a more local small version of it and it must have been years since I’d actually walked through it, lol) so a trip to the city and later a trip to the other center was on the cards. Tuns out it was quite nice to do this with wife and son and later with wife and daughter. Better still, the gifts turned out to be very well received which is always nice.
Fortunately the Saturday was basically free of plans. As usual there was always a little this or that errand to run or someone to drive, but basically free. So with the thermometer at minus 3 I set out to put the Granada outside and do the test fit of the loom. How’s that for dedication, lol.
It took a bit to get the power and earth sections in, than the first of the internal connector bits that were done. Then moving the lot up to the firewall to get the ecu connector in. Which it wouldn’t. I know I had made the original rectangular hole very small, but with the new bundle of wires, som thicker than original it just wouldn’t go in and I didn’t want to risk damage. So I’ll have to enlarge the hole a tad. I’ll see if I still have the original round grommet in my stash or make something myself. Anyway this kind of thwarted my plans. I was now not able to see if all power feeds would go where they needed to go. Also how was I going to assess which wires were too long and which were fine. I decided I have one fixed reference point to work from. The main connectors between the engine loom and the new ecu loom have a fixed position on a bracket. So I put that bracket on the connectors and bodged it in place for the time being. I then worked the loom back toward the firewall and forward towards the edis and fan control and beyond to the other side of the engine bay for the maf sensor and some AC bits. Only the hego to route to the other side but from the other end of the engine bay (firewall side).
This showed that I might have given my three main relay wires a bit more length. Although I think it will all reach nicely. Just not overly long. Most of the other bits were right where I wanted them, some got trimmed. Hego, Edis, a sensor here or there. All this had taken most of the morning and I was cold. The loom was cold as well… I took it all back out and put it on the table again… and this is when it hit me. I wasn’t finished yet. I should have left the loom in! I needed to add that final fan circuit. As the fan circuit has only two wires linked to the ecu and those were confirmed for the right length, I just ran the circuit in the car without the loom present. I knew where I needed to be. Nothing too difficult, just three power feeds, a couple of bits between the relay and the fans and an earth. I had bought extra thick wire for this circuit, as it was the thickest in the original loom as well. This presented a bit of an issue on joining the wires together.
I had spent ages depinning the connectors as well, even after all this work I don’t have depinning tools. I just use micro screwdrivers and so far that was enough, of not always convenient. Anyway, these final three pins just wouldn’t release. In the end I succeeded, but man, this was frustratingly time consuming. I had know before that I wouldn’t be able to fully crimp this one with new pins, as some were very big and there were only two or one. And sourcing one or two pins is just not economical. I was amazed that the three reluctant pins were of a type I had been able to source so at least much of it is fresh and new. But I had to crimp the ends of the original thick wires to my new even thicker wires. But this was not very easy because of the thickness. I got it done though, confidently so. So with that the loom should now be complete. I’ll need to run through my excel to be sure but I think it’s all there now. With it all there now I had some extra wires going to the ecu and beyond for power so I didn’t just want to add them onto the wrapping so I cut away bit by bit following right after with the tape to re-wrap. Wrapping does make it al a lot more stiff though… But I also do wrap pretty tightly as otherwise it becomes a bit messy.
The box o'wires can now stay shut for a bit, until I start adding the other non BOB related circuits back in.
Unfortunately where I didn’t succeed this week was in the connector department. Adding that one fan control connector and the first of the actual fan connectors took so much time… I just wasn’t able to finish the rest. I think it’s three sensor connectors, one fan, two hego’s, the edis one, the exhaust gas pressure transducer and the octane relay. These are all relatively easy and can be done on the table/bench. Then there are all those wires for the relays. I’m in two minds about just crimping on the terminals (they’re all the same) or doing so with the loom in the car. The relays aren’t fixed in place yet, a bracket needs to be made so if I do need to shift them a bit there’s a little wiggle room.
So that’s it. Do I consider this a good weekend? Yes I do! I got a lot accomplished! Though falling short of all goals (maybe I just set them too high), I managed to realize most of them. Adding the connectors I should be able to do in the evening during the week. Search for my metal and that grommet as well.
After that opening up the hole in the car and wrapping the full loom should see it ready to go. I was debating wrapping it in full before testing, but it’s just too much hassle to take it out and put it in each time. The end of the project would be finalizing the power feeds to the fuse boxes, oh and creating new feeds for the ground and starter motor. Sort of a while I’m at it. The gauge is the same as the current stuff, but it’s a bit more flexible and fresh.
With that I am starting to see both the light at the end of the tunnel as well as the fear of first power up. Somehow this conjures up an image of space shuttle power up in magnitude. I just keep fearing that after all this work there’s either a mistake in the loom or it’s going to burn away again or the car just won’t start and run… I had figured, to reduce risk, I’d add one fuse at a time starting with the unswitched fusebox, seeing how it all would go, then continuing fuse by fuse on the switched one. But then I thought, is that even sensible? The switched box is powered from the ignition being on so should get power before anything else so in my thinking this gives me a chance to have some more control. Well, onwards to the final pushes.
Did some work on the loom for about 45 minutes or so yesterday in the cold of the garage. Being busy I didn't really mind. It wasn't until I stepped back into the house and had sat for a few minutes that I noticed that the cold had gotten to my muscles a little...
Anyway, I digress. I went in there to check the remaining thick wire crimps and finish off the fan circuit. Now with better scrutiny (the light in the livingroom is set for cosyness, not for clinical scrutiny) they all looked fine and all withstood a serious pull test. I'm confident in their function so I sealed them with shrink wrap. I added the final two pins for fan number two to the other end of these wires and also shrinkwrapped them. Put them in the connector and called it done. this also meant I could push the last pin on the fan relay connector home as well and fit the internal cap that locks it all in place. I wrapped that section up in tape so it's another bit ready to go.
At that point I was debating continueing with something like the edis connector or stopping. In the end I decided to stop for the day. Turned out a good decision as moments later I got word that my son needed some help on a homework assignment which cost me the rest of my evening.
Happy with a small bit of progress none the less. If I get to do a little bit every night, the loom should be ready for the weekend. Oh right, this means I have to think about my battery terminals. Will I reuse what was there or buy new. I guess that depends on how I'll arrange the feeds to the starter and the alternator...
With the train moving at ever more speed towards year end it’s no surprise another week has come and gone. I’d hoped life would slow down a bit, but it really doesn’t seem to let off. And as if the cold, dark and wet aren’t enough to deal with, the economic effects of the actions of a certain power hungry puppet on my family life drain any remaining bit of pleasure out of me. It’s hard to see light at the moment.
Anyway, there was a task at hand. The loom should be finished this weekend. As usual my goals and my achievements didn’t really line up, but then again I had to do some other things I hadn’t planned on either. This meant my usual Friday was taken up and I could only get a start on Saturday.
This time it was supposed to be easy. Just add the connectors. Simple! Well, mostly but not everywhere. I was able to de-pin most of the connectors I needed to add after cutting them from the old loom. But the 3 sensor connectors (injector type thingy’s) were a curse word to get the pins from. I admit I don’t have the tools for it, but I’d been able to get each and every other connector done with just those tiny watchmaker screwdrivers. But these 3, no way in hell. Getting the locking tab out was relatively easy, but the pins would just not cooperate. I had new pins for them so after spending wayyyy too much time on them with only partial success I decided to punch them out from behind, which eventually both worked and didn’t even cause any damage. Loads of time wasted here. Anyway, I put on the connector going to the fuel pump cutoff and ignition first. Next were the two HEGO’s. Again ones I had pins for so no issues there. I could have counted better upon ordering as I had just enough new rubber boots to keep the water out. I decided to wrap each section that came available and that had to run it’s own course immediately. Surprising how much time and meters of tape goes into simply wrapping some wires.
At that point I was interrupted to go finish a job I had started a while ago at my MIL’s. She had a broken lock that meant a key would not move the lock tab anymore. I had previously figured that I could fix this myself by taking out the door from the hinged side as these hinges were from before the anti-theft tabs. But upon a previous try I could only get two of the three pins out. One was stuck solid. And off course it was the lower one that you have little purchase on. Anyway, second attempt. Armed with a bigger hammer, a pry bar and some wood blocks and an old drill bit (well it was now, lol) I started working on that stubborn pin. I got it to move but fully getting it out required some clever prying, hammering and swearing. It turned out the thing was both crooked as well as paint had gotten in… With the pins now all out, I found that the door would not come out. It had to be forced past the hinges that protrude just a little over the wood of the door. So with my wife in front to catch the door if it came free, I hammered away from the inside on a block of wood. My plan actually worked and I got the door out! With that the changing of the lock would be mere minutes. That is until the one screw that holds the cylinder in the lock from the side of the door turned out to have a bad head and to be stuck fast. I managed to tap it just right to get it to move. Thankfully as I was already having visions of what to do if I couldn’t get this out. Two muntes later the new lock was in and proven to work. 10 minutes later the door was built back up and hung and working. But all in all 45-60 minutes had passed again. Now I had to wait for my wife and MIL to get back from the shops before I could go back home. Had to jump her car as the battery just couldn’t keep up. Car is driven 2500km’s a year tops… So ordered a new one as well.
Back home I went on to the EDIS connector. This was easy just making sure I pinned it from the right side out. Another bit of loom done and wrapped. I then set to the EPT sensor for which I didn’t have new pins. I crimped the new wires to the shortest bit of old wire I possibly could and shrink wrapped them. Did the Octane plug with new pins and wrapped those two. Then came those pesky three sensors. The pinning went fast, but it had taken me so long to get them de-pinned that by now it was Sunday already.
With those pinned and wrapped however, the bulk of the loom was done. All connectors present! The only bits that still needed termination are the wires to the relays, the ground and power sections. These are still mostly a mess of loose wires to be routed in situ and crimped together where needed. I then wrapped the entire loom to be one complete unit.
I’m now looking into the connecting bits that I removed from the car but aren’t part of this loom bit themselves. I feel I can improve on them as well, although I couldn’t get the pins for this connector type.
Being later in the weekend by now and cold as hell I didn’t get to fit the loom in the car. I did however search for the grommet that is on an original loom for the firewall. I couldn’t find it so I’ll make something up. But first I need to enlarge the hole as the way I built it, the ecu end is a little less compact, but I didn’t want all wires coming from the ecu taking those hard bends they originally do. But for that I need the car outside and a bit of dry weather, which this week will be a challenge.
I also started looking into my battery cables and clamps, but not sure what to do there yet. I’ll ask some advice in my next post...