Testing the wiring looms

It's taken a significant amount of time to retrofit all of the Toyota Starlet wiring loom and add any new wiring to the Mini, but it was time to test it all by making my way through my wiring diagram/document and checking off all items - one wire and one fuse at a time.

There weren't any interesting photos to take here, but it took approx 20 hours of poking and prodding with multimeter probes and a test light. I initially performed a continuity test on every connector pin and every wire to confirm it was all wired correctly, matched my wiring document and were no broken connections.

Thanks to my methodical approach to installing and modifying the wiring, there were no wiring issues that had to be to resolved. The only issue I found was actually in my wiring document - relating to the alternator and a couple of other wire colours that had to be corrected.

I then connected a laboratory power supply to the system (in lieu of a car battery) and with a test light in hand, began confirming power to everything.

I had to confirm power was available to :

• Main, EFI, circuit opening & radiator fan relays
• All fuses
• ECU
• Injectors, ignitor & coil
• Park light/signal - for front & rear lamps, dash, radio etc 
• Headlights (low & high beam)
• Brake lights
• Indicators and hazard functions
• Reverse lamp
• Door headlight reminder/buzzer
• Horn
• Interior lights
• Heater fan
• Fuel Pump
• Radio / Power antenna
• Instrument cluster warning lights & illumination bulbs
• Wiper motor (including speeds)
• All new accessories (power windows, digital display, wideband controller, central locking controller, USB ports, cigarette lighter outlet)

I only had two power-related issues - half of the light bulbs in the instrument cluster were blown, and that the flasher relay was not functional. I replaced ALL of the bulbs and bought a new flasher relay.

Once all those items were tested, it was time for the better test - turning over the engine (without fuel). I connected a car battery to the Mini, then with the main power, trigger and ground cables for the starter motor also connected (without the ECU plugged in) attempted to turn the engine over. Unfortunately the starter motor did not turn over - I could hear the solenoid engage but not the main motor. I removed the starter motor and bench tested it.

I found that the connection between the solenoid and motor was very loose so that was as easy fix. After refitting the starter motor, it was a success. Next step is fuel & a proper start.