What to do about cracked loom wires?

[MWP]

Hi all,

Im re-sleeving / re-routing my 1UZ's loom at the moment.

Quite a few wires near the connectors are cracked like this:



Whats the best way to go about fixing them?

Thanks!

[Chrisso]

It's tedius, but I would suggest that the best longterm solution would be to push the pins out and re-pin the wires. Either buy new pins or open the crimps on the old ones, crimp, solder and heatshrink them together for good measure. Pushing pins out is a pain in the arse, but at least you won't have any dodgy joining bits of wire, or exposed wire just wrapped in pvc tape.

Chris.

[LeeRoy]

I had the wires from my distributor (where the plug is) look like that. Cause theyre nice and close they were shorting out making it loose ignition intermittently and it took me a fair while to find.

There more than likely only going to have occured in areas of the loom where there is both heat and movement so i'd probably check other plugs that live in a similar environment.

Theres probably 2 ways you can fix that:
1. Cut the wire off and re-pin it. Problem with this will be undoing the legs of the pin so they can be reused (ie not breaking them).
2. Put some heatshrink over it (i did this to my damaged wires and theyve been fine since)

Regardless of what you do i'd probably look into bracing the wire so it doesnt continue.

[MWP]

Well it seems to have happened to the important things
Nearly all 8 injectors, CAS, ign coils, etc. Sigh.

How are the pins pushed out?

[edit]
Worked it out.
Those little rubber seals that are also crimped on the end will make this a huge PITA

[LeeRoy]

Toyota pins will cost you heaps. I'm sure that someone makes replacement aftermarket ones but I can't point you in the right direction.

Pins puch out by putting a small needle in the front (ie the side that plugs in) on the underside of the pin. It pushes up a tab that locks them in and allows you to remove them.

edit: I couldnt find any pics on the net but ill grab and upload one for you when i get home.

[LeeRoy]

Dig the rubbers out and slide them down the wire. Be careful not to damage them though

[Hyper101]

If you decide to get new pins try these guys, I get all sorts of Pins and plugs from them

Jay-Dee Auto Cables Pty Ltd
19 Ramage St, Bayswater, VIC 3153
p: (03) 9720 4864

[Cuzzo]

New pins is what you want but i have no idea where from and i would really like to know.

That said you could remove pin from plug and plug heatshrink aroud them and then put them back into the plug. You will prob need to tape them aswell to stop the heatshrink sliding back down.

[thechuckster]

Go to the wreckers and find plugs that use the same pins. Trim them with a long tail and then insert into pockets

Take home and replace the borked sections/pins with pins+wires that you filled you pockets with at P-n-P.

[79GT]

auto electricians.....im sure they would face these problems daily, if they couldnt supply you with any, i am sure your local guy could point you in the right direction.

my 2c. .....what a prick of a job.,...

Jamie

[JZA70R_92]

its an anal job like jamie said i had to do this.....if you can find new plugs and pins that would make life 10x easier

[MWP]

Well ive fixed the connector/wires that are in the photo above.

I did the following:
- Pulled the wires & pins from the plastic body
- Uncrimped the rubber (now like plastic) boots and broke away the rubber
- Cut the wire off at the pins where they are tightly crimped
- Cut the wires about 2cm shorter, stripped & tinned the ends
- Slid on heatshrink tubing
- Soldered the wire onto the pins on top of the small crimped area
- Slid the heatshrink down and crimped it under the larger crimp
- Shrank the heatshrink tubing
- Put the pins back into the connector
- Sealed the entry of the wires into the connector with a little Sikaflex

Sounds difficult, but it was actually quite easy and only took me 5mins.

Ill take photos the next time i do it if anyone wants more details...

[ed]

If you decide to get new pins try these guys, I get all sorts of Pins and plugs from them

Jay-Dee Auto Cables Pty Ltd
19 Ramage St, Bayswater, VIC 3153
p: (03) 9720 4864

do they do toyota pins?

[Chrisso]

Well ive fixed the connector/wires that are in the photo above.

I did the following:
- Pulled the wires & pins from the plastic body
- Uncrimped the rubber (now like plastic) boots and broke away the rubber
- Cut the wire off at the pins where they are tightly crimped
- Cut the wires about 2cm shorter, stripped & tinned the ends
- Slid on heatshrink tubing
- Soldered the wire onto the pins on top of the small crimped area
- Slid the heatshrink down and crimped it under the larger crimp
- Shrank the heatshrink tubing
- Put the pins back into the connector
- Sealed the entry of the wires into the connector with a little Sikaflex

Sounds difficult, but it was actually quite easy and only took me 5mins.

Ill take photos the next time i do it if anyone wants more details...

Nice job. I've been rewiring my car to fit a new fusebox, and make some alterations to the loom. This is the way I've done all my connections so far. Fiddly, but worth the effort imo.

[wilbo666]

There is a Toyota manual with the part number for plugs etc...
e.g.
http://departments.weber.edu/automot...s%20Repair.pdf

It also lists the pins the plug use, and the Toyota part numbers for 'repair' pin (Already have a crimped length of wire).

Toyota don't sell bare pins from what I can tell.

AMP however do most (all?) of Toytas plugs, and I have found the AMP part number for some Toyota pins in the past

Hope this helps...

Cheers
Wilbo