Ok so I got the engine harness out today (what a pita, gotta do a hose job again)

I'm going to redo all the wires. What kind of wire should I use, and what kind of insulation? I don't want to have to deal with brittle/cracking wiring harness woes evar again.

For the connectors, will radio shack sell any that will fit the pins on the ecu?

 

God bless you my man. i am going to have to doubt that you will accomplish this, but good luck. i have striped a few harnesses down to do haltech installs...damn i hate that part of the job!!

 

this is gonna be a major undertaking...process of elimination, ad nauseaum. I have a feeling the tricky part will be pushing out the connectors in the harness, and splitting off the wires at the correct lengths.

I probably should go all the way with a haltech install =P

this would also be a good time to steam clean the engine

 

Well, the problem is this. There are a number of different connectors. There are also a number of different colored wires.

The connectors may or may not be sourced. I was able to source some connectors to a company BUT the problem was that they only dealt w/ shops (and therefore needed a business license). This wasn't a problem since my friend owns a shop, BUT the other issue was that I needed to buy in bulk quantities (of at least 10 connectors for example) not individual quantities.

And just as I mentioned, there are different colored wires. Buying multiples spools of wire ended up being very costly. (Unless you decide to limit the number of colors and precisely label them for your own knowledge)

I'm still not sure if I want to tackle a project like this.

Good luck to you if you want to do it the "right way".

 

Buy a new harness and forget it. $476 from Mazdamotorsports

Jeff

 

Save the Hassel and buy a NEW OEM harness - Building a harnes from scratch is one BIG PAIN IN THE A**

 

Since you're like really into self-abuse, perhaps you should consider going a slightly less painful path…. Head for the nearest junk- yard and find every Mazda you can. If you’re lucky, you’ll find a wreck that has a fairly intact wiring harness you can buy. Point is, the plugs on Mazda wire harnesses are made by the same manufacturer and will increase your chances of getting the correct plugs. Plus, you’ll have plenty of scrape wire in the correct gauge for your cut & splice project!

For example, the 4-pin plug that plugs into the TPS (it’s gray and orange) was fractured on my original harness. I got the needed plug from a Mazda 626 harness…. Same plug! Worked like a charm…. As far as the brittle nature of your existing harness, I’d be willing to bet that the “Loom Coating” is what is cracking and brittle. Not the wires within; at least that was the condition mine. …. I have a 93 R-1, that clearly received attentions from the American Tourister Gorilla in it’s past. Point is, you can go to Pep Boys Auto or whatever and purchase the needed exterior looming material in various diameters. Buy some wrapping tape and you’re in business.

Another thing to consider, the plug configuration on the Mazda engine wiring harness is unique in that no two plugs are exactly the same…. Mazda did a pretty good job in making it idiot proof. Remember, even they (Mazda Corporate) were aware that dealership mechanics were going to service these cars. We all know how good those guys are!

 

well, what I mean by replacing the harness, im keeping the yellow and blue connectors, as well as the all the sensor/solenoid connectors. I will be replacing the wires only. Im going to push out the copper pins inside each connector and replace them with new ones. Or...that's what I want to do, at least.

Unfortunately, the wires themselves are brittle. The copper inside is not too flexible/kinda rusty, and if bent too much, they will snap.

"Since you're like really into self-abuse"

I think that's a given for all 3rd Gen owners

476 for a brand new one? Thats pretty cheap (relatively speaking). I was under the assumption that a brand new wiring harness was around $1,000

 

Brand new, $476. Join Mazdamotorsports, enjoy DEEP discounts.

Not worth a second thought IMHO.

Jeff