Replacing cover on alternator wiring harness

[p911dad]

As I was replacing the spark plugs on our 1984 Carrera I noticed the 28 year old rubber cover in the alternator wiring harness was in bad condition. This harness is expensive and difficult to replace so it needs to be protected. I ordered 1' of 1 1/2 " shrink tubing from WireCare.com (cheap), the tubing is fuel and heat resistant.


First, disconnect the battery


Then, remove the fuse cover and elbow and release the harness loop holding the harness to the fuel rail. Disconnect the harness from the fuse panel.[img]

http://forums.pelicanparts.com/uploads20/DSC_11091330115652.jpg[/img]
The 28 year old rubber cover is badly deteriorated.


Snake the harness over the fuel rail and tape the rips in the cover.


Carefully cut the rubber grommet free of the harness. You will be putting it back. Remove the top of the connector being careful not to let the contacts get loose (cover with a little tape). Slip the shrink tubing over the connector and onto the old rubber sheath.


Using a heat gun shrink the tubing. Replace the grommet, replace the top of the connector and plug it back in place in the fuse panel. Reattach the loop holding the harness to the fuel rail.


Replace the fuse cover, the elbow and reconnect the battery. All done in about 2 hours.

[86 911 Targa]

Originally Posted by p911dad

As I was replacing the spark plugs on our 1984 Carrera I noticed the 28 year old rubber cover in the alternator wiring harness was in bad condition. This harness is expensive and difficult to replace so it needs to be protected. I ordered 1' of 1 1/2 " shrink tubing from WireCare.com (cheap), the tubing is fuel and heat resistant.


First, disconnect the battery


Then, remove the fuse cover and elbow and release the harness loop holding the harness to the fuel rail. Disconnect the harness from the fuse panel.[img]

http://forums.pelicanparts.com/uploads20/DSC_11091330115652.jpg[/img]
The 28 year old rubber cover is badly deteriorated.


Snake the harness over the fuel rail and tape the rips in the cover.


Carefully cut the rubber grommet free of the harness. You will be putting it back. Remove the top of the connector being careful not to let the contacts get loose (cover with a little tape). Slip the shrink tubing over the connector and onto the old rubber sheath.


Using a heat gun shrink the tubing. Replace the grommet, replace the top of the connector and plug it back in place in the fuse panel. Reattach the loop holding the harness to the fuel rail.


Replace the fuse cover, the elbow and reconnect the battery. All done in about 2 hours.

What type of heat resistant electrical tape did you use?

[KTL]

You could also use some self-fusing silicone tape. Kind of expensive but easily found in the electrical supply (wiring, conduit, terminals, wire nuts, etc) location at you hardware or home improvement store.

[p911dad]

86 911 Targa, the tape is normal electrical tape. Its purpose is only to close up the gaps in the old cover and pull it back into a nearly round shape to make the new cover fit better before shrinking. It could have been done without the tape, but it made it neater. I could have cut the old sheath off, but I don't like the idea of a knife mixing with all those wires. Cutting the rubber grommet to split it to allow the new sheath to get past the grommet was tricky enough. I searched Pelican and Auto Atlanta for a new cover, but came up empty. Our host carries shrink tubing, but it is sold in a kit. All I needed was a short piece (about $3.00 + handling and postage.

[86 911 Targa]

Originally Posted by KTL

You could also use some self-fusing silicone tape. Kind of expensive but easily found in the electrical supply (wiring, conduit, terminals, wire nuts, etc) location at you hardware or home improvement store.

Thanks.