Wiring Loom Replacement
The idea behind this page is to show you the straight forward process of replacing the main wiring loom in your VW Transporter. Though the looms changed many times throughout production, the process of replacing the loom remains the same. My loom is a 1966 European Spec Loom (i.e. non-usa) from August 1965 Chassis No. 211 000 001 and will be fitted to out Dec 1965 Pick up Truck.
Before I start I would like to say a big thanks to Ron Richman for his support and sponsorship of this page. I was lucky enough to see my loom being made from scratch and can assure you a lot of time, effort and knowledge goes into it's manufacture. Ron's looms use thin wall cable as used in modern car production. This means the overall diameter of the cable is smaller and therefore easier to connect with the added advantage of carrying a higher voltage.
Parts
Wiring Diagram - see the
samba
Ron Richman Wiring
Loom
Spade Connectors x Vehicle
Wiring Products
The Main Wiring Loom Explained
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Well here it is, it may look daunting in this form. I spent a little time to familiarize myself with it which was a great help. I broke the loom down into four main area's |
1. Front of Loom (Fuse Box and under Dash Area)
This part splits into two area's, Fuse box / indicators and under dash area. Here are tables to explain where the wires go Under
Dash
Fuse Box. In the wiring diagram the fuse box is upside down, as shown in picture 2 below. So when we refer to the Top and Bottom it is as detailed in picture 2 (i.e. upside down!!!). If it bothers you turn the the wiring diagram upside down!!!
Next two pictures show all the wires which go to the fuse box, as you can see there are more than just the ones from the main loom and I will include details of the under dash loom installation later.
Indicators (Those two
remaining wires with the Fuse box wires)
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2. Front Middle (Horn and Brake Master Cylinder Switch)
Horn
Brake Master Cylinder
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3. Rear Middle (Engine Bay Electrical Components and Starter)
Starter
Engine Bay Electrical Components
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4. Rear of Loom (Rear Lights)
Right Rear Tail Light
Number Plate Light
Left Rear Tail Light
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| Ok here we are ready to install
the loom. In addition to the loom you will need to print off this
page, female terminals, female terminal insulators (optional) PVC
electricians tape a wire stripper, crimping tool and a hand brake
cable or similar. I got all my supplies from Vehicle
Wiring Products You can also buy additional wire to make up the
smaller looms found under the dash such as the head light loom.
Start at the rear. Disconnect the battery. Then pull the wires off the rear tail lights, number plate light, oil warning switch, coil (not the condenser wire), Automatic choke, Electro Magnetic Pilot Jet, Ignition Coil and the blue bottom wire on the regulator. Take the wire out of the body clips. I tape the wires together so it is nice and tight with no odd wires hanging out to get caught. At this time get underneath the bus near the right rear wheel so I can see the loom coming thru the bulk head. I pull the main loom out from the engine bay so it is hanging down from where it passes thru the chassis leg. It's now time to tape the hand brake cable to the end of the loom. Once done you need to pull the rear of the loom into the middle of the van. Remember you are on the floor. attach the new loom to the handbrake cable and pull it back thru the chassis leg. You are looking to get the Starter motor wires lined up with the starter motor. You will need to push the other wires thru the bulk head into the engine bay. The front of the loom is very similar. You need to remove both kick panels and undo the under dash tray, it can rest on the cab floor. Familiarize yourself with the fuse box and under dash stuff like the speedometer. You need to undo the fuse box from it's fitting, you do not need to take any wire off at this time.. There is a little spring tab that keep it in place on the right hand side of the box. OK so you need to start detaching the 4 under dash wires use the bigbulli print off to find the wires, this is very straight forward. do the same with the fuse box. At this point you will notice the horn and brake master cylinder run on a separate loom for the factory loom and are part of the main loom with Ron's loom. Do not panic this is correct! You will need to remove the separate loom for horn and brake master cylinder this goes thru the inner box section to the left of the main loom, we will not be replacing this as the new loom incorporates it. Ok so the loom is now detached and ready to be pulled thru, again tape it where necessary and fix it to the hand brake cable (I suggest you attach something to it like mole grips so the cable doesn't get pulled all the way thru. Get under the cab floor and pull the loom out so it's now ready to be pulled thru the chassis leg. Go to the middle of the van and pull the loom out. Attach the new loom to the handbrake cable and pull it back thru the chassis leg take of the tap on the brake master cylinder switch and horn wires, they will not be joining us on the journey to the cab! Now pull the rest of the loom up into the cab, nice and easy, get it all lined up. Now it's a case of adding new Female terminals and re attaching them using the bigbulli print off. There you go, you've just replaced the main loom - well done! |