I haven’t written for a while and since I last wrote I’ve had a pretty marvelous adventure through Utah and Arizona on foot.
I’m not an electrician. I’m a trained nurse and a hat-maker and a successful, self-taught PHP developer (programmer). Yet here I’m going to write about a Vanagon wiring project I just completed.
I took on this wiring project I’ve been wanting to do for a long time, because if you know me you know I’m not scared to learn new things. I thought I’d share the results in case it could help other folks.
The Crusty Old Wiring Harness
These Vanagon harnesses are now over forty years old. Where the outer insulation hasn’t hardened, burned, and/or cracked, internal corrosion has typically progressed well beyond visible inspection. Corroded conductors increase circuit resistance and susceptibility to electromagnetic interference. This elevated resistance degrades signal integrity across your input circuits—if power is reaching your sensors at all, the voltage levels and signal-to-noise ratio are compromised, forcing your ECU to make fueling and ignition decisions based on degraded input signals.
It’s time to see how the engine is supposed to run with a new wiring harness!
My New Harness
This was a pretty straightforward project, using the old harness as a template for wire length and the wiring diagrams as reference for pinning, gauge and color. I’m very pleased with the results. As of 2026 my Vanagon is still flying high, all diagnostics WNL (within normal limits).
Want one?
If you would like me to build you a sexy new wiring harness for your Digi-jet engine, reach out. As of Spring 2026 I’ll do it for $550 you can supply an intact core harness and $750 if you cannot. Shipping to USA destinations is included; other locations can be quoted. These will take up to a month to ship; if you need it rushed, that can be quoted, too.
I use USA-made GPX wire matching the original colors/gauge (if not thicker in some places) and fiberglass sheathing, not split loom.
When you receive it, everything will be marked as to where it goes–it’s plug n’ play. For people with average or ambitious technical ability, it is a 4-hour max project to swap out harnesses. I recommend taking detailed photographs of your old harness arrangement before you remove your old harness. (I’ll want to see those photos, too.)
There are other options we can talk about – let’s chat. You’ll easily get another 40 years out of your new harness.
If you can’t do a new wiring harness at this time for whatever reason, at least install a new ground strap for your engine and transmission (That can be done well under $50 and today via your FLAPS). If you can’t do that, remove those ground straps briefly, clean/degrease/debride everything well, and re-install. Thank me later.
I will only make Digi-jet harnesses, so if you need something else, definitely buy from Kyle!
DIY Vanagon Wiring Harness Shopping List
Where’s the shopping list? Sorry, long story short: it’s no longer available without a password.
Content with a passwordThis content was updated April 2026 and was then password-protected.
FWIW, harness materials alone can easily cost $250-300 in 2026. Copper wire is not cheap.
Other DIY Materials
- Bentley manual (for the wiring diagram)
- electrical tape (recommend: narrow white for labeling and regular width black for binding)
- wire cutters
- wire stripper
- terminal pin removal tools
- reliable crimpers for 10-22ga connectors (recommend IWISS SN-28B and Klein VDV200-010)
- scissors
- measuring tape
- fine point Sharpie
- rubber gloves and a respirator if you’re using fiberglass wrap
Update: since this post I’ve made a second engine harness for a friend with the same Vanagon.
