93 Engine wiring harness help

[FZJ80 TN 93]

I’m working on trying to replace all my heater hoses, vacuum hoses, and get my injectors cleaned/ rebuilt. Every wiring harness connector I have needed to disconnect under the hood, the retaining clips have broken.
So I look up the part number for the engine wiring harness and of course it’s discontinued.
Are there any aftermarket options or what have others done? I can’t be the first one to have this issue. Thanks.

 

[petegangies]

is this the part number for the entire harness? There is a harness repair document in the resources section that will provide part numbers for individual connectors. You may need to depin and replace invidividual connectors.

 

[Malleus]

Yes, the 2nd gen engine harness is NLA. The individual connector housings are still available singly. You will also have to buy seals and in some cases plugs for them. The last five digits of the part numbers are embossed on the rear face of each connector housing. All connector housing part numbers begin with "90980-".

The best way to do this is just to remove the entire harness and do it on a bench. Believe me. Unfortunately, this requires removal of the intake manifold halves and the fuel rail. The whole job, if you have all the parts in hand before you start, will take a long weekend, at most.

It's also the time to replace all the vacuum lines, if you choose this way to do it.

Although the individual connector housings are still available from Toyota, they are also available for much less, along with seals, plugs, and terminals, if you need them, from Ballenger Motorsports. Corsa may have some also, but I've never dealt with them, so I'll let others chime in on them.

 

[Fj80oregon]

This thread has all the info you need!

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

Dec 20, 2023

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...

• OGBeno
• 1fz fe fzj80 obd1 wiring harness wiring repair
• Replies: 48
• Forum: 80-Series Tech

• 
• 

 

[60 toy ota]

Corsa may have some also, but I've never dealt with them, so I'll let others chime in on them.

I've dealt with corsa more than ballinger. I've almost never given them something they didn't have, and they're good with working off the Toyota part numbers or even just pictures. Superb customer service and knowledge base

 

[FZJ80 TN 93]

So are you guys just extracting the pins and putting them in a new connector? If so what tool are you using to extract the pins?

 

[Malleus]

Correct. I use the smallest (–) screwdriver from a generic "precision" set. The "correct" tool is illustrated in the wiring harness repair manual (in the Resources forum, 80 section).

You only need to replace the terminal if they are severely corroded or damaged so that they won't securely stay in contact with their mates. In this case, DO NOT buy the repair wire from Toyota. Buy the terminals from either Ballenger or Corsa. I encourage you to buy the terminal crimping tool, if you need to replace any terminals. The generic wire crimping tool you probably have won't do the job.

If you look up the connector housing on Ballenger's website, the page has a couple of tabs below the photo, and one of them lists the terminals for that connector housings, so you don't have to look them up. All the engine harness terminals are Type 2.3 II (buy 50 of each male/female; they're cheap).

 

[FZJ80 TN 93]

I've dealt with corsa more than ballinger. I've almost never given them something they didn't have, and they're good with working off the Toyota part numbers or even just pictures. Superb customer service and knowledge base

Looking at the Corsa website, you have to select the wire size for their connector kits. Did you pick the smallest size or the medium size?
Most of the wires measured between 1.5mm and 2mm on the outside but I’m not sure what gauge the actual wire is.

 

[FZJ80 TN 93]

I’ve seen so poor engineering in the past, this ranks right up there.

Hey how do you want to run the engine wiring harness.
Just run it through the middle of the intake manifold.
But won’t that make it a real pain to remove the intake since the intake blocks easy access to all the electrical connections.
Yeah but who cares we only have to make it work not repair it.

 

[Malleus]

You actually think that's worse than the bolts on the rear face of the head for the water bypass tube? You can solve that problem with a sawzall...those bolts are there for good.

 

[Malleus]

Looking at the Corsa website, you have to select the wire size for their connector kits. Did you pick the smallest size or the medium size?
Most of the wires measured between 1.5mm and 2mm on the outside but I’m not sure what gauge the actual wire is.

View attachment 4101455

Most of the wire in the engine harness is the millimeter equivalent of 20ga.

 

[FZJ80 TN 93]

So I run into a bit of a problem. When working on taking the engine wiring harness out of the car, the B1 connector on the drivers side appears to have been previously damaged or not properly connected because there was water corrosion on the pins.

The power source wiring document doesn’t appear to have validated part numbers. I couldn’t find any numbers on the connector. Does anyone have a correct part numbers. It looks like I’ll need both the male and female connectors. Thanks.