What Can I Do to Combat Wire Embrittlement?

The very short answer is that heat isn't a significant problem for the wire. Heat is a problem for the insulation. So if you have wires failing I think there is something else going on. The problem with dealing with failing insulation is that there isn't much you can do about it short of rewiring the affected parts. In a modern car that could be a non-trivial project. As Agent_L mentioned there are good high temperature insulation materials, but retrofitting them isn't really practical in many cases.There are a few practical things you can do:Heat shrink tubing, though this usually requires reterminating the wire since most heat shrink won't shrink enough to fit over most connectors.

Electrical tape, it's not elegant, but it can be effective and is relatively easy to do."Paint on" electrical tape I've never used the stuff, but it is available and it might work well in some applications, I think it would do a better job of excluding moisture than tape.If the affected area is small and the car is old one of the easier approaches might be to replace the section of the wiring harness, or to rebuild it. If the car is old then I wouldn't even worry too much about getting better wire, unless it is a classic, as the replacement wire will last for many years before it fails

I live in a very hot climate where temperatures regularly touch 45 deg C and the heat in the engine bay area means that under-hood wires, especially the thinner ones, endure high levels of thermal fatigue.

As a result, when working on older cars (10 years) I am very apprehensive about flexing any wiring in the engine bay area in case I introduce a break (and a new headache). This includes wires for things like coolant temp sensor, MAF sensor, coil and injector power supply

Is there anything that one can do to delay the onset of wire embrittlement? Would it help if manufacturers use a different grade/gauge of wire to help with longevity?

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