1994 engine harness fire

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SKULLGRINDER

SKULLGRINDER

Joined
Jun 24, 2023
Threads
28
Messages
306
Location
Tucsonistan
Last weekend while on the trail I smelled burning. Popped the hood and sure enough had a fire. Fortunate enough to get it out in time and continue on for the evening. Today I chased the harness back to attempt to make repairs. What I found was less than ideal to say the least. The wire that I believe arced is the center wire of the cruise control actuator ( cannot see color of sheathing from burn) this wire is completely fried all the way back past the fire wall. It claimed other victims along the way as well. This section of harness appears to be to my front locker, wiper motor as well as cruise control. My original plan was the re-protect all damaged wires and wrap up the harness but now seeing that I need to somehow get past the firewall has thrown a wrench in things. Anyone have any viable options to make repairs other than pulling my entire 31 year old Arizona weathered dash to access cab side connector? Any tips to removing the grommet on the firewall side? At a total loss here and to be honest all I am concerned about is making the harness safe again and not prioritizing resorting cruise control… never had to deal with this sort of thing before. Appreciate any help. Thanks

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SKULLGRINDER said:
Last weekend while on the trail I smelled burning. Popped the hood and sure enough had a fire. Fortunate enough to get it out in time and continue on for the evening. Today I chased the harness back to attempt to make repairs. What I found was less than ideal to say the least. The wire that I believe arced is the center wire of the cruise control actuator ( cannot see color of sheathing from burn) this wire is completely fried all the way back past the fire wall. It claimed other victims along the way as well. This section of harness appears to be to my front locker, wiper motor as well as cruise control. My original plan was the re-protect all damaged wires and wrap up the harness but now seeing that I need to somehow get past the firewall has thrown a wrench in things. Anyone have any viable options to make repairs other than pulling my entire 31 year old Arizona weathered dash to access cab side connector? Any tips to removing the grommet on the firewall side? At a total loss here and to be honest all I am concerned about is making the harness safe again and not prioritizing resorting cruise control… never had to deal with this sort of thing before. Appreciate any help. Thanks
Click to expand...
That grommet is installed from the inside a couple of plastic trim tools (preferred) or small screw drivers should be able to force out of the opening.

That portion of the harness extends from the interior, and is part of the dash harness (Front Wiring Harness), so would not be an easy replacement, you will probably need to repair in place, but you will need to be proficient with soldering, heat shrink, and crimping pins. You can look for that grey connector in the wire harness repair manual (in the resources section) (you can confirm the part number on the housing)

I believe from the pictures, the gray connector that appear most affected are:
7P Waterproof Type:
Female Housing: 90980–10931
Male Housing: 90980–10930

Repair wires:
Female Repair wire with Terminal: 82998-12440
Male Repair wire with Terminal: 160mm length: Blue (~18 Gauge) 82998–12430;
500 mm Length: Blue (~18 Gauge) 82998-12590; Yellow (~14 Gauge Wire) 82998-12800

Bare Pin Contacts:
Mfr: Yazaki
Series: 090II Sealed Series, RK/090II Hybrid
Female Pins:
0.3-0.5 mm2 (22-20 AWG): Tin Plated 7116-4025 (Gold Plated 7114-4028-08)
0.85-1.25 mm2 (18-16 AWG): Tin Plated 7116-4026 (Gold Plated 7114-4029-08)
2.0 mm2 (14 AWG): Tin Plated 7116-4027
Male Pins:
0.3-0.5 mm2 (22-20 AWG): Tin Plated 7114-4025 (Gold Plated 7114-4028-08)
0.85-1.25 mm2 (18-16 AWG): Tin Plated 7114-4026 (Gold Plated 7114-4029-08)
2.0 mm2 (14 AWG): Tin Plated 7114-4027

There are several vendors on this site that may be more affordable than going directly to Toyota for the repair wires; the pins are generally only available from non-Toyota dealer sources.

It may be “easier” to pull the fender to access if all the wires on the outside are serviceable and can be repaired.

Here is a picture of that portion of the wiring harness from Cruiseryard of a used front harness they have listed:
Picture1.webp


It also looks like more wires than what goes to that gray connector were also affected, so those will need to be researched.
 
getsthr said:
That grommet is installed from the inside a couple of plastic trim tools (preferred) or small screw drivers should be able to force out of the opening.

That portion of the harness extends from the interior, and is part of the dash harness (Front Wiring Harness), so would not be an easy replacement, you will probably need to repair in place, but you will need to be proficient with soldering, heat shrink, and crimping pins. You can look for that grey connector in the wire harness repair manual (in the resources section) (you can confirm the part number on the housing)

I believe from the pictures, the gray connector that appear most affected are:
7P Waterproof Type:
Female Housing: 90980–10931
Male Housing: 90980–10930

Repair wires:
Female Repair wire with Terminal: 82998-12440
Male Repair wire with Terminal: 160mm length: Blue (~18 Gauge) 82998–12430;
500 mm Length: Blue (~18 Gauge) 82998-12590; Yellow (~14 Gauge Wire) 82998-12800

Bare Pin Contacts:
Mfr: Yazaki
Series: 090II Sealed Series, RK/090II Hybrid
Female Pins:
0.3-0.5 mm2 (22-20 AWG): Tin Plated 7116-4025 (Gold Plated 7114-4028-08)
0.85-1.25 mm2 (18-16 AWG): Tin Plated 7116-4026 (Gold Plated 7114-4029-08)
2.0 mm2 (14 AWG): Tin Plated 7116-4027
Male Pins:
0.3-0.5 mm2 (22-20 AWG): Tin Plated 7114-4025 (Gold Plated 7114-4028-08)
0.85-1.25 mm2 (18-16 AWG): Tin Plated 7114-4026 (Gold Plated 7114-4029-08)
2.0 mm2 (14 AWG): Tin Plated 7114-4027

There are several vendors on this site that may be more affordable than going directly to Toyota for the repair wires; the pins are generally only available from non-Toyota dealer sources.

It may be “easier” to pull the fender to access if all the wires on the outside are serviceable and can be repaired.

Here is a picture of that portion of the wiring harness from Cruiseryard of a used front harness they have listed:
View attachment 4139705

It also looks like more wires than what goes to that gray connector were also affected, so those will need to be researched.
Click to expand...
Super helpful thank you! I am hoping I can get the grommet out of the firewall and pull enough slack to find the end of the wire that arced out. It seems like it stopped somewhere close in there as no more wires seem to be fused together. I cannot really get my head under the dash enough to see the harness coming in from the harness from the cab side. May have to remove my blower and other HVAC components to gain access. Hoping that is not the case.
 
SKULLGRINDER said:
Super helpful thank you! I am hoping I can get the grommet out of the firewall and pull enough slack to find the end of the wire that arced out. It seems like it stopped somewhere close in there as no more wires seem to be fused together. I cannot really get my head under the dash enough to see the harness coming in from the harness from the cab side. May have to remove my blower and other HVAC components to gain access. Hoping that is not the case.
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It really petty easy to remove a fender to gain some access.
IMO better to just replace that part of the harness.
I would reach out to the guys that do partouts on the board @slow95z is one and great to work with.
@swamp-thing is another that comes to mind.

Good luck with the repair

I would steer clear of Cruiser Parts 🤷‍♂️
 
Just rebuild it. I provided all of the part numbers needed to rebuild your harness.

OGBeno

FAQ Thread 'Engine Wiring Harness Information 8/1992-12/1994 FZJ80: 82121-60340/1/2'

Hello all:

I’m lucky enough to be working on a cool project at the shop where we will be rehabilitating a OBD 1 1FZ-FE engine harness. As such, it seems there is some information useful to the community as I go through this process that might be worth passing along and sharing.

We’ll be disassembling an 82121-60342 engine wiring harness and reconstituting it using all OEM parts. This engine harness has been discontinued for a long time. I know of one NIB/NOS iteration owned by another well-known parts nerd for his own vehicle. Other than this person, I don’t know of another version...
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OGBeno said:
Just rebuild it. I provided all of the part numbers needed to rebuild your harness.

OGBeno

FAQ Thread 'Engine Wiring Harness Information 8/1992-12/1994 FZJ80: 82121-60340/1/2'

Hello all:

I’m lucky enough to be working on a cool project at the shop where we will be rehabilitating a OBD 1 1FZ-FE engine harness. As such, it seems there is some information useful to the community as I go through this process that might be worth passing along and sharing.

We’ll be disassembling an 82121-60342 engine wiring harness and reconstituting it using all OEM parts. This engine harness has been discontinued for a long time. I know of one NIB/NOS iteration owned by another well-known parts nerd for his own vehicle. Other than this person, I don’t know of another version...
  • Like
  • Love
Click to expand...
I agree if it were my engine harness it wouldn’t be too bad to pull and referb… however, after looking at the EWD and photos of complete vehicle harnesses pulled my damaged area appears to be what the EWD is calling the “cowl harness” and looks to run length wise of the dash to the instrument panel…. I.E. complete dash removal to chase fried wire down since there is no other connection points where I’d be able to isolate just the section of harness I need to make repairs to.
 
OGBeno said:
The wires on the inside of the cabin right after the firewall/the rubber grommet are a part of the main engine wiring harness.
Click to expand...
Right the 7 connectors back there under glove. Really really hoping the heat didn’t travel that far back and damage ECU harness. But I see your point if I am going to be right there may as well do it. Nice thing is.. whatever did get burnt didn’t seem to have much effect on the truck. Drove it for 3 days post fire without any issues other than the idea it may melt down on the back of my head which has lead me to where I am at.
 
OGBeno said:
Pull the harness and rebuild the whole thing. Don’t half ass something as important as the main engine wiring harness. It’s 32 years old. All the connectors and splices are about $700 total. A crappy used one is $700+.
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And I even have the cheat sheet you made 🥰
 
OGBeno said:
Pull the harness and rebuild the whole thing. Don’t half ass something as important as the main engine wiring harness. It’s 32 years old. All the connectors and splices are about $700 total. A crappy used one is $700+.
Click to expand...

Dang, I have a nice harness and I couldnt seem to get the $300 shipped I had it listed for.
 
peacesells63 said:
Dang, I have a nice harness and I couldnt seem to get the $300 shipped I had it listed for.
Click to expand...

Desert harnesses aren’t good. East coast harnesses are good in this specific situation.

Desert harnesses: rodent damage and heat sink into plastic over 30+ years. Brittle connectors. They all disintegrate
 
OGBeno said:
Desert harnesses aren’t good. East coast harnesses are good in this specific situation.

Desert harnesses: rodent damage and heat sink into plastic over 30+ years.
Click to expand...
This one is the nicest 1fz harness I have ever pulled. AZ truck, but it was only on the road for about 15 years. I have quite a few 93-94 customers, so now i'm saving it as part of my retirement plan
 
Everything I own is for sale for the right price 😂
 
SKULLGRINDER said:
Last weekend while on the trail I smelled burning. Popped the hood and sure enough had a fire. Fortunate enough to get it out in time and continue on for the evening. Today I chased the harness back to attempt to make repairs. What I found was less than ideal to say the least. The wire that I believe arced is the center wire of the cruise control actuator ( cannot see color of sheathing from burn) this wire is completely fried all the way back past the fire wall. It claimed other victims along the way as well. This section of harness appears to be to my front locker, wiper motor as well as cruise control. My original plan was the re-protect all damaged wires and wrap up the harness but now seeing that I need to somehow get past the firewall has thrown a wrench in things. Anyone have any viable options to make repairs other than pulling my entire 31 year old Arizona weathered dash to access cab side connector? Any tips to removing the grommet on the firewall side? At a total loss here and to be honest all I am concerned about is making the harness safe again and not prioritizing resorting cruise control… never had to deal with this sort of thing before. Appreciate any help. Thanks

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ugh!!!
 
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