I re-did my loom when re-building my 1600.  Not a hard job, just a lot of sticky mess when undoing the loom.  Considering it is a spare loom, before pulling it apart, take the old loom out and plug it in.  Make sure everything works how it is supposed to.  Otherwise if it plays up after you have re-wired it, you'll be none the wiser if it was your modified wiring, or was like that originally. 
 
If you are not too confident, label everything.  Undo the loom a bit at a time.  Where the different wires run off to different points, tape them off at the right point on the loom.   Work along the whole loom.  You'll have a bunch of multicoloured wires, all neatly bunched together, with various wires branching off.
 
I you have an old alternator with an external voltage regulator and you are running out of charge ie stereo, driving lamps etc, change it to an internally regulated one, most common would be a 60A (amp) BOSCH unit from a Bluebird.  Bolts straight in.  The large bolt on the output goes back to the battery (via a fuseable link and suitable 80A wire would be wise).  The 'L' output goes to your dash lamp.  All the other wires to the old external regulator can be pulled out, or taped up, what ever you like.  The old regulator can be ditched.
 
You can also wire the output terminal from the alternator to pin 30 of the high beam relay (in reference to the article that Terry sent on the list earlier, regarding installing extra highbeams).
 
Wire in any extra's you want to cater for, ie thermo fans etc.  I modified my loom so that all the various relays went to one point.  I bought some Bosch relay mounting blocks that snap together.  You wire your loom to the block and plug your relays into that.  Makes it easier to change a relay if need be, and also looks neat.
 
Now that you're nearing completion, put the loom back in the car as is, and plug it all in.  Make sure your wires branch off where you want them to, shift them if need be and trim any wires to tidy it up.  Make sure everything works as it should.  If all is O.K., then pull it out again.  Now tape it up using back 3M or similar electrical tape.  Re-install, and you're done.
 
It sounds easy on paper, but it is a bit of work.  Have fun,
Wardy
 
----- Original Message -----
Sent: Monday, October 23, 2000 11:22 AM
Subject: Loom modifications

List, I have an old loom that is in very good nick that I am going to install into my 1600 to replace the old monstrosity.
I plan to undo it, clean it out, check the wires and then do it back up again but include the wires for my thermo fan and a few other bits and pieces. Neatness is not of highest priority, but reliability and performance is. I would also like to do the high beam relay trickery and Haydn was telling me something about different alternator wiring which is a lot simpler.
 
Can anyone recommend the best way to go about this? Anything else I should do to it at the same time?
I'm not terribly cluey on auto electrics so I have to ask the list first!
 
zac

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