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Wiring nearly done

April 11th, 2009

Wow, that took way longer than I anticipated.    The new wiring harness is finally installed, with a few random wires still to be run.   I still need to zip tie the bundles and secure the split loom.

Here’s the American Autowire HiWay 22 panel.   It is installed behind the drivers seat, in the rear cabin.


I elected to run separate grounds, using American Autowire’s vehicle ground kit.   The black box below the fuse block is a terminal for grounds to be attached.   It has always bothered me that vehicles use the chassis/body metal as the ground return.   Firstly, steel isn’t that great of a conductor (though there is a large cross-sectional area), and secondly corrosion can degrade connections to the steel body.    This seems a better, more reliable way.   It also will help eliminate possible ground loops.    There’s a ground terminal block at the rear, this one near the fuse block, behind the guage panel and near the old fuse panel in front of the passenger seat.    6 gauge wire connects the 4 nodes.

The new dash rear.



I ended up using the old harness for the somewhat complicated windshield wiper logic which uses 4 relays and quite a few connections to the switches.

At the top is a tachometer I added.    It’s a VDO 6K tach that mostly matches the existing VDO instruments.


The new glove compartment area:


vs the old:


Overall, I liked the American Autowire Hiway harness kit.    Each wire is run individually, which adds a lot of flexibility, but greatly adds to the time required to wire.   I really should have preplanned where each wire went and made my own bundles to route as a group.    The long wires included in the kit meant that I only had to splice some of the wires which ran to the rear taillights.

Some things I didn’t like about the harness kit included the lack of a reverse light circuit(!), it assumed the stop/run lights are run with a single wire,  and it assumed a GM column for turn/brake/hazard logic.    I had to emulate the GM logic, mapping it to the Volvos system and placement of switches.

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