Nice work. Just curious, but what led you to the decision to change the engine harness? Just aging, or performance issues? Is it possible to source a complete engine harness, or do you have to build it yourself from scratch? The male/female plugs could be reused, I assume?
It's partly Brad's fault (aka Cush). He started a thread on harnesses that got me looking at mine
Many of the boots were broken and because the plastic connectors housings were crimped on, could not be replaced without cutting the wires. The sleeves that are supposed to protect the wiring had become brittle and fell apart when bent. The wires near the connectors were therefore also toasted and insulation brittle. I think most old Djets would be similar.
On top of that I had a slight hesitation when driving. One possibility was a bad harness connection. When I started taking the plug ends apart, I found that some connectors had a loose fit on the injector/sensor spades. The design of the plugs is such that they can only be re-inserted a certain number of times. At 40+ years old, my harness was no doubt past it's best until date
You can (or at least could) buy complete new harnesses. I haven't priced them, but I think they are in the $800-$900 range. (Checked List $1129, Discounted $840
So far as rebuilding a new harness is concerned, the only connectors that would likely be re-used, would be the ECU plug (Apparently unobtainable new), the relay plug, and the Thermo-Time switch plug. Not sure if the firewall grommet is available (It is: List $129, Discounted $96.75!
) On most cars, it seems the housings of the plug ends have been heat fused making them unusable. Replacements can be purchased for low cost from same place in Germany that has the rubber boots. Or you could use the new style Audi/VW connectors Brad is keen on.
For most, a harness can be rejuvenated by installing new wire from connector back to the main harness. That is what I am going to do this winter (using the new style of plug that Brad has kindly sourced for me and has written about in his harness thread.)
Brad likes doing this sort of work and is THE man on this forum if you feel your harness needs an upgrade and you don't want to tackle it yourself. Harnesses are easy to remove - just need to tag all the branches so you can put it back correctly (although wires are color coded)