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Connecting Mismatching Harnesses..


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Trying to wire up the 110 so i can get on with the megasquirt and get this thing running.

I need to match up a pre-2002 main harness to a post-2002 chassis harness. Both are TD5 types.

I have compiled a list below showing plugs 1-3 of the main harness, and their corresponding chassis harness connectors that they should match up to. I have shown the RAVE connector numbers next to each connector.

I understand that i will need to move some wires around between connectors to get things mating up between the chassis harness and main harness connectors but my problem is that no matter what combination i try, im left with some spare wires left over that dont appear to have a home. Could someone please tell me what i need to do so i can get on with this...

1999 MAIN HARNESS - 2002 CHASSIS HARNESS

PLUG 1 (C0391) - CHASSIS GREY (C0377)

Orange/Green, Green/Brown, Green/Brown Orange/Green, Green/Black, Green/Black

White/Green, White/Black, Green/Red White/Green, White/Black, Grey/Black

PLUG 2 (C0392) - CHASSIS BLACK (C0378)

Purple, Purple/White, Green/Black Purple, Purple/White

Grey/Black

PLUG 3 (C0376) - CHASSIS ORANGE (C0390)

Red/Black, Red/Yellow, Red/Green Red/Black, Red/Yellow, Red/Green

White/Green, Green/Purple, Red White/Green, Green/Purple, White

Green/Brown, Red/Orange, Grey

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some wires are not used on all the vehicles, in the connector diagram it shows the face that fit the match socket the wire positions are listed as cavity [CAV] & the next coloumn is wire colour, then 3rd column is relevant to the model of parent vehicle, there should be a corresponding list of codes in the wiring library section, I can't check, as I don't have RAVE on my laptop.

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Yes but if you notice from my original table at top of post, Plug1 (C0391) has 2 green/brown wires. One of which i have matched to a green/brown on the orange chassis harness plug (C0390).

Im also left with a green/red (C0391), red (C0376), green/black (C0377), white, red/orange, grey (C0390)

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After noticing an error in my previous harness connector table, ive posted a corrected version. I would appreciate someone helping me out with telling me what needs moving where.

Due to the post preview not working im hoping the table doesnt lose its format. Knowing my luck it will. Here goes.

1999 Main Harness 2002 Chassis Harness

Plug 1 (C0377) Grey (C1760)

Orange/Green - Reverse Lamps to Reverse Switch Orange/Green

White/Black – Header to Heated Rear Screen White/Black

White/Green – Rear Screen Wiper Motor White/Green

Brown/Lt Green – Rear Screen Wash/Wipe Switch Black/Green

Red/Lt Green – Rear Screen Wash/Wipe Switch Green/Black

Orange/Green – Water Filter Sensor Orange/Green

Plug 2 (C0378) Black (C0392)

Purple – Engine Compartment Fusebox to C0392 Purple

Grey/Black – Instrument Pack to C0392 (Fuel Sender)

Green/Black – Instrument Pack to C0392 (Fuel Sender)

Purple/White – Fuel Pump Relay to C0392

White/Purple ? White/Purple

Plug 3 (C0376) Orange (C0390)

Red/Orange – Header to Tail Lamp RH Red/Orange

Red/Black – Header to Tail Lamp LH Red/Black

Red/Yellow – Instrument Pack to C0390 (Rear Fog) Red/Yellow

Green/Red – Header to C0390 (Indicator Rear LH) Green/Red

Green/White – Header to C0390 (Indicator Rear RH) Green/White

Green/Purple – Header to C0390 (Tail Lamps) Green/Purple

Grey

White

Green/Brown

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That must just be my mistake in identifying the 2002 connectors. If it was a 90 chassis harness the connectors wouldnt reach the front of the chassis as the harness would be a couple of feet too short.

I'll rectify connector ID easily enough but i'll still need some advice regarding what wires go where.

PaulMc and DaveW both said id probably have to cut off a connector and swap wires around but they have both disappeared.....

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After noticing an error in my previous harness connector table, ive posted a corrected version. I would appreciate someone helping me out with telling me what needs moving where.

Due to the post preview not working im hoping the table doesnt lose its format. Knowing my luck it will. Here goes.

1999 Main Harness 2002 Chassis Harness

Plug 1 (C0377) Grey (C1760)

Orange/Green - Reverse Lamps to Reverse Switch Orange/Green

White/Black – Header to Heated Rear Screen White/Black

White/Green – Rear Screen Wiper Motor White/Green

Brown/Lt Green – Rear Screen Wash/Wipe Switch Black/Green

Red/Lt Green – Rear Screen Wash/Wipe Switch Green/Black

Orange/Green – Water Filter Sensor Orange/Green

Plug 2 (C0378) Black (C1761)

Purple – Engine Compartment Fusebox to C0392 Purple

Grey/Black – Instrument Pack to C0392 (Fuel Sender)

Green/Black – Instrument Pack to C0392 (Fuel Sender)

Purple/White – Fuel Pump Relay to C0392

White/Purple ? White/Purple

Plug 3 (C0376) Orange (C1759)

Red/Orange – Header to Tail Lamp RH Red/Orange

Red/Black – Header to Tail Lamp LH Red/Black

Red/Yellow – Instrument Pack to C0390 (Rear Fog) Red/Yellow

Green/Red – Header to C0390 (Indicator Rear LH) Green/Red

Green/White – Header to C0390 (Indicator Rear RH) Green/White

Green/Purple – Header to C0390 (Tail Lamps) Green/Purple

Grey

White

Green/Brown

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Thanks for that Ralph. I wont be in a position for a while to find out if it works or not as ive got a load more work to do before i get to the 'turn of the key' stage. Need to refit a lot of electrical components first.

Ive got every faith that your diagram is spot on though ;)

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