My Wire Tuck and Engine Bay Clean Up Part 1

[Blurred Talon]

, Pat!
I'm taking my sweet ass time with this and still have many many more things to order. Don't forget I'm adding many new systems into the harness too plus I want to do it all right the first time. Any wire that I lengthen I'm going to try and get of a matching color. Any new wire will be mil-spec, new connectors will be Deustsch.

 

[Blurred Talon]

More updates, I've been slowly working on the harness over the past couple of days, I should have everything I want removed from all 3 harnesses (fuse box, engine and dash) by the end of this weekend.
From there I can plan out everything else, I want to have all my aftermarket accessories in the fuse box so I don't need the accessory fuse box anymore. I also need to figure out where to mount all the S2000 cluster stuff, I've got some ideas for that.

Anyhow, here's updates.
First, here's the wiring note book. I'm documenting everything.

Here's all the ABS junk, I can't believe how much wiring there was for it. One nice thing is it was all ran separate from the rest of the harness for the most part so it was pretty quick and easy to remove.

All the wiring that's been pulled so far.

Here's what I've pulled so far:
ABS
Fuel Pressure Solenoid
EGR Solenoid
Brake Level Switch
Theft Alarm Horn
EVAP Solenoid
Fuel Pump Check Connector
MAF Connector (let the IAT wires)
Ignition Timing Check Connector
O2 Sensors

What's left?
A/C
Cruise Control
Fog Lights
Oil Pressure Gauge
Hood Switch
ISC Motor
EGR Motor

Here's the fuse box so far. I've removed some of the relays (want to figure out how to get those to work for aftermarket stuff if possible), fusible links and fuses. Most of this stuff will be reused.

 

[92AWDHX40]

sounds good milspec and deustsch, doing a wire tuck on awd when i get it, it looks clean you get rid of a lot of things you dont need

 

[Boostinsideways]

My firewall hole is 3.5" Inches tall by 2.5" Inches wide.

 

[Blurred Talon]

Thanks man. I'll have to see what I can find to plug that. I don't think the AC one will fit.
EDIT: Confirmed, it won't fit

 

[tkstoygsx]

you def got your work cut out for you but it should be pretty sweet when finished... Good luck and nice work so far

 

[dadnkid]

Man... wish i had the patience to do this

 

[Blurred Talon]

Thanks guys.
Engine harness is pretty much done, fuse box harness is done, next is the dash.

 

[Blurred Talon]

I've finally finished both engine and fuse box harnesses. Now, my tuck/rewire is a little different from other peoples. I pulled my Alternator plug out because I'll be doing the Saturn Alternator swap (and relocation) using the self exciting regulator that Motorcity Reman offers for the DSMs, this is a 1 wire hook up so I won't need any of the stock wiring. I've lost the battery light by doing this but I've got a volts gauge so it's not a big deal for me.
I'm also installing a Davies Craig Electric Water Pump (EWP115) and fan controller so all my OEM relays for the fans and the wiring has been removed.

Here's a comparison of how little wire is left after all this is remove. Bottom is the fuse box side of the plug, top is the engine harness side.

Chassis harness done (for now).

Amount of wire removed! (still need to do the dash harness)

Dash flipped over and ready to be taken apart. You see why I want to redo the dash harness, it looks HORRIBLE!

Now I know what plug (plugs) I will be using on the fuse box itself so I will get those ordered up then I can crimp them on and mount the fuse box plus figure out how secure the air bag door back on (I think dzus fasteners are the ticket). I've also got a lot of planning left to do for all the other things I want to incorporate into the fuse box.

 

[92AWDHX40]

Looking good.

 

[Blurred Talon]

Dash harness is out and all the tape is off for the most part (I left the dash speakers alone for now). I wanted to do more but I haven't slept much the past couple of days so I did some of that early and I'm doing more after I post this.

Here's the dash harness out, you can see the piece of lexan I mounted all the stuff for the S2000 cluster on. I HATE this now so it had to go. All the S2000 cluster converter as going to be behind the dash bezel now so when I need to access it, I pop the bezel out and bam it's there. There's also a lot of wiring for gauges, shift light blah blah blah, that's all going.

Most of the excess wiring removed.

Electrical tape removed.

Close up of the S2000 cluster wiring, like I said I'll be redoing things. I'm not happy with it one bit.

Fog light wiring and cruise wiring will be removed tomorrow plus I'm gonna see if I can get my hands on the block off plates for where the switches use to be. I'm also starting to work on my HID retro again and my LED lighting conversions (all lights on the car will be LED).

 

[gixrman]

Were are you putting the fuse box? I removed my A/C condesor and mounted a multipin Deustsch connector to my firewall but may due away with it in favor of a gromet when I relocate the fuse box to that hugh open space I have now.

 

[Blurred Talon]

Where the passenger air bag use to be.

 

[Blurred Talon]

Well, I'm finally done removing all the wiring I don't need. Cruise and fog light switches came out today.

Here's all the wiring that's been removed.

Now I need more connectors and to get some time at the car so I can start shortening/lengthening the harness.

 

[keltalon]

Man I must say you have handle this task as organized and skilled as an open heart surgeon. Look good

 

[-Joe-]

looks like a lot of work but i'm sure its worth it!

 

[-Joe-]

looks like a lot of work but i'm sure its worth it!

 

[banishedmunk]

Just out of curiousity where will you be running your map sensor to if you removed the Baro circuit with the maf plug?

 

[Blurred Talon]

Via my MDP sensor; only 2Gs have them.