How the heck are they going to see the wiring under the intake manifold that's cracking, unless they take the intake manifold off? Even then, only some of the wire is defective--only the green wires (base color green with stripes of various colors) are cracking on my engine harness, all the others appear fine (making it much easier to think about just replacing the bad wires, which are all green).
Oddly enough, all of the base color green wires are connected to the same place, 12V, so even if they touch it won't hurt anything.
Here's what I intend to do:
1)Remove engine harness from engine.
2)Crack off all the split-loom tubing (it's very brittle) to expose all of the wiring.
3)Doing one wire at a time, cut the defective wires from their connectors, leaving 1" of bare wire sticking out of the connector.
[Alternatively, if you have a cooperative dealer, they have repair terminals with 4" of wire attached, they come in a kit of about 150 different types of terminals, but they can order them in bags of 10 with the part number which should be listed somewhere on the kit, if not see TSB 99-2-2 which lists the part number of every terminal in the kit]
4)Taking the new green wire of the proper rating/gauge, slip a 1.5" piece of 1/4" heatshrink tubing with waterproof wax (Digi-Key sells this)over the new wire.
5)Solder the new wire to the 1" bare wire.
6)Slide the heatshrink tubing over the joint and the bare wire, butting it against the connector seal.
7)Shrink the tubing with the soldering iron.
8)Repeat for the other end.
9)Wrap the harness in cold-shrink tape (also available from Digi-Key), don't forget to wrap the tape around the clips that secure the harness to the bolts on the engine, or find some better split-loom tubing.
Brian
