engine and drivetrain Building new wire loom - NEED HELP

[winstontj]

Thanks to Peteinjp I've now found the perfect source for wire and it's only about an hour away from where I live. They sell the same exact wire, fittings, connectors, etc. that went into our cars. Having learned this what I now intend to do is build a new wire loom that is color correct, rather than just buying an assortment of different gauge red, black, white, blue, green & yellow, which was all that I had been able to find reasonably priced previously.

http://www.riwire.com

Rhode Island Wire has all the correct colors and gauges needed. So my question is: What colors and gauges should I buy and how much? Cost asside, I'd like to have enough left over to run my EFI/MSII project as well when I'm done with this.

For now the current project is:

Rear Loom (everything aft of the dash) - exact replica + addition of 3rd Brake light.

Engine Bay - I've torn out all the emissions, added a pusher fan and would like to run an exact copy of the headlights, horn, fan, engine temp gauges, etc. under the hood.

Under Dash/Heater, Steering column - Exact copy with my current modifications.

I'd like to make an exact stock replica, minus the emissions equipment that I have removed. In the future I will "piggyback" the EFI loom on the side rather than add it on later.

Has anyone ever done this and if so did you keep track of the colors, amounts and gauges of wire you used? I took a look at the HTK and realoem and they both have limited descriptions for color and gauge. Any help would be much appreciated.

TIA,

TJW

[02Les]

This is the wiring diag for the 2002tii Touring. I would not expect it to differ too much from the saloon version. If nothing else, it gives you colours and cross section for the wires.

Use MS Office Picture Manager (or whatever) to increase the size and they should be legible. If you have problems reading, email me and i'll send you direct larger (1mb) versions.

lescartwright at juno dot com

[H_Krix]

Dude, i've been there... I've got one of those 3" three-ring binders from Bimmerparts, and in the back is every wiring diagram for every '02 you could think of. I used this when I was rebuilding my own harness. I didn't go all-out new, but i did replace about 30% of the old wiring, and almost every connector.

Send me an email, let me know what year your car is, along with:

Spec (american or euro)

Auto or manual

AC or no AC

tii, ti, turbo, or standard '02

and I can scan in a few things for you. Back when I did mine, I printed a 7' wide by 3' tall diagram to help out with the reading. If you're interested in this as well, let me know. I was thinking of making them for guys on the '02 board.

Pic below.

[peteinjp]

Rear loom- fuel pump?

Engine bay- one of the headlight circuts is unfused- might not hurt to fuse that.

Add a relay in for the high beams so you can run higher wattage bulbs. Run a larger gauge for this Susquhenna Motosports

http://www.rallylights.com/useful_info/headlamp_wiring.htm

I put the relay under the dash near (behind) the fuse box (my fuse box is in the original location)

Battery in trunk? RI wiring service did not have the battery cable that I wanted- so west marine was the answer.

I unwrapped the original harnesses and placed a single bit of electrical tape at every junction and every so often on the longer sections. Then replaced one wire at a time. I did not replace all of the wires so this was the way to go. But even I were to replace them all I'd do it that way.

Ri wire has heat resistant braided tubing as well. Great for stuff that goes to the engine. Starter cable, thermostat wire, alternator stuff- etc. Really amazing what they have there. In fact they have these braiding machines that................... it is worth the trip down to check it out.

[johnhup]

peteinjp,

Where did you get those nice battery terminals and cover's for your engine bay?

[peteinjp]

I was fussy enough to switch it all to metric. Easy to access for jumping as well as running timing lights etc.

[winstontj]

I was fussy enough to switch it all to metric. Easy to access for jumping as well as running timing lights etc.

West Marine is a great source. You can get everything that West Marine sells - and MORE at www.jamestowndistributors.com (brother works there had to throw it out there).

Where and how did you run your positive terminal? Is the red coming in your 0/00 gauge long wire or did you run it inbetween the inner and outer fender somehow? That's a really nice job! I'll be going to RI Wire as soon as I can get a day off - (not open saturdays :-( )

[TJW]

(nt)

[peteinjp]

I ran 2 cables all the way back. I ran them thru the fuse box location so they come into the engine compartment with the wiring that goes to the fues box. They are anchored with stainless clamps as you can barely see in the first pic.

[johnhup]

Peteinjp where did you get that awesome throttle ratio reducer lever and mount?! I need one so badly. Man I love you're setup.

[peteinjp]

Peteinjp where did you get that awesome throttle ratio reducer lever and mount?! I need one so badly. Man I love you're setup.

Thanks for the compliment! I worked hard to get a setup that I thought would be usable and servicable for another 20 plus years of daily use. The throttle bracket is a stock tii part. It runs down to the assembly bracket. It seems like a great start for a throttle cable assembly as well.

[aleahy]

Do you have a diagram covering the 1600 cabriolet? The ones I've seen for the standard 1600 don't correspond to the wire colors I'm seeing on my car, making it difficult to get things working correctly.

[BillWilliams]

and a new rear harness if that is any use to you in your endevor.

bill

[bimmerboy]

(nt)

[BillWilliams]

I am just offering them to use as a pattern.