Making a New Engine Loom

Hi Folks,

I'm just in the process of an engine bay refresh ready to fit my 2.0 AAD lump. Whilst the current loom is functional and will do for now, I'd like to replace it with a new one. Does anyone make new looms to sell, or can anyone give me some pointers on making one myself?

Cheers,
Dave

I've never seen them for sale new anywhere

aye you'll get people to convert the loom to fit, some just do a piggy back loom which requires some work from you and others do fully integrated looms repairing any bad wiring as they go.

Ah well, looks like I'll have to have a crack at making a new one then. I assume all the connections are pretty generic electrical plugs?

It's all spade etc just re use the plastic plugs

fusebox pins are a bit special, but easily available. you need multimate type for the small ones, and mate-n-lok for the big ones. I get all my supplies from farnell:

163084-1 - multimate III - 0.75-1mm (2.01 - 2.49 insul.) 0.319 per 100
925661-1 - mate n lok 0.5-2mm (2.50 - 4.50 insul.) £0.249 per 100
350390-1 - mate n lok 2-6mm (2.54-4.57 insul) £0.22 per 100

if you have spare looms you can chop donor pins out with a sharp knife, but you may not even need any depending on your donor engine harness, for example carb looms have the pin in D/13 you need for fuel relay trigger on injection engines, but kjet 8v looms do not.

however, what management are you running this engine on? if its on the original kjet system then you could just get a replacement from a newer car which hasn't been bodged up, or at least use it as a template for repair. I have made kjet 8v looms from scratch before as there is next to nothing to it, just my waiting list is pretty long…

I'm still on K-Jet.

One from a breaker could be an option, main reason I want a new one is due to the corrosion on the terminals and within quite a few of the wires.

cool, theres not a lot to these kjet looms really.

You;ll have some standard 6.3mm latched spades plus the clippy plugs all use junior or power timer pins which are all dead easy to get from ebay or farnell.  You dont really have many pins on the fusebox for this, most of it is in the bay

Thanks Jonny, on further inspection I was quite surprised how little there is to the engine loom. However, the ancillaries loom is a right mess, worsened by what I assume is meant to be some kind of headlight upgrade loom.

Think I'll also strip out the alarm that is fitted, already do that once on this car when I previously owned it  

What thickness wire should I be using?

it depends what yo0u're wiring up, but if you look in my signature for g2krecuce1.pdf that covers all the basic kjet wiring and lists all the mm2 for each wire. obv ignore the isv control unit and ecu wiring, just look at the basic kjet stuff

Cheers John, I've printed that and g1wiring81gti.pdf