16v Donor Wire Harness Removal

Most of this is from memory so don't chew on me if I've overlooked something, make a contribution...

16 VALVE DONOR HARNESS REMOVAL
(preferably from engine donor vehicle)

Disconnect & remove the battery (if not already done)

Disconnect engine harness (under driver's side dash) and firewall components. Carefully cut & remove the firewall grommet. Extract under-dash connectors via engine bay side. Note: it may be necessary to partially unwrap the firewall harness to separate the engine wiring. Remove engine harness (intact) with engine.

Assuming you also want to upgrade the Samurai’s power distribution system (while you’ve got everything apart), remove fusible link block (located in front of battery on right fender well). Disconnect the alternator & battery feeds (should be bolted/screwed on) and unplug any remaining connectors. Unwrap harness as needed to extract the feed wires (WHT/YEL, WHT/GRN, BLK/RED, WHT/BLU – color combination may vary slightly). It is highly preferable to remove this wiring with connectors on both ends. If this is not possible leave the fuse block connectors attached and cut the wire at the connector on the other end. It can be spliced but this upgrade requires every inch of the heavier gauge wire.

Disconnect headlights, turn signals, parking lights and all remaining components on both fender wells.

Remove donor vehicle instrument cluster and dashboard (per FSM if available – use caution with air bag system). It is not absolutely necessary to remove the dash but its well worth the time aggravation it saves.

Disconnect & remove ECM (under driver’s-side dash)

Disconnect ECM/under-dash harness. Start at ECM connectors and follow from there. Remove clamps, brackets, ties, tape, etc., as necessary, disconnecting plugs as you go. DO NOT CUT ANY WIRES!!!

Locate Main & fuel pump relays. They should be in a bank of 4 just to the right of the heater box. Disconnect & remove them (all) along with the bracket they are attached to (save for x-plant)

Also disconnect and remove the combo switch, ignition switch and instrument cluster sub-harnesses. Generally you won’t mess with the HVAC, audio, and air bag harnesses and/or components (unless they’re in your way). Feel free to cut, bend, remove, or otherwise damage any of these parts, clamps, brackets, etc., if it makes removing the other stuff easier (same goes for the dashboard really – just watch the air bag!).

Force remaining firewall grommet(s) into the cab, then extract the entire harness from inside (carefully feeding the engine bay connectors through the holes).

Remove the engine harness from the engine.

Note: this process took me about 6 hours at a "local" salvage yard.