This is also posted in the GXOR FB group. I'll link this over to the Non-Nav Conversion thread as well. Still trying to figure out how to link the circuit board files here, but they're available on the GXOR FB page under the files section.
Hopefully, this guide will help to create a simple and very reliable wiring extension that does not involve any cutting, soldering (save for the circuit board plug connections) or permanent modifications to your factory harness.
2. Materials Needed to purchase/make
3. Tools Required/Making Life Easier
Wire cutter/ stripper – Must go down to 22 AWG – There is a nice set for small wires at Home Depot (Milwaukee) that are now my favorite pair.
Milwaukee 9 in. Multi-Purpose Cutting Pliers 48-22-6579 - The Home Depot - https://www.homedepot.com/p/Milwaukee-9-in-Multi-Purpose-Cutting-Pliers-48-22-6579/305761219
Open Barrel Contact Crimper – Used Engineer PA-09 for making these contacts.
Amazon.com - https://www.amazon.com/ENGINEER-AWG32-AWG20-Connectors-Oil-Resistant-PA-09/dp/B002AVVO7K?th=1
NOTE: I tried simply using a set of needle nose to make these crimps at first, but the wings are tiny and difficult to form properly. Get the tool. You are going to do 164 crimping operations. Additionally, you will mess up a crimp and it will be difficult to slide into the tiny hole on the connector. If this happens, you will want a good crimp in there so you can pull it back out. There is nothing more frustrating than having to buy new connectors, wait for shipping, strip wires, and start over because a pin got stuck in the connector.
4. Circuit Board Instructions
LINK TO PRINT CIRCUIT BOARD AND 3D PRINT COVER FILES
ih8mud Print Circuit Board and 3d Print Cover files - Google Drive - https://drive.google.com/drive/folders/1MTF468ickoIJjCU480zG5E8sXfW-gZGT?usp=sharing
4.1 Print Circuit Board
Go to PCBway.com (or similar)
Online Gerber Viewer - PCB Prototype the Easy Way - PCBWay - https://www.pcbway.com/project/OnlineGerberViewer.html
Upload LEXUS_EXTENDER_GERBERS.ZIP
Get a quote/order (use all the standard options)
It should be ~$25 for 5 (5 is the minimum order), most of this is $20 in shipping
4.2 Circuit Board Soldering
Attach the 80 pin connector to the PCB with one on top and one on the backside.
Secure the connector to the board with screws (I believe they are M2 or M3)
Put on your glasses or magnifier.
Solder each pin to the board (I recommend a fine-tipped soldering iron)
Check for bridging/ cold joints/ missed pins
5. 3D Printed Electrical Covers
Slice and print two of the STL files in your favorite insulating material that can withstand your under-dash environment. Remember that your heater blows in this area and it may get quite warm. If you don’t have a printer don’t worry! I am sure you have a friend with one, or choose some other insulation method!
The finished product should be two covers that look like the image below
6. Wiring Harness Instructions
When crimping on the ferrules- one pair of tabs holds the insulation, and one pair is for the conductor. You may have to trim the conductor to get it to fit. The crimper should do a nice job of rolling the wings into the center of the wire strands. Check for strength of connection on each. (Give it a light pull to make sure it does not slide off).
I recommend doing the first few and putting them in the connector to make sure that your technique is correct. They should slide in, click, and not be able to pull out. (!WARNING! I haven’t found a tool or method to remove the wires that does not involve the destruction of the plastic connector. Make sure you’ve got the right connector! )
6.1 Insert the wires into the connector pairs
It is imperative that the wires go from and to the same location in the connector pairs. It’s an extender so it's not complicated, but it is tedious. I like to do this by holding the pair side-by-side and doing one wire at a time. L-R, Top-bottom.
Before inserting any wires into the connector, the “keeper” must be raised up to allow insertion. Raise the “keeper” by lifting up through the openings in the side of the connector. The keeper is typically raised on new plugs.
Check connector and ferrule are correct (see table)
Push the assembled wire in until it clicks.
Pull gently to make sure it is captive.
Repeat with the other end of the wire assembly.
Proceed one at a time to avoid miswiring
Once completed, push the “keeper” back into position to secure all the terminations
6.2 Cigarette adapter wiring
The illumination comes from the power-ground pair supplying the cigarette lighter bulb. We simply splice in the two wire connectors here to avoid cutting the factory harness.
Hopefully, this guide will help to create a simple and very reliable wiring extension that does not involve any cutting, soldering (save for the circuit board plug connections) or permanent modifications to your factory harness.
1. Disclaimer
I am providing this guide to assist others and for others to improve upon this design. It has not been widely tested, but it has been tested in 1 vehicle (at the time of writing) and works well. I am not an electrical engineer, nor am I certifying that this guide will provide you with a perfectly safe, problem-free article. I haven’t done a circuit board before this project. I think most people realize that this is a guide from a stranger downloaded from the internet. Treat it as an output of my hobby and use it at your own risk. I am not responsible for the design, content, safety, or your ability to wire or install this item.2. Materials Needed to purchase/make
| Item | Qty | MFG PN# | Purchase from |
| Circuit Board | 1 | See Gerber Files | PCBWAY etc. |
| 80 Pin Board Connector | 2 | TYCO -1318751-7 | Mouser |
| 30 Pin Connector | 2 | TYCO -1318758-1 | Mouser |
| 26 Pin Connector | 2 | TYCO - 1746863-1 | Mouser |
| 24 Pin Connector | 2 | TYCO -1746864-1 | Mouser |
| 2 Pin Connector (M) | 1 | YAZAKI 7283102030 | Mouser |
| 2 Pin Connector (F) | 1 | YAZAKI 7283102030 | Mouser |
| Power Pin | 30 | YAZAKI - 71164020 | Mouser |
| Signal Pin | 100 | TYCO - 1123343-1 | Mouser |
| Other Signal Pin | TYCO – 1674311-7 | Digikey | |
| Power connector, Cig Lighter | 2 | YAZAKI - 71144020 | Mouser |
| Wire, 24 AWG, PVC | 320’ | ATLAS AWM24GN10 | Automation Direct |
| 3D Print Cover | 2 | Su CASA | Su CASA |
3. Tools Required/Making Life Easier
Wire cutter/ stripper – Must go down to 22 AWG – There is a nice set for small wires at Home Depot (Milwaukee) that are now my favorite pair.
Milwaukee 9 in. Multi-Purpose Cutting Pliers 48-22-6579 - The Home Depot - https://www.homedepot.com/p/Milwaukee-9-in-Multi-Purpose-Cutting-Pliers-48-22-6579/305761219
Open Barrel Contact Crimper – Used Engineer PA-09 for making these contacts.
Amazon.com - https://www.amazon.com/ENGINEER-AWG32-AWG20-Connectors-Oil-Resistant-PA-09/dp/B002AVVO7K?th=1
NOTE: I tried simply using a set of needle nose to make these crimps at first, but the wings are tiny and difficult to form properly. Get the tool. You are going to do 164 crimping operations. Additionally, you will mess up a crimp and it will be difficult to slide into the tiny hole on the connector. If this happens, you will want a good crimp in there so you can pull it back out. There is nothing more frustrating than having to buy new connectors, wait for shipping, strip wires, and start over because a pin got stuck in the connector.
4. Circuit Board Instructions
LINK TO PRINT CIRCUIT BOARD AND 3D PRINT COVER FILES
ih8mud Print Circuit Board and 3d Print Cover files - Google Drive - https://drive.google.com/drive/folders/1MTF468ickoIJjCU480zG5E8sXfW-gZGT?usp=sharing
4.1 Print Circuit Board
Go to PCBway.com (or similar)
Online Gerber Viewer - PCB Prototype the Easy Way - PCBWay - https://www.pcbway.com/project/OnlineGerberViewer.html
Upload LEXUS_EXTENDER_GERBERS.ZIP
Get a quote/order (use all the standard options)
It should be ~$25 for 5 (5 is the minimum order), most of this is $20 in shipping
4.2 Circuit Board Soldering
Attach the 80 pin connector to the PCB with one on top and one on the backside.
Secure the connector to the board with screws (I believe they are M2 or M3)
Put on your glasses or magnifier.
Solder each pin to the board (I recommend a fine-tipped soldering iron)
Check for bridging/ cold joints/ missed pins
5. 3D Printed Electrical Covers
Slice and print two of the STL files in your favorite insulating material that can withstand your under-dash environment. Remember that your heater blows in this area and it may get quite warm. If you don’t have a printer don’t worry! I am sure you have a friend with one, or choose some other insulation method!
The finished product should be two covers that look like the image below
6. Wiring Harness Instructions
Cut 80 wires into 4-foot lengths (can shorten if you want from the other writeups, but I wanted to ensure the wires would reach and allow plenty of room
Strip Both ends of the wires back ¼”
Crimp on connectors to both ends of wire, according to the table.
KEEP THE SIGNAL WIRES SEPARATED AND IDENTIFIED. They look nearly identical but do not go into the connectors the same. Trying to insert the wrong signal ferrule into the wrong connector will be a problem. You can insert it with force but it won’t make a connection.When crimping on the ferrules- one pair of tabs holds the insulation, and one pair is for the conductor. You may have to trim the conductor to get it to fit. The crimper should do a nice job of rolling the wings into the center of the wire strands. Check for strength of connection on each. (Give it a light pull to make sure it does not slide off).
I recommend doing the first few and putting them in the connector to make sure that your technique is correct. They should slide in, click, and not be able to pull out. (!WARNING! I haven’t found a tool or method to remove the wires that does not involve the destruction of the plastic connector. Make sure you’ve got the right connector! )
| 71164020 Power | 1123343-1 Signal | 1674311-7 Signal | 71144020 Power | ||
| TYCO -1318758-1 | 2 | 28 | |||
| TYCO - 1746863-1 | 6 | 20 | |||
| TYCO -1746864-1 | 4 | 20 | |||
| YAZAKI 7283102030 | 2 | ||||
| YAZAKI 7283102030 | 2 | ||||
Wire Assemblies to make | 14 | 28 | 40 | See Inst | |
Totals x 2 | 28 | 56 | 80 | 2 |
6.1 Insert the wires into the connector pairs
It is imperative that the wires go from and to the same location in the connector pairs. It’s an extender so it's not complicated, but it is tedious. I like to do this by holding the pair side-by-side and doing one wire at a time. L-R, Top-bottom.
Before inserting any wires into the connector, the “keeper” must be raised up to allow insertion. Raise the “keeper” by lifting up through the openings in the side of the connector. The keeper is typically raised on new plugs.
Check connector and ferrule are correct (see table)
Push the assembled wire in until it clicks.
Pull gently to make sure it is captive.
Repeat with the other end of the wire assembly.
Proceed one at a time to avoid miswiring
Once completed, push the “keeper” back into position to secure all the terminations
6.2 Cigarette adapter wiring
The illumination comes from the power-ground pair supplying the cigarette lighter bulb. We simply splice in the two wire connectors here to avoid cutting the factory harness.
- Cut the two wires (I know you just made them) approximately 18” back from the connectors you plan to use in the center dash. Keep the 18” end and remove the long end (the ends that will come from the kick panel)
- Cut and strip two 8” wires. We are going to splice the wires together within the crimp ferrule (to avoid soldering). Join the ends of one of the 8” pieces with one of the 18” wires and crimp them into one of the 71144020 ferrules. Repeat for the other 8” and 18” wire pair.
- Crimp 71164020 onto the remaining end of the 8” wire
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if I see more than 2 wires my mind explodes just a mechanical engineer no sparky lol
