A gift for anyne planning a 1g wire tuck

[1990clipse]

Im in the process of building my 91 TSI and since I cant spend any money right now, I am trying to do all the inexpensive but time consuming tasks. I recently started on a wire tuck and fuse box relocation (to console). as I started taking apart the engine wiring harness I decided to make a wiring diagram so that anyone wanting to tackle this job can refer to it. This wiring diagram is a must for any fuse/relay box relocation on a 1g. There are two main harnesses in the engine bay, and as of right now I have only Diagrammed the one on the driver side. The passenger side harness will come soon I hope. I have not diagrammed A/C wires B/C i will not be using them sorry.

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[91-GS]

Thanks! Have been looking for something like that for a while.

 

[1990clipse]

Thats exactly why I decided to diagram this because i knew that I couldn't be the only guy looking for this.
Im glad someone will get use out of it.

 

[91-GS]

Are you going to do interior rewire as well?

 

[1990clipse]

idk yet, i have thought about it, but since you cant really see any of the interior wires I cant really find a good reason to mess with all that. I am doing this in order to make the cleanest engine bay I can, I plan on a seam sealer removal / bay shave as well. although Im not looking forward to filling all the holes left after the wire tuck.

 

[91-GS]

Good luck with that. Let me know how it turns out. I'm planning on doing something similar with the engine bay, but decided to work on the interior as well sice alot of stuff on the inside got removed/redone and it did not seem right to leave bunch of wires/plugs loose in there.

One thing i gotta say is that if you ar eworking with harnesses out of the car, you should get a peg board (like a piece of wooden panel with bunch of holes in it), few hooks for the board, and some velcro strips. That will make the task a bit easier since everything will be more or less organised and you can use the velcro strips to hold bunches of wires together and be able to easily undo the velcro to work on the wires.

Was also thinking about moving the ECU to the engine bay, but would have to build a water-tight box for it to keep crud out.

 

[1990clipse]

thanks for the tip, i will update as i go.

 

[GSLENK]

A wire tuck is a long way away for me, so thanks in advance. This should become handy in the future.

 

[codeofdastreets]

This is good to have,

 

[1990clipse]

So today I used the diagram I made to start running wires and see how much extra wire, mesh conduit and heat shrink im going to have to buy. I started at the interior harness connectors that attach to the fuse panel next to the driver door. I used the diagram to separate which wires go out the firewall (lights, sensors) and which go to my relocated engine bay fuse/relay box (relocated to the console).

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I cant take credit for the idea of putting the relay box in the console I actually found it from this thread. http://www.dsmtuners.com/forums/dsm...kend-warrior-tucked-everything-hta68-n20.html

 

[DaRKSiDeGSX]

I've always wanted to do a wire tuck and it seems the 1g ends up super clean after it's done. I just picked up a 90 fwd laser rst so I may be using your diagrams and a little inspiration to tackle this over the summer.

 

[91-GS]

With everything unnesessary removed, how many fuses and relays will the car need? Have been thinking about making a custom fuse block to go in the area above the glove box.

 

[1990clipse]

Actually, all the fuses and relays are still being used. The only thing I tossed was the a/c relay box on the driver side near the firewall. of course i got rid of about 50 Ibs of unnecessary wire, plastic wire loom, and electrical tape.

 

[9!'clipseDOHC]

Once you finish all your diagrams this would make a good tech article. It looks good so far!

 

[DaRKSiDeGSX]

50 lb. diet....the hard way! that's a nice chunk of weight there.

 

[11secDSM]

Nice work on the diagram. I did mine a while back and it's so much better now that I got rid of mitsus cluster fu@k of a wire harness.

Ps...50lbs is an exaggeration considering the harness itself weighs half that to begin with.

 

[1990clipse]

yes.... 50Ibs was an exaggeration. probably between 5 and 7Ibs.

 

[11secDSM]

I'm aware...just seems like a few people believed you.

 

[DaRKSiDeGSX]

I did. you never know.

 

[90awd4g63]

Awesome!!!! I've been trying to get mine done, but being military, married with children, deploying, and having to move 3 times in 6 years, my time is always prioritized elsewhere. I'll start on it then have to stop, then when I go back to it I forget where I left off and have to start all over.

The time you spent on compiling this info will GREATLY assist on me getting my car running again after 3 years!! If it don't, I'm getting rid of the car!!! I'm tired of dragging it around!!!