Engine Harness Repair

[NOT THE BLUE LAMPSHADE]

So I recently swapped a new engine into my Mazda and now it's dead again. I discovered that the part of the wiring harness that goes to the injectors, crank sensor, and emissions valves, etc, is melted through. I apparently routed it over a hot exhaust part to the intake manifold and it finally broke now.

The question is, can I just cut the wires back, get some butt connectors and wire and connect it all up? And then the obvious of insulating it and sleeving it back up.

I've done this with other shit, JW if this can be held true with a engine wiring harness. I can't afford 850$ from Mazda for a new one.

[ESchwanz]

Originally Posted by NOT THE BLUE LAMPSHADE

So I recently swapped a new engine into my Mazda and now it's dead again. I discovered that the part of the wiring harness that goes to the injectors, crank sensor, and emissions valves, etc, is melted through. I apparently routed it over a hot exhaust part to the intake manifold and it finally broke now.

The question is, can I just cut the wires back, get some butt connectors and wire and connect it all up? And then the obvious of insulating it and sleeving it back up.

I've done this with other shit, JW if this can be held true with a engine wiring harness. I can't afford 850$ from Mazda for a new one.

Should be fine. Personally I would solder them then go to home depot & ask for silicone splicing tape(it's high temp) Use that to wrap it. It might be near the duct tape near heating stuff. Last time I had a problem like that I also used a Kevlar spark plug boot shield from O'Reilly Auto Parts . I just cut the metal ring out to make the sleeve expandable.

[NOT THE BLUE LAMPSHADE]

I actually have some high temp tape I planned on using. I'm debating soldering, it's the best way to do it, just more time consuming.

[FattyBoomBatty]

Butt/crimp connectors can work just fine if the wire doesn't fall out. Just do that, tape it up and be on your way. Solder works well, but can be hard to use on old wires.

[NOT THE BLUE LAMPSHADE]

That's what I was actually wondering about with older wires that may be semi-corroded, but not bad enough to still use and repair.

[Goat Blower]

I would definitely wire it. I've never had fantastic luck with butt connectors, even the good ones from a real store, not Radio Junk.

[Kevin 1G Drummer]

The key to using butt connectors is to get a crimper that actually pinches the wires in there. most normal crimpers look like () when they are closed, but you want the kind that look kinda like }) ...it's hard to describe on the internet... Also, if you're going to use butt connectors, make sure you get the ones with heat shrink on them so that they seal out any water, and possibility of corrosion.

[Matt D.]

Please do it right and solder, and use heat shrink tubing on all of your work. I don't see how soldering will take longer, you still have to cut and strip each wire and make sure it's clean.

[NOT THE BLUE LAMPSHADE]

It won't take that much longer, it's just more tedious since I need to be more careful with soldering.

Anyway, I've had to hand it over to one of my mechanics at work since I can't figure out where some of the wires go, and the diagrams don't tell me shit. So it'll be done tonight. I did solder with heat shrink tubing and all that fun stuff, just had to have the mechanic finish it for me.