1.7.3 Harness Inventory¶

Purpose¶

Catalogs each fabricatable wire harness in the build. A "harness" here = a discrete bundle of wires with a defined start connector, end connector(s), routing path, and BOM — something you'd lay out on a workbench and tape together as a unit.

This page is the index and system-wide view. The detailed, build-it-from-this specs (conductor tables, gauges, colors, lengths, protection, connectors) live on the three build sheets below — each pairs the harnesses with the LJ Tub Map diagram that shows their physical routing.

Use these docs to:

• Order connectors and lugs in correct quantities
• Plan fabrication order (build harnesses bench-side, install in vehicle)
• Identify reuse / consolidation opportunities
• Define service-replaceable units (one harness fails → replace just that segment)

Bundling philosophy: Each harness terminates at a connector at every transition point (firewall, body penetration, distribution box). This makes harnesses individually serviceable and lets you lay them out flat for fabrication. The cost is more connectors; the benefit is much easier R&R.

Numbering note: Two prior bundles (the old H1+H4 power trunk and the old H6+H7 rear cabin bundle) were merged in May 2026. The catalog was renumbered to a single sequence H1–H9 — there are no compound names (no "H1/4", no "H6/7"). See the interference assessment for why the merged bundles are safe.

Harness Build Sheets¶

Each build sheet embeds the matching tub-map diagram and the workbench specs for the harnesses it shows.

Harness Summary¶

Wire Color Convention¶

Colors on the build sheets follow this convention. Power and ground colors are universal automotive practice; signal colors are the builder's choice — pick a consistent scheme and keep it the same across every harness.

For protective wrap/loom, heat sleeve, abrasion sleeve, and P-clamp standards by location, see Wire Protection Standards. This build wraps power runs in braided sleeve with per-harness tracers — see Protective Sleeve & Tracers.

Protective Sleeve & Tracers¶

Wrap preference for this build:

• Default is black braided expandable sleeve (PET, e.g. Techflex Flexo PET) over the full length of power runs, sized to the bundle OD. Black is the base color; a contrasting tracer stripe woven into the sleeve identifies each power trunk where several run together (e.g. in the cabin trunk). Braided sleeve is abrasion-resistant, flexes around the sill / trans-tunnel path, and lets you fan branches out without cutting the wrap.

• Heat sleeve still applies where any run enters the engine bay within ~12" of exhaust — over the braided sleeve as needed.
• Split loom remains fine for the small-wire signal/lighting bundles (H4, H5, H7, H9) and for short, branchy, or frequently-accessed runs where braided sleeve is awkward; use a braided sleeve with a tracer instead if you prefer to color-code those too. H8 ships as a factory harness (no added wrap needed beyond loom through the tunnel).

Harness Map¶

                  ┌──────────────────────────────────────────────────┐
                  │                  ENGINE BAY                       │
                  │                                                   │
  H2 START trunk ─►──┐                                                │
                     │ alt, starter, PMU feed, START+ fwd-bus feed    │
                     │                                                │
                     ▼                                                │
                  ┌─────┐                                             │
                  │ PMU │◄────── H4 SP front ◄──┐                     │
                  └──┬──┘                       │                     │
                     │                          │                     │
  ═════════════════════════════════ FIREWALL ═════════════════════════│
                     │                          │                     │
                     ▼ HDP24                    │                     │
                  ┌──────────────────────────────────┐                │
                  │  FIREWALL CLUSTER (cabin side):  │                │
                  │  SwitchPros + GND bus + BODY PDU │                │
                  │  + Firewall CONSTANT bus + CBs   │                │
                  │  (audio amp on direct AUX feed)  │                │
                  └────┬──────────────┬──────────────┘                │
                       │              │                               │
                       │      H5 Rear Cabin Trunk Bundle              │
                       │      (SwitchPros rear + PMU rear, ~10 cond)  │
                       │              │                               │
                       ▼              ▼                               │
                  ┌─────────────────────────────────────────┐         │
                  │  CABIN TRUNK                            │         │
                  │  Forward (passenger side): H1           │         │
                  │  Forward (driver side): H2              │         │
                  │  Rearward: H5 + CT4 turn + H6 signal    │         │
                  │  Cross-cab: H3 (under rear bench)       │         │
                  └────┬──────────────────────────┬─────────┘         │
                       │                          │                   │
                       ▼                          ▼                   │
       ┌─────────────────────┐         ┌────────────────────┐         │
       │ DRIVER REAR WELL    │         │ PASSENGER REAR WELL│         │
       │ • START battery     │◄────────│ • AUX battery      │         │
       │ • 250A + 80A CBs    │  H3     │ • 300A + 150A CBs  │         │
       │                     │ BCDC    │ • SafetyHub        │         │
       │                     │ cross   │ • BCDC             │         │
       │  H2 ↑ (4 cables)    │ (under  │  H1 ↑ (3 cables)   │         │
       │  driver floor/wall  │  rear   │  passenger         │         │
       │  to engine bay      │  bench) │  floor/wall to     │         │
       │                     │         │  sealed grommet    │         │
       └─────────────────────┘         │  at firewall;      │         │
                                       │  winch portion     │         │
                                       │  continues to      │         │
                                       │  front bumper      │         │
                                       │  H6 ARB compressor │         │
                                       │  → under pass seat │         │
                                       └──────┬─────────────┘         │
                                              │                       │
                                              ▼                       │
       ┌─────────────────────────────────────────────────────────────┐
       │  FRONT BUMPER (H1 winch portion terminates)                 │
       │  REAR CARGO BULKHEAD (H5 multi-pin breakout)                │
       └─────────────────────────────────────────────────────────────┘

Bundle Interference Assessment¶

Two harnesses (H1 and H5) bundle multiple originally-separate runs into a single sleeve. EMI/crosstalk evaluation:

H1 (Passenger Rear Power Trunk) — 1× 2/0 AWG forward feed + 2× 1/0 AWG winch power/ground:

• All three conductors carry power only — no sense lines, no signal returns, no CAN/audio/analog.
• Inductive coupling between adjacent power conductors is irrelevant for distribution (the coupled noise has no signal path to corrupt; loads see CB-protected DC).
• Winch peak current (~409A, seconds) raises a strong transient B-field but does not couple to the parallel forward-feed cable in any way that matters at the firewall CONSTANT bus.
• Verdict: no interference risk. Safe to bundle.

H5 (Rear Cabin Trunk Bundle) — SP lighting outputs + PMU OUT-21/22/23 + 1 SP trigger return:

• SP OUT-6/7/10/12/13 are switched DC for lighting loads (14 AWG), not PWM.
• PMU OUT-21/22/23 are switched DC for brake / reverse / parking tail signals (16 AWG), not PWM in this build (no dimming required; tail circuits run at full output when commanded).
• TRIGGER-2 (18 AWG) is a switch return from the rear cargo rocker. SP triggers require sustained 12V to register; brief inductive transients from adjacent switched outputs are filtered by the SP input.
• No CAN bus, no audio signal, no analog sensor wiring shares this bundle. (CT4 rear turn signals were considered for inclusion — they would also be switched DC and remain safe to add later.)
• Verdict: no interference risk under current load profile. Safe to bundle. If a future change introduces PWM dimming on any PMU rear output, re-evaluate — twisted pair or shielding may be warranted for the TRIGGER-2 line in that case.

Other bundles (H2, H3, H4, H6, H7, H8, H9): Each is single-purpose with homogeneous content (H2 = power only; H3 = power + ground reference; H4 = SP outputs; H6 = ARB power + signal already noted as physically separable; H7 = trigger logic only; H8 = factory shifter harness; H9 = TCU connections, includes twisted CAN pair). No new bundling concerns.

Cabin Trunk Bundle Summary¶

The cabin trunk (trans tunnel / sill, firewall ↔ rear wheel wells) carries multiple harnesses in parallel. Total bundle inventory:

Passenger sill/floor (H1): ~3 cables, ~1.5" OD bundle, continuous through a sealed 2-piece grommet at the firewall (no bulkhead studs — see optimization note below)

Driver sill/floor (H2): ~4 cables (3× 2/0 AWG + 1× 2 AWG), ~1.6" OD bundle, terminates at heavy power grommet at firewall

Trans tunnel rearward (H5 + CT4 + ARB signal): ~14 conductors of small wire (14–18 AWG)

Suggested trunk wrap: 1.5"–2" braided expandable sleeve (preferred for the power runs) or split loom per side, tracer-coded per harness so the bundles stay identifiable — see Protective Sleeve & Tracers. P-clamp every 12–18".

Bundle Optimization Opportunities (Summary)¶

These were noted inline on the build sheets; consolidated here for review:

1. ~~Old H4 + old H1 share rear-well → firewall path~~ Resolved (2026-05-30): Merged into single H1 Passenger Rear Power Trunk. Firewall transition uses a single sealed 2-piece rubber grommet (e.g., Steele Rubber) — cables run continuously, no service break. Bulkhead studs (Blue Sea 2203/2204) max at 250A and were underrated for the winch peaks (409A); Anderson SB175 was also undersized. Continuous-cable + grommet is WARN's documented standard for high-current firewall pass-through.
2. ~~Old H6 + old H7 + CT4 rear turn + old H8 SP signal wires share cabin trunk → rear~~ Partially resolved (2026-05-30): Old H6 + old H7 merged into H5 Rear Cabin Trunk Bundle with single multi-pin breakout (Deutsch DT15 or AMP CPC ~15-pin) at rear cargo bulkhead. CT4 rear turn signals and ARB control wires could still join — pending decision.
3. H5 sub-harness (firewall → rear breakout) is a single straight pull; R&R of any individual rear light becomes a pigtail swap.
4. H6 motor cables only. Move control/pressure wires into H5 since they originate at SwitchPros.
5. Front lockers + rock lights + fog in one bundle through SwitchPros firewall bulkhead to engine bay → grille area. Splice/breakout at front for fan-out.
6. ~~HDP20 firewall connector pin budget~~ Resolved (2026-05-30): Split into two dedicated bulkheads — HDP24-24-29 for non-SP traffic (18/29 used, 11 spare) + HDP24-18-14 for SwitchPros forward outputs (6/14 used, 8 spare). SP harness stays Delphi-native end-to-end. See Pin Budget Audit.

Outstanding Items¶

Build Tasks¶

• Decide front bumper breakout connector style (Deutsch DT, AMP CPC, etc.)
• Decide rear cargo bulkhead breakout connector style and pin count
• Confirm SwitchPros front locker wire routing (front axle access)
• Decide if ARB control wires merge into H5 (recommended) or run as H6 signal pair
• Source connector + lug + heat shrink BOM totals
• Confirm braided-sleeve sizes and per-harness tracer colors for the power runs (see Protective Sleeve & Tracers); decide split loom vs braided for the small-wire bundles per zone
• Define and record the signal-wire color scheme for non-vendor signal/trigger wires (power = red, ground = black are fixed; see Wire Color Convention)

Related Documentation¶

• Power Distribution Build Sheet - H1, H2, H3 with tub-map diagram
• Lighting & SwitchPros Build Sheet - H4, H5 with tub-map diagram
• Controls, Recovery & Drivetrain Build Sheet - H6–H9 with tub-map diagram
• Wire Routing - Zone-based routing reference and protection standards
• Firewall Ingress - HDP24 pinout and penetrations
• AUX Battery Distribution - H1 source
• START Battery Distribution - H2 and H3 source
• SwitchPros SP-1200 - H4, H5 source controller
• PMU24 Outputs - H5 source
• SafetyHub 150 - H6, H7 source
• Recovery Systems / Winch - H1 (winch portion) destination
• Air Compressor - H6 destination