FAQ Engine Wiring Harness Information 8/1992-12/1994 FZJ80: 82121-60340/1/2 (4 Viewers)

[Broski]

Happy that I was just able to purchase a low mile ( less than 30k miles ) OEM 94 year model harness that was installed just a few years back from another member.
Mines not having any issues, so it just goes into my parts stash.
And he had rapped it in heat shield where it passed by the PVC tube before he installed it. Basically like new

 

[milskeymalone]

Damn. This thread died. I thought I hit the jackpot finding a Beno thread to the very thing I’m about to start. Any updates? Where did you source wire?

 

[OGBeno]

Damn. This thread died. I thought I hit the jackpot finding a Beno thread to the very thing I’m about to start. Any updates? Where did you source wire?

What do you want to know?

The harness came out great. We only reused 4 connectors total.

We used factory wire supplier Yazaki for the whole rebuild. They sell wire in large bundles. But it’s all out of Japan and one has to do the translational legwork to get it all jimmey’ed correctly.

Toyota service parts splices (82998-Xxxxx) are Yazaki as well and we utilized a lot of these PNs for the rebuild.

Injector splices are gold plated internally and ergo expensive as fűck.

Everything was soldered, wire-by-wire. Every wire was inspected from end-to-end.

I believe we had about 55 man hrs into the harness rebuild: not including removal, cleaning, disassembly, and research hours for ordering parts, etc.

 

[milskeymalone]

What do you want to know?

The harness came out great. We only reused 4 connectors total.

We used factory wire supplier Yazaki for the whole rebuild. They sell wire in large bundles. But it’s all out of Japan and one has to do the translational legwork to get it all jimmey’ed correctly.

Toyota service parts splices (82998-Xxxxx) are Yazaki as well and we utilized a lot of these PNs for the rebuild.

Injector splices are gold plated internally and ergo expensive as fűck.

Everything was soldered, wire-by-wire. Every wire was inspected from end-to-end.

I believe we had about 55 man hrs into the harness rebuild: not including removal, cleaning, disassembly, and research hours for ordering parts, etc.

Sounds like a lot of work. But I’m ok with that. No time pressure for me. So I’m looking at the Wire harness repair manual and I can see on the table where it shows terminals and repair wire part number amongst other info. Maybe I’m misunderstanding but did you splice in all new connectors with the 160mm long repair wire or just in some areas of the harness? Did you have to phone in your order to Yazaki?

 

[milskeymalone]

@OGBeno i PM'd you a few questions if you have the time.

 

[MileHigh80Guy]

View attachment 3513398

 

[MileHigh80Guy]

Anyone know what this guy is? Hard plastic line, looked through the part diagrams and could not ID it.

Mine was plugged with screw from the PO. Trying to get this back to normal.

 

[ZackR]

View attachment 3860661

Anyone know what this guy is? Hard plastic line, looked through the part diagrams and could not ID it.

Mine was plugged with screw from the PO. Trying to get this back to normal.

The windshield washer hoses connect to this

 

[MileHigh80Guy]

The windshield washer hoses connect to this

Awesome, I saw the lines going to the washers, so I immediately ruled that out. But this diagram tells a different story.

Oooof, more and more surprises...

TJANKS!!!