: Wire Harness Repair

07-16-11, 02:29 PM
I plan on taking off my PCM wire harness to troubleshoot the connections to the EBTCM (and the others for good measure). I plan to check for opens and repair with 18 AWG wire and butt splice connectors (weatherproof) and I'll also check for wire-to-wire shorts, repairing insulation with tape.

Is 18 AWG wire a good size to use? I got 18-20 AWG connectors. Those were the smallest they had at the auto parts store.

Anyone know what size wire the factory used? The connector wire looks like 18 but at the PCM it looks smaller. I'm hoping it's not smaller than 20.

I also got new red conduit. :yup:

I know I'll have to replace some connectors that are falling apart, I hope to utilize the local pull-a-part for those. I'll also clean off the grounds and use new star washers.

Anyone have any other tips that might be helpful in this?

07-16-11, 05:59 PM
Unfortunately, it all depends upon the application. I've got my steering column down at the moment and half of what I have is at least 14 awg. If I remember correctly, that's the blue connector, not the red. However, I seem to recall using the red 18-24 awg splice and butt conns. successfully with 14 ga wire in the past -- WAY in the past.

The only tips I can give you are to work slowly and carefully and to use heat-shrink tubing over the ends of all your splices. I usually go to Radio Shack for that -- unless someone has a line on less expensive stuff. When it comes to wiring, there is no room for error. If you're meticulous about not cutting any strands as you splice the wires -- hard to do unless you don't cut the insulation completely before starting your splice -- and you ensure a good crimp capturing all the wires, then seal it all with shrink tubing, you should be okay.

I wish you luck in your rather ambitious endeavour. Keep us posted on how things turn out.


07-16-11, 06:05 PM
One more thing.

Try to only work with one wire at a time when you cut things apart. It ensures you don't splice a hot wire to a ground.