Toyota Innova wiring harness replacement — AN40, 2004–2025

Harness assemblies we build for the Toyota Innova

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.
Rear cabin & blower harness	Second-row and third-row cabin loom with rear blower, reading lamps and USB charging circuits.
Door & window harness	Door-grommet section built on flex-rated cable with window-motor, lock-actuator and mirror connectors.
Lighting harness	Built to the original routing and circuit count with the OEM connector family retained.

Fitment

Chassis / generation	AN40 / AN140
Production years	2004–2025
Engine variants	2.0 1TR-FE · 2.5D 2KD-FTV · 2.4D 2GD-FTV · 2.7 2TR-FE
Main markets	SEA, India, MEA
Body styles	MPV
Order basis	OEM part number, VIN, or physical sample

Known failure points on high-mileage Innovas

These are the faults that bring Innova 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.

• Rear blower and AC control loom failure on 7-seat taxis
• Sliding-door loom fatigue
• Corroded body ground behind the kick panel
• Hacked-in CNG/LPG wiring cutting into the injector loom

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 AN40 / AN140 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 Innova harness questions

What does a full wiring harness for a Toyota Innova cost?

A complete set for a Toyota Innova (AN40 / AN140, 2004–2025) 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 Innova harness when the factory part is discontinued?

Yes. For discontinued Toyota Innova 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 AN40 / AN140 generation now that dealer stock has dried up in most markets.

What is the lead time and MOQ for a Toyota Innova 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.