1988 3.2 Alternator Wiring Harness

[UK Carrera]

Having pulled my alternator to have it rebuilt it was obvious that the main live cable had seen better days. Lots of heat damage visible. I had (naively) thought I could strip it back and re-insulate but it looks as though I need to replace it.

Does anyone sell an alternator wiring harness as a ready-made item? I'm in the Uk so a local supply would be good.

[timmy2]

I make them, but Kroon wiring in The Netherlands is more “local” to you.

[gamin]

I HIGHLY recommend Dennis, timmy2. I have lots of his harnesses and all are high quality and labeled for dummies like me. He's easy to contact and stands behind his work.

[al lkosmal]

Dennis (Timmy2) makes the harnesses for my EFI kits...highly recommended.

[mysocal911]

Originally Posted by UK Carrera

Having pulled my alternator to have it rebuilt it was obvious that the main live cable had seen better days. Lots of heat damage visible.

That's what typically happens when the battery is reverse jumped continuously.

[UK Carrera]

Originally Posted by mysocal911

That's what typically happens when the battery is reverse jumped continuously.

I've owned the car for the last 20 years, had 43k miles on it when I bought it.
Never been jump started in my tenure.
What would cause what you describe?

[John W.]

Those wires definitely got hot. Either the engine got extra hot or a heavy current drain somewhere in the electrical system or a combination of both. Make sure all grounds are good.

[timmy2]

Definitely look for and eliminate the source of the problem before installing a new harness.
Usually the alternator to engine case ground melts as well on reverse polarity. (Looks ok in your photo)
This looks more like a short to ground elsewhere. Maybe in the existing engine harness or at the starter if the damage to the main cable goes that far.

[mysocal911]

Originally Posted by UK Carrera

I've owned the car for the last 20 years, had 43k miles on it when I bought it.
Never been jump started in my tenure.
What would cause what you describe?

Then previous owner or garage may have caused the damage. The same wiring damage occurs when a battery is installed backwards.

[mysocal911]

Originally Posted by timmy2

Definitely look for and eliminate the source of the problem before installing a new harness.
Usually the alternator to engine case ground melts as well on reverse polarity. (Looks ok in your photo)
This looks more like a short to ground elsewhere. Maybe in the existing engine harness or at the starter if the damage to the main cable goes that far.

Remember, the case of the alternator makes the major ground, and the wire ground just supplements it.

[timmy2]

Yup, key word was usually.
After 40+ years fixing high voltage high/current faults, the juice goes wherever it wants to...

[UK Carrera]

Thanks for your replies guys!
I'm torn between making up a new cable for the Alternator to starter motor alone, or biting the bullet and springing for a harness from Kroon. (Or @timmy2 if you make one/have one).
The new harness seems like overkill though.
Time to get the car up in the air and remove that red cable.

[timmy2]

The red cable is sheathed along with just a few wires going straight back to the starter.
If the other wires are undamaged, just replace the red cable. (Reverse switch wiring, yellow solenoid wire, oil switch wiring) You might have “fun” trying to pull the cable out of the engine tin grommet...
Use some good harness tape to replace the old vinyl sheathing you will have to remove.
Most harnesses before 84 were wrapped in tape anyways.

[UK Carrera]

I have ordered an engine wiring harness from Kroon.
I'd rather do this job right and do it once. There may be damage to the other wires, and anyway it's all 33 years old.
The car has quite a high agreed value and I'm not planning on selling anytime soon.
It's not that expensive and the labour is all mine.

[gerakroo]

Thank you for your order.
Always on stock so it will be shipped tomorrow !

Regards from the Netherlands.

[timmy2]

Say thanks, Gerald...

[gerakroo]

Originally Posted by timmy2

Say thanks, Gerald...

I almost forgot !

Thank you Timmy2 !

[UK Carrera]

Originally Posted by gerakroo

Thank you for your order.
Always on stock so it will be shipped tomorrow !

Regards from the Netherlands.

Thanks.

Would have been great to have an update via e-mail though!

[gerakroo]

Bank payments always take a few days :-) But its on its way to you (see the updates from our webshop)

[UK Carrera]

Originally Posted by gerakroo

Bank payments always take a few days :-) But its on its way to you (see the updates from our webshop)

Thank you!