Given the condition of the wiring elsewhere
on the car, it was a given that the wiring on the engine be reworked as
When each wire is removed from a sender
or other electrical component, it MUST be labeled.
Label each wire before
proceeding on to remove the next wire. Do not depend on
your memory to reconstruct the locations later on. Do not depend
on the factory specs that indicate wire color. I have found them
to be inaccurate.
Follow each wire to the plastic connector
that is on the crossmember. Each wire will have a counterpart on
the other side of the connector. The counterpart wire connects
to the various warning lights, ignition switch, etc. Label each
of the counterpart wires that matches to the appropriate wire coming
from the engine.
Once you have labeled the wires that are
still attached to the car, set out the engine-side harness and cut ONE
wire at the plastic connector. DO NOT CUT ALL THE WIRES.
You must prepare the new harness one wire at a time, so that you do
not confuse the wires. Construct each new wire completely before
proceeding through any steps to replace the other old wires.
Save the plastic sleeve, if any.
Measure the length of the old wire and
cut an equivalent length of new wire. I usually give myself a
little bit of slack - extra length in the wire. You can always
cut out the extra wire at installation.
Remember the sleeve on the wire you just cut from the
connector? Put it on the new wire,
before you install the terminal. Don't forget
to label the wire.
The completed new engine harness. Each
wire is labeled and has the colored sleeve, if any.