Hi all, I just want to share my quick disconnect harness (in progress ).

I have 2 extra harness laying around for parts and decide to do a quick disconnect.
This is not a brand new harness with new wiring and new connectors etc., It's just a used harness mod it to be a quick disconnect, so I just cut wires that are bad and replace them with good wires from the same harness.

Currently, I have a wire tack in my car but is routed to the stock outlet (behind the battery) and is not a quick disconnect, that's without saying that I am running speed density now, so I don't need some connectors and I have added some other once for the fuel and IAT sensor, so I thought why not to do a quick disconnect while doing the swap and update everything.

Well, I started this a couple of days ago and the engine side is almost don, I still have to do the inside and get that famous connector to get it don,

The quick disconnect will be placed on the firewall, on one side where the shift cables comes from (towards to the driver side), the Injector resistor, Transistor and capacitor (Noise Condenser) will be installed inside the car.

Here are some pics of the progress, hope you enjoy it.

EDIT

Sorry guys, I couldn't upload any pics, there was an error everytime I try.
I will post some pics once the system let me upload them.

I got it.













Pics where to big, that's why I was having problems to upload them, I resized them and it solves the problem.

cool how much for one of this??

Really nice work, bud. Looks perfect. Im dreading doing mine but its one less thing to worry about. That harness you have there will hold up for 200k miles.

Very cool!! Where did you get the wire loom?

99bluegst said:

cool how much for one of this??

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Seriously, I don't know how much this thing would be worth, which is the stock harness and connectors,..

I don't do things to sell them, I just do it for my DD, I don't have to much experience on making things to sell, Well for me the hard part would be to set the price and not to make the product.

However, I'm off for a month and could do some of this, But it is not really what I am looking for, If I do this, then I will have no time to spend on my DD.

New wires and new connectors would be adeal specially the once from the engine bay, but is theeeeem hard to find some of this connectors and pins to make a complete harness from scratch.

boost97gst said:

Really nice work, bud. Looks perfect. Im dreading doing mine but its one less thing to worry about. That harness you have there will hold up for 200k miles.

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Thanks bud, For sure it will hold.

The harness I currently have in my DD is almost the same, But it is not as good as this one, I am afraid to touch the harness because it will come apart.
I have to be so careful when working on it, because the wire loom will come off and everything will be a mess.

Compared to this one, this is bullet proof, I have done some test and try to move the wire loom and stretch every single part and It doesn't give.

I never thought it was going to come out this good.
I'm really happy the way it came up.

dsmcrzy said:

Very cool!! Where did you get the wire loom?

Click to expand...

I got it from an electronic store (FRY'S), I don't know how much heat it can resist, But the one I have in my DD is the same material and I have had it for 2 years now.
The loom is holding on the heat and it haven't change at all, it still looks and feels as the fist time I install it..

I cover my vacuum hose for the external wastegate with this loom and it did melt, But we all know that's a really hot area,...

I have no doubt why this new will not hold which is the same material that I'm running now but better design.

Nice work, I sorta did that once but not that loom ill be doing another in the future some things are actually mounted inside the car.

That is a nice looking harness. You might want to back the heatshrink a little further away from the connectors. When you pinch the wires together close to the connector, it can pull on the rubber wire seal inside the connector, and allow a path for moisture to get into the connector.

miguelmcv said:

New wires and new connectors would be adeal specially the once from the engine bay, but is theeeeem hard to find some of this connectors and pins to make a complete harness from scratch.

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Which connectors and pins are you having a hard time finding?

miguelmcv said:

I got it from an electronic store (FRY'S), I don't know how much heat it can resist, But the one I have in my DD is the same material and I have had it for 2 years now.

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Waytek wire sells automotive temp rated sheathing like that. I use stuff that is high temp and coated so that it is solid. Dirt can work into the open loom like you used, and be like sandpaper on the wires.

brads said:

That is a nice looking harness. You might want to back the heatshrink a little further away from the connectors. When you pinch the wires together close to the connector, it can pull on the rubber wire seal inside the connector, and allow a path for moisture to get into the connector.

Which connectors and pins are you having a hard time finding?

Waytek wire sells automotive temp rated sheathing like that. I use stuff that is high temp and coated so that it is solid. Dirt can work into the open loom like you used, and be like sandpaper on the wires.

Click to expand...

Thanks for the suggestion, You are right., I will keep that in mind next time I do another one and get it sealed up 100%.

I didn't search a lot for the connectors, but I checked here and there are only some of them,.
Here is where I looked.
http://www.dsmtuners.com/forums/electrical-tech/422985-brand-new-oem-connectors-pins.html

If you know any source for the connectors and pins, please elaborate adding the link to the thread for the community.
Part Numbers will be nice as well.



Well, I start doing the interior wiring (ECU), I removed (depin) all the wires I'm not using to have a clean look.

Here are some pics of the process..

Man that looks good !


Eventually I'd like to do this , get all new wires and connectors

miguelmcv said:

Thanks for the suggestion, You are right., I will keep that in mind next time I do another one and get it sealed up 100%.

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Glad to help. Waytek also is a great source for parts like harness mounting clips, etc.

miguelmcv said:

I didn't search a lot for the connectors, but I checked here and there are only some of them,.
Here is where I looked.
http://www.dsmtuners.com/forums/electrical-tech/422985-brand-new-oem-connectors-pins.html

If you know any source for the connectors and pins, please elaborate adding the link to the thread for the community.
Part Numbers will be nice as well.

Click to expand...

Let me know which ones you specifically are looking for. Unfortunately, that DSMTuners thread links to a supplier that doesn't carry many of the Mitsu or Kum brand connectors. And many of the underhood connectors are that.

The problem with those connector brands is that they have poor distributorship in the US, and you have to buy parts in bulk pack(costing a few grand or more) from Asia.

I told the moderator that there is a source that actually imports and stocks some of the Mitsu or Kum parts in small quantities specifically for us DSMers, hopefully at some point he will correct the page to indicate that.

Harness looks great. I know I have been asked a lot over the years to build these and after doing I a few I quitt. Its just way too much work and for the amount it would cost its hard to find people who understand the dedication and also have the means to fund it.

Keep up the good work.

brads said:

Glad to help. Waytek also is a great source for parts like harness mounting clips, etc.



Let me know which ones you specifically are looking for. Unfortunately, that DSMTuners thread links to a supplier that doesn't carry many of the Mitsu or Kum brand connectors. And many of the underhood connectors are that.

The problem with those connector brands is that they have poor distributorship in the US, and you have to buy parts in bulk pack(costing a few grand or more) from Asia.

I told the moderator that there is a source that actually imports and stocks some of the Mitsu or Kum parts in small quantities specifically for us DSMers, hopefully at some point he will correct the page to indicate that.

Click to expand...

I would like to find the Throttle position sensor, Speed sensor and temperature sensor connectors with pins,.

I have found so many that looks alike but when looking for the pins for the connector, they come in different pin diameters, they all looks the same but some are wider then others, that's where I get lost, also I couldn't see the insulation where the pin connects to the wires.

TSimage said:

Harness looks great. I know I have been asked a lot over the years to build these and after doing I a few I quitt. Its just way too much work and for the amount it would cost its hard to find people who understand the dedication and also have the means to fund it.

Keep up the good work.

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Thanks bud,.

You are right, it takes forever and is to much time.

Some people think it's a cake, but it does takes a lot of time, patience and care full.

After every wiring is finished, it needs to be tested before going to any car to make sure everything is all good.

If the wiring is messed up, the ECU will become garbage right away, and this is what people doesn't understand.

If the wiring is bad, they blame on you (off course), but at the same time, they don't want to pay to much money for the wiring ether, They think you can test the harness in a couple of minutes, But it does takes times to do that,. That's why some times it just doesn't worth it.

miguelmcv said:

If the wiring is bad, they blame on you (off course), but at the same time, they don't want to pay to much money for the wiring ether, They think you can test the harness in a couple of minutes, But it does takes times to do that,. That's why some times it just doesn't worth it.

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This is a real problem a lot of people don't get. It is a lot of effort to build one right. And the guys that don't do it right, but sell it cheap wind up making it tough to price a good harness at the price it should go for. I saw that all the time at work when I was sourcing automotive harness designs for the aftermarket, as well as OEMs.

Which engine coolant temp connector are you looking for? Mouser sells the 2 pin one that is on the 2G. The single wire connector, I am still looking for as well. If you are talking about the 2G TPS and VSS, they are both made by Mitsubishi, and are the ones normally only available in bulk.

I think I saw a source for buying them in small quantities posted recently. But maybe it was a link posted on the ECMTuning forum, or maybe it was NABR.

brads said:

This is a real problem a lot of people don't get. It is a lot of effort to build one right. And the guys that don't do it right, but sell it cheap wind up making it tough to price a good harness at the price it should go for. I saw that all the time at work when I was sourcing automotive harness designs for the aftermarket, as well as OEMs.

Which engine coolant temp connector are you looking for? Mouser sells the 2 pin one that is on the 2G. The single wire connector, I am still looking for as well. If you are talking about the 2G TPS and VSS, they are both made by Mitsubishi, and are the ones normally only available in bulk.

I think I saw a source for buying them in small quantities posted recently. But maybe it was a link posted on the ECMTuning forum, or maybe it was NABR.

Click to expand...

The 2 pin one on the 2g,.
I will look for it and will save the part number including for the pins, I will start buying them and keep all the information I can to post them here for future reference, However, it will take some time for my next project with all new, (connectors, pins, insulation and wires).



Here is a pic of the progress, well it doesn't looks like much, but It did took me some time for this port.

miguelmcv said:

The 2 pin one on the 2g,.
I will look for it and will save the part number including for the pins, I will start buying them and keep all the information I can to post them here for future reference, However, it will take some time for my next project with all new, (connectors, pins, insulation and wires

Click to expand...

The part numbers for the 2 pin(made by Tyco) one are:

plastic housing: 184006-1
terminal: 184030-3
wire seal: 184140-1

these parts are all available through Mouser.com.

brads said:

The part numbers for the 2 pin(made by Tyco) one are:

plastic housing: 184006-1
terminal: 184030-3
wire seal: 184140-1

these parts are all available through Mouser.com.

Click to expand...

Thanks bud,

I did see the part in that site, looks like they sell all separate,.,

I googled the part numbers and I found another site where they sell everything as a package, (Housing, pins and seals), it's cheaper then the site you mentioned.

I just found 3 plugs, Termperature, Injector and Alternator and they all comes as a package with the pins and seals.

Check it out.

Temperature.
http://www.corsa-technic.com/item.php?item_id=418&category_id=92

Injector.
http://www.corsa-technic.com/item.php?item_id=347&category_id=52

Alternator.
http://www.corsa-technic.com/item.php?item_id=444&category_id=55

I will keep looking and save it for tomorrow.

I'd LOVE to find all new pins. I want to completely remake my harness one of these days (milspec, wrapped in Raychem DR-25).

Miguel, if you are doing a cannon plug on the fire wall, they can be bought on Mouser. The expensive part is the crimper for the pins.

miguelmcv said:

Thanks bud,

I did see the part in that site, looks like they sell all separate,.,

I googled the part numbers and I found another site where they sell everything as a package, (Housing, pins and seals), it's cheaper then the site you mentioned.

I just found 3 plugs, Termperature, Injector and Alternator and they all comes as a package with the pins and seals.

Check it out.

Temperature.
2-Way Receptacle Kit

Injector.
2-Way Receptacle Kit

Alternator.
4-Way Receptacle Kit

Click to expand...

Nice find. Double check your math though, the Mouser site is still cheaper. Mouser is part of a major distributor of connectors/terminals etc for the big companies. Most of the smaller shops get their connectors from places like Mouser. Corsa didn't mark it up much though, so it'd be worth it to get it from them, if you were getting the other connectors too.

Is the injector connector the exact same part as what is on the later 2G? If so, that is a great find. Make sure it is though, there are a lot of injector connectors that look very similar but don't fit quite right.

Blurred Talon said:

I'd LOVE to find all new pins. I want to completely remake my harness one of these days (milspec, wrapped in Raychem DR-25).

Click to expand...

For the age of these cars, if you are doing pins, you might as well also replace the plastic connector too. They only last so long before they start becoming brittle from age/heat.

I am just wondering what people will do once the connectors that are molded into the sensors start breaking from age.

Blurred Talon said:

Miguel, if you are doing a cannon plug on the fire wall, they can be bought on Mouser. The expensive part is the crimper for the pins.

Click to expand...

I did found the cannon connector, But I got lost on the sheet,.

I couldn't find a 47-50 pin cannon connector and I wouldn't like to use 2 connectors to do the job.

I went with a different brand (cheap as well), I really don't care much about the material which this wirings is just to see who it comes up, If I like the way it looks, then I will do another harness from scratch with new connectors and a better quick plug connector.

Thank you for the suggestion, but if you find a 47-50 pin cannon plug, please post the link or part number here for future reference, including the pins please.

brads said:

Nice find. Double check your math though, the Mouser site is still cheaper. Mouser is part of a major distributor of connectors/terminals etc for the big companies. Most of the smaller shops get their connectors from places like Mouser. Corsa didn't mark it up much though, so it'd be worth it to get it from them, if you were getting the other connectors too.

Is the injector connector the exact same part as what is on the later 2G? If so, that is a great find. Make sure it is though, there are a lot of injector connectors that look very similar but don't fit quite right.

Click to expand...

I will try to get all of them from Mouser, The site posted above is cheap, 2ish for the housing, pin and insulation is not bad, even the injector connectors aren't pricy, for that price I can buy only one and fit test it, to make sure I'm getting the right one.

for the injector plug, it is the later 2g's, I will get one of them to fit test it, but it will be later, after I finish this project though.

Great job! Harness looks amazing.

miguelmcv said:

for the injector plug, it is the later 2g's, I will get one of them to fit test it, but it will be later, after I finish this project though.

Click to expand...

Looking at the later 2G injector connector:

http://www.dsmtuners.com/forums/151528340-post3.html

The one you posted is definitely not the exact same connector. It MIGHT fit. But look at the corners, the one you linked to looks like it fits an injector that is more rounded at the corners. And the keying slot at the bottom is slightly offset to one side, where the mitsu one is centered.

The alternator connector looks like the right one though.

There is another place that has the later style squeeze release injector plugs, spoolinup.com. These aren't exactly the OEM connector, but are close enough.

There is a source for the exact connectors on the 1G and early 2G, with the wire clip. They also have the TPS and VSS connector. It's been posted on here before, but you could probably find it easier on DSMLink website. Maybe even the DSM Canada website.

I found these 47 pin Delphi connectors. looks like it would take a while to get them though.....

Delphi Connection Systems Harsh Environment Series Automotive Connectors | Mouser

.......and the min order is quantities of 37 . I will see if I can find them else where.

brads said:

Looking at the later 2G injector connector:

http://www.dsmtuners.com/forums/151528340-post3.html

The one you posted is definitely not the exact same connector. It MIGHT fit. But look at the corners, the one you linked to looks like it fits an injector that is more rounded at the corners. And the keying slot at the bottom is slightly offset to one side, where the mitsu one is centered.

The alternator connector looks like the right one though.

There is another place that has the later style squeeze release injector plugs, spoolinup.com. These aren't exactly the OEM connector, but are close enough.

There is a source for the exact connectors on the 1G and early 2G, with the wire clip. They also have the TPS and VSS connector. It's been posted on here before, but you could probably find it easier on DSMLink website. Maybe even the DSM Canada website.

Click to expand...

You are right, it does looks alike but might not work.

I will look into spoolinup.com later on when I get a free space and look for the plugs, see if I can find them.

dsmcrzy said:

I found these 47 pin Delphi connectors. looks like it would take a while to get them though.....

Delphi Connection Systems Harsh Environment Series Automotive Connectors | Mouser

.......and the min order is quantities of 37 . I will see if I can find them else where.

Click to expand...

I found this one and ordered them, I ordered the male and female with pins for both ends.

Search: 38803

Total was not even $100, so I am good with that for now.

I might consider the MILSPEC connector when doing a complete harness from scratch with everything new.

brads said:

For the age of these cars, if you are doing pins, you might as well also replace the plastic connector too. They only last so long before they start becoming brittle from age/heat.

I am just wondering what people will do once the connectors that are molded into the sensors start breaking from age.

Click to expand...

Next time around I will be replacing all the connectors.
Most of the sensors can be replaced too.

miguelmcv said:

I did found the cannon connector, But I got lost on the sheet,.

I couldn't find a 47-50 pin cannon connector and I wouldn't like to use 2 connectors to do the job.

I went with a different brand (cheap as well), I really don't care much about the material which this wirings is just to see who it comes up, If I like the way it looks, then I will do another harness from scratch with new connectors and a better quick plug connector.

Thank you for the suggestion, but if you find a 47-50 pin cannon plug, please post the link or part number here for future reference, including the pins please.

Click to expand...

My connector is a 57 pin IIRC, I used no where close to that many. I'll get the part number off it later on. I know Mouser sells them.

Blurred Talon said:

Next time around I will be replacing all the connectors.
Most of the sensors can be replaced too.



My connector is a 57 pin IIRC, I used no where close to that many. I'll get the part number off it later on. I know Mouser sells them.

Click to expand...

I removed a lot of sensors (emission and MAF), I have only 48 wires, a 47 pin connector will not work in my set up.

A 57 pin connector sounds huge, that's more for a Stock components, But who knows, we just keep adding things and looks like it never ends.

Update

I almost finish the inside wiring, I just need to split the connection for the fuse box and another connection that will run on the passenger side for the wipers, factory alarm horn and transmission (reverse signal) and that's it,.

I am using an automatic ecu bracket to mount the injector resistor and transistor.

Hopefully at the time I finish the split connections, the quick plug gets here to finish all up.

However, I will update the thread later on.

Pics of the almost done project.










By the way, Have all of you a HAPPY CHRISTMAS