Rewiring a 20 year old minivan can be an intimidating task, but with some planning and elbow grease, it can be done on a budget. As the owner of a 1997 Toyota Sienna, I recently took on this project myself and was able to rewire my old minivan for under $150. Here's how I did it:
Assessing the Existing Wiring
The first step is to thoroughly inspect the existing wiring in your minivan. Pop open the hood and see if you notice any damaged or frayed wiring. Also check under the dash and behind interior panels. Some key things to look for:
- Frayed or damaged wiring. This can cause shorts and electrical gremlins. Damaged wires will likely need to be replaced.
- Corrosion. Look for green or white dusty corrosion on wire connectors and terminals. This can cause resistance and voltage drops. Corroded areas will need to be cleaned or replaced.
- Burnt/melted wiring or connectors. This is a sign of excessive resistance which can lead to fires. Burnt wires and connectors must be replaced.
I found several corroded connectors under the hood which would need some cleaning and replacement. Under the dash, a few wires were cracked from the plastic becoming brittle over time. No major damage though.
Planning the Rewire
Once I assessed the scope of the project, it was time to plan out my rewire.
- Make a wiring diagram. Map out the existing wiring and plan any changes, additions, or deletions you need to make. This is an essential step to stay organized.
- List all needed parts and materials. Make a list of the wire, connectors, terminals, loom, tape, etc you'll need. Buying in bulk can save money here.
- Calculate total cost. Add up the cost of your needed supplies and make sure it fits your budget. If not, scale back the project scope.
- Develop a tentative schedule. Give yourself plenty of time in case issues come up.
For my minivan, I only needed to rewire the damaged sections, not a complete rewire. I allotted 2 weekends for the project and my parts came to $112 total.
Rewiring Step-by-Step
With planning done, it's time to get to work. Follow these steps:
Safety First
- Disconnect the battery. Cut all power to the minivan before doing any work.
- Protect your eyes and hands. Wear safety glasses and work gloves when handling wires.
Remove Old Wiring
- Label each wire as you disconnect it. Use tape and a permanent marker to note what it powers.
- Try to save as much wiring as possible for reuse. Only remove damaged sections.
- Vacuum carefully around work area as old insulation debris can be harmful if inhaled.
Install New Wiring
- Route new wire through loom. This protects against rubbing and abrasion.
- Use proper terminals and connectors. Crimp or solder all connections securely.
- Insulate connections. Wrap electrical tape around any exposed terminals.
- Cable tie and secure wires so they won't vibrate or shift around.
Testing and Finishing Touches
- Reconnect battery and test all circuits. Check for shorts with a multimeter.
- Replace any interior panels removed during the rewire.
- Seal any drilled holes with rubber grommets to protect from water and dust.
Follow basic electrical safety, take your time, and don't skip steps. And be sure to test all electrical components before driving your minivan again!
Tips for Rewiring a Minivan on a Budget
Here are some handy money-saving tips:
- Buy wire, loom, and connectors in bulk online instead of at auto parts stores. I saved over 50% buying in bulk!
- Use salvaged parts stores for cheap deals on wiring harnesses and fuse boxes. Get them out of scrapped cars.
- Learn to solder connections instead of buying expensive crimp connectors. A soldering iron costs around $20.
- Replace only damaged sections, not the whole harness. Limit the scope to the essentials.
- If totally rewiring, consider lower-cost primary wire run in thicker gauges, then branch off with cheaper secondary wires.
- Shop discount retailers for cheap electrical supplies. Check dollar stores before you pay dealer prices!
Common Problems and Solutions
Even with good planning, issues can come up. Here are some common problems DIYers face when rewiring an old minivan and how to solve them:
Problem: Aftermarket accessories stop working after rewire.
Solution: Use a multimeter to trace each wire and confirm connectivity. Check fuses.
Problem: New wiring doesn't match wiring diagram. Previous owner may have changed something.
Solution: Trace each wire manually with a multimeter and map the actual existing wiring layout.
Problem: Intermittent electrical gremlins persist after rewire.
Solution: Thoroughly inspect every inch of wiring for damage. Replace corroded ground wires and terminals.
Final Thoughts
Rewiring an old minivan takes patience and diligence, but it can be done on a budget with proper planning. The effort is well worth it to get your trusty old minivan back on the road and running smoothly. Just take it slow, adhere to basic electrical safety principles, and don't be afraid to ask for help online if you get stuck. Your budget rewire project will be complete before you know it!