Need help figuring out how to fix factory wiring

[toverturf]

So this wiring in the footwell has been like this for a few years since I bought it. When I bought it there was a whole mess of wiring from a alarm system that didn't work anymore. I pulled all that out. My dash light sometimes wouldn't work either. Turns out that was a loose wire in a bad splice that basically just fell out. I fixed that and haven't had any issues since. I'd like to fix it better though because as you can see in the picture below it's a bad splice with bare wire showing. In the 2nd picture you can see where the wire runs to in the background. Green wire into a red splice that goes up to the dash.

I also saw a yellow wire running to the fuse box and back into the wiring inside. Looking at the wiring it's a green wire that somehow got hot and melted so they fixed it this way. This is what the picture below shows. You can see the wire running from the plug to the fuse box in the engine bay but then it comes back in and goes into the other end of the same green wire which makes no sense to me. That one green wire should have just been replaced. I don't get why the yellow wire is coming back.

Here's some pictures of the wiring diagram that shows what these wires are. So the path of this green wire is it comes from the engine fuse box into 4(1E) which is the 2nd image. Then comes out at 5(1B) and goes up into the dash junction box.

So my questions are what size of wire is this? I'm thinking 16 or 18awg? How do you repin these plugs? I'd like to buy some green wire and just repin what I can and run fresh wire but I don't know what pins to buy. I still need to pull the engine fuse box apart and see exactly where the yellow wires are running to but I assume it's just to the junction connector shown in the diagram.

 

[AuSeeker]

The linked document maybe all you need to answer your questions and help with your repair, it doesn't come right out with the answers but guides you through how to get the answers.

https://www.toyota-tech.eu/wire_harness_rm/RM06H0E.pdf

 

[toverturf]

Perfect. I think I found what pin I need. Does anyone know what wire gauge all this wire is?

 

[toverturf]

I pulled the engine box up to see how the wiring was under it and the wiring is weird here. In the picture below the yellow wire goes into the green wire Tail fuse. That yellow wire is the one running from the harness splice in the 2nd picture in the OP. Now looking at the wiring diagram below that doesn't seem right. The Tail green wire should run to the 3rd green wire in, in the junction connector in the 3rd picture below . That green wire in the 3rd picture though just runs down into the main harness. I can't tell where it goes after that. I need to cut that harness open and see where it goes I guess. I wish I could see a picture of how the fuse box wiring is supposed to look.

The 4th picture shows the other side of the junction connector. You can see the green wire on the top left and that wire should just run inside into the 4(1E) spot. I don't know where the yellow wire coming from 4(1E) goes though. It just runs out into the harness between both fuse block so it must splice into some wire that's wrapped up.

So what's the best way to fix this? All the green wire i've talked about is melted a little bit so it probably should be replaced. Should I just repin everything and run fresh wire based on how the diagram shows?

 

[phattyduck]

Its a bit hard to tell from the photos what is going on, but I did want to mention something - much of the brown you see on the wiring is just old dielectric grease. Don't assume that coloring is an indication of burning (though it still can be!).

All of the connectors can be de-pinned, but you need to find all the right repair parts, which is a challenge. Generally all those will have a little piece that slides into the middle of the connector (from the side opposite the lock tab) that pulls up 1-3mm, then you can move the lock tang and pull the wire out.

-Charlie

 

[toverturf]

Its a bit hard to tell from the photos what is going on, but I did want to mention something - much of the brown you see on the wiring is just old dielectric grease. Don't assume that coloring is an indication of burning (though it still can be!).

All of the connectors can be de-pinned, but you need to find all the right repair parts, which is a challenge. Generally all those will have a little piece that slides into the middle of the connector (from the side opposite the lock tab) that pulls up 1-3mm, then you can move the lock tang and pull the wire out.

-Charlie

Yea all that brown on the plug is just old grease from what I could see. I pulled the plugs and everything seemed fine. It's just the green wire that is dark and you can tell got too hot and started melting if you follow it back.

I think i've found all the parts I need to repin the plugs and fuse box. Now I just need to open up the harness that goes between the engine fuse box and footwell box and see what's going on and how the green wire is ran. As far as I can tell the previous owner tapped into the green wire somewhere with something that used too much power and it melted it.

 

[brillo_76]

You can buy all the pins connectors etc off of Toyota. You can de-pin the connectors and even buy pigtails with new pins as well.


Sadly you going to have to use a wire gauge tool to see what old gauge is of the wire is. I tired to upload the wiring repair manual but it fails. :-(

 

[2TH4IST]

Here are my sources for factory connectors.

Ballenger motorsports

Corsa technic

I usually just repin if the wire is cut to close to the connector. Just got to find the pin or connector type. Usually sumitomo (spelling?) Connectors and pins.

 

[toverturf]

Fixed all of this today. Just repinned everything and ran 18awg wire. Whoever fixed this before did a bad job. Stuff wasn't ran in the right order and was horribly spliced but somehow still worked. Glad to know it's been done right now though and shouldn't have any issues in the future.

 

[brillo_76]

Glad you got it fixed. Also good to have a few sources for connectors and pins as I am sure the OEM Toyotas are the most expensive for the pins and pigtails too..:-(