Rebuilding 7MGE harness

[ochocinco5k]

So I have the harness out of my car, wanted to repair an open in the THW circuit properly. I also discovered open copper on the speed sensor on the distributor. I am repairing this harness step by step, and getting the materials is first on the list.

Wire : I planon using GXL wiring supplied from this site : http://www.wireandsupply.com/category_s/319.htm

I measured the wiring in the harness and the 10pin connector has 2.5mm wiring and the other two have just 2mm wiring. From the website I can use 20 AWG wiring with an OD of 0.085" that comes out to 2.1mm and 16 AWG, which is 2.6mm, OD is 0.106". Does this sound about right as far as copper and insulation thickness ?

 

[ochocinco5k]

Can someone move this to the TCCC and Electrics section ?

I also just want to learn how to properly repair my harness.

 

[7mx63]

I rebuilt my entire 2JZGE harness used in my Cressida swap. New terminals, wire, shielding, etc. I used 18 gauge GXL on the whole thing, and it has been running fantastic. I bought it, and other supplies, from Del City.

Repairing the distributor wires will be a pain, because it is 4 wires INSIDE a single braided tube of shielding, which is a bit different than the knock and O2 sensors, which are individual shielded wires (RG58A/U Coax wire). When I did my distributor wires, I bought a length of the braided tubing, and fished the wires through one at a time. It was a huge pain; but it still was only a 30-40 min job for all 4 wires.

Of course, I had the whole harness mounted on a pegboard in my office, with every plug labeled, and a matching EWD for the car it came out of for reference.

 

[ochocinco5k]

This may sound bad but I want to make sure. My plan was to cut the connectors about 3" from the connector and just solder new wire going from where I cut to the ECU pins. Does it sound like it will hold up ? I will be rerouting a little bit, like run the passenger side electronics along the AC line path, to keep it clean instead of going over the valve covers.