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Toyota Hilux wiring harness replacement — 8th Gen, 2015–2025
Hilux is the best-selling pickup outside North America and the standard mining, plantation and NGO vehicle from Thailand to Chile to Nigeria. Dust, brine and 400,000 km duty cycles destroy loom conduit and connector seals long before the mechanicals give up, which makes full-harness replacement a routine fleet job rather than a rare repair.
Harness assemblies we build for the Toyota Hilux
Each assembly is a separate part number with its own drawing and test fixture, so you can order the complete set or replace one failed loom. All five share the same splice points as the factory harness.
| Assembly | Build specification |
|---|---|
| Engine & ECU harness | Firewall-to-engine routing with injector, coil, O2, cam and crank branches, sealed ECU header and the OEM connector series retained so the loom plugs in without re-pinning. |
| Body / cabin harness | Main body loom carrying the fuse and relay block, BCM connectors, interior lighting, audio, immobilizer and convenience circuits on the original circuit count. |
| Chassis, ABS & suspension harness | Wheel-speed, ABS/ESP sensor, ride-height and fuel-tank branches in abrasion-resistant conduit with sealed sensor connectors. |
| Rear body & trailer harness | Bed or rear-body loom with 7-pin / 13-pin trailer socket, lamp clusters, rear camera and number-plate lighting. |
| Lighting & front-end harness | Headlamp, fog, horn, washer and front-sensor branches with sealed, keyed connectors. |
Fitment
| Chassis / generation | AN120 / AN130 (8th Gen) |
|---|---|
| Production years | 2015–2025 |
| Engine variants | 2.4D 2GD-FTV · 2.8D 1GD-FTV · 2.7 petrol 2TR-FE |
| Main markets | SEA, LATAM, MEA, ANZ |
| Body styles | Pickup |
| Order basis | OEM part number, VIN, or physical sample |
Known failure points on high-mileage Hiluxs
These are the faults that bring Hilux owners to us. If your symptom matches one of them, the loom — not the component — is usually the cause, and a section replacement is often enough.
- Conduit cracking and copper corrosion in the rear chassis harness on mine-spec trucks
- Differential-lock and 4WD actuator loom water ingress
- Trailer socket loom chafe where the rear body flexes
- Injector loom insulation rub-through against the rocker cover
How we build it
- Drawing first. We map your sample or OEM drawing into a circuit list, connector list and 2D layout, and send it for approval before production.
- Connector parity. The original connector series is retained for the AN120 / AN130 (8th Gen) so the loom plugs into the existing ECUs, BCM and sensors without adapters or re-pinning.
- Wire spec matched to the branch. 0.35–0.5 mm² for signal, 1.0–2.5 mm² for lighting and motors, 4–6 mm² for feeds, with heat-rated insulation on engine-bay runs.
- 100% test. Continuity, short and pin-out test against the drawing; hipot where HV is involved; bend test on hinge loops. Test record ships with the carton.
Specifications
| Wire | TXL / GXL stranded copper, 0.22–6 mm² (AWG 24–10) |
|---|---|
| Connectors | Sumitomo, Yazaki, Aptiv, TE, Molex, KET — original series or documented equivalent |
| Protection | Tape, corrugated conduit, heat-shrink breakouts, grommets, sealed pass-throughs |
| Temperature | -40 °C to +125 °C continuous, +150 °C engine-bay branches |
| Testing | 100% continuity & pin-out · crimp pull test · bend test · salt spray on chassis runs |
| MOQ | 50 sets per part number, 1 unit for a paid sample |
| Lead time | 25–30 days production · 7–10 days sample |
| Warranty | 24 months / 50,000 km against manufacturing defect |
Toyota Hilux harness questions
What does a full wiring harness for a Toyota Hilux cost?
A complete set for a Toyota Hilux (AN120 / AN130 (8th Gen), 2015–2025) typically runs USD 320–1,450 depending on circuit count, connector count and whether HV sections are included. A single engine or body assembly is USD 120–520. Send the OEM part number and a photo of the label for an exact figure — quotes are issued within 24 hours.
Can you supply a Toyota Hilux harness when the factory part is discontinued?
Yes. For discontinued Toyota Hilux looms we rebuild from your original harness: we map every circuit, identify the connector families and produce a new drawing. This is the standard route for the AN120 / AN130 (8th Gen) generation now that dealer stock has dried up in most markets.
What is the lead time and MOQ for a Toyota Hilux harness?
Sample in 7–10 days after drawing approval, production in 25–30 days. MOQ is 50 sets per part number, with one unit accepted for a paid sample. Repeat orders on an approved drawing are faster because the test fixture is already built.
Other harnesses buyers order with this one
Need a Toyota Hilux harness that actually fits?
Send the old loom or a photo of the OEM label. We confirm the AN120 / AN130 (8th Gen) variant, quote in 24 hours and ship a sample in 7–10 days.