5 6 7
Sparkydog
Sparkydog Reader
8/20/18 11:13 a.m.

Just prior to jumping into wiring I painted the inside of the firewall area. This is highly unusual for me - normally I rush into wiring and then regret it as I over-spray later on.

An action shot of my spreadsheet and various schematics!

A growing collection of extra circuits off of fuse block #2. (The coiled up orange and pink power wires above the fuse block.)

The donor harnesses - having a rest between getting raided for colored wires.

This is a nice piece of tech off another Lesabre. It's a 38 pin quick release connector that is becoming my primary dashboard harness interface. It doesn't have all 38 pins fully wired but it has enough fresh out of the car to supply all the connections for the instrument cluster and the data port. It is also very easy to harvest out of the car - it hides in the engine bay at the base of the left strut tower. 2 snips with the wire cutters and a 10mm bolt and it's MINE!

Mezzanine
Mezzanine Dork
8/20/18 11:19 a.m.
Sparkydog said:
This is a nice piece of tech off another Lesabre. Its a 38 pin quick release connector that is becoming my primary dashboard harness interface. It doesn't have all 38 pins fully wired but it has enough fresh out of the car to supply all the connections for the instrument cluster and the data port.

Did you find replacement pins, or are you just splicing into the pigtails from the Lesabre?

Sparkydog
Sparkydog Reader
8/20/18 11:24 a.m.

A small side project - turns out the 96 Crammit L36 motor featured some new-fangled quick connect heater hose couplings made of plastic. The plastic fails over time and the only options are $$$ replacement hose assemblies or $$ aftermarket coupling replacement kits. So I chose door #3. Take the casting off the motor, shave off the quick connect features and drill/tap the casting for good old barbed hose fittings!

Once again I stuck it to the man! I spent $10 on hose fittings and 3-4 hours of my time instead of $50 for the aftermarket adapter couplings. (Sarcasm emoji goes here.)

Sparkydog
Sparkydog Reader
8/20/18 11:35 a.m.

In reply to Mezzanine :

I moved some of the pins around within the shell but did not convert the stub wire's colors. Just spliced onto each side with whatever color code I needed for the circuit function. But where possible if there was a stub with the correct color I used it for that function.

Sparkydog
Sparkydog Reader
9/4/18 1:48 p.m.

Over the long weekend I was able to finish up all my splicing/harness creation. Then I took a deep breath and went back through everything and buzzed it out. So far no gross miswires and only about 3 things to verify. 

So now I have stripped both fuse blocks down (after taking pictures) and am ready to start adding fuses/relays back 1 at a time. This was the only way I could ensure that all the excess circuits and wires don't come alive while I proceed with testing out the engine management circuits.

I've also created a "low energy stunt battery" so I can have just one more layer of protection before I get into high amp shenanigans. This is made up of 2 D batteries and a single 9v and some tape. I can test out most of the ECU, BCU, Start & Gauge Cluster circuits with the stunt battery before moving on to the real battery.

Mezzanine
Mezzanine Dork
9/5/18 11:06 a.m.

Stunt battery! HA! My impulse here is to call you chicken, but on second thought it's probably a good idea given the amount of surgery you're putting into this thing. yes

Sparkydog
Sparkydog Reader
9/5/18 1:11 p.m.

Definitely a big chicken on this phase of the build! Before I began posting here on GRM, I started a welding fire that got big enough to spook me pretty good - not to mention almost knock me out from the fumes. So now I overkill it on the things that can cause fires.

Sparkydog
Sparkydog Reader
9/12/18 12:11 p.m.

I'm getting my ass kicked on wiring. For example, several hours spread over several days were spent trying to solve a mystery of why 1 of 3 grounds from the ECU wasn't there. I eventually got my head wrapped around the sitrep that the engine harness had the ground network but no longer possessed the actual lug that is needed to connect to ground. I had to snake most of the engine harness up off the engine, split open the loom and find the affected ground network. I expected to find a broken off stub or wire or something but finally had to just let it go and splice in a stub and new ground lug.

(Keep in mind this engine and harness was running OK and without fault codes before I pulled it out of the Crammit.)

There! Take that you bastard! Another week of life has passed.

Sparkydog
Sparkydog Reader
9/12/18 12:25 p.m.

Then I thought I was ready for low-energy testing of the start circuits. So Blitzy came down off the blocks and out into the sunshine. About 1 hour later I realized I had to redo a bunch of stuff. Back in and up in the air we went.

Out came the coffee and schematics.

That was a week ago and I've slowly realized that 6 years of GM wiring changes is kicking my ass. What I mean is that when I fell in love with the relay blocks and body harness out of a 2002 Lesabre and thought it would work well with the 1996 engine and the 1986 Porsche key switch - I didn't realize that in 1996 the wires left the fuses and went to where they need to go but by 2002 the wires almost all feed off of hidden circuits that are buried inside the fuse blocks and a crap ton of relays are involved in getting the circuits powered up.

So I have to undo most of my decisions and wiring of the ECU, BCM, Anti Theft and key switch. I am also having to spend huge amounts of time studying Lesabre schematics and essentially re-drawing what I need on paper to try and understand what's going where. It doesn't help that I am not good at this stuff. It also doesn't help that much of the fuseblock is like a giant PCB with layers of busses between the top where the relays go and the bottom where the harness connector blocks mate. Sometimes the correct wires are directly underneath the appropriate relay/fuse and sometimes they aren't.

 

Sparkydog
Sparkydog Reader
9/14/18 12:58 p.m.

Mrs Sparkydog doesn't know this yet but her car is getting kicked out of the garage for a week or so. I'm going to yank my harness out of the 944 so I can work on top of a table with better lighting and less contortionification. I've taken the time to consolidate all the relevant GM schematic info onto a single, unified, all-inclusive Blitz-schematic.

 

If I can't figure it out now I don't deserve to get it running!

Mezzanine
Mezzanine Dork
9/14/18 4:45 p.m.

Ugh. Adapting and modifying factory work from one car is almost as hard as just building an entirely new harness.

Adapting and modifying factory work from THREE DIFFERENT CARS is like a death-wish. I know you're committed to this path and all...maybe you could swing by the internet on the way home and pick up some GM Delphi pins and just build your own harness using the fuse blocks from the Buick?

Good luck. I actually enjoy the "studying schematics and second guessing every decision I've made in life because wiring" phase of a project.

5 6 7
Our Preferred Partners
Q1bDqg4TNwVEUtV8KSbrvKS1yNQuHFPVtLJU5URRSmiJcoveyAUjLAikuG48kfa4