New Engine/Battery Relocation/PowerFC Install Wiring Problems...
New Engine/Battery Relocation/PowerFC Install Wiring Problems...
Hi All,
I've spent the last 2 months or so swapping in a s5 n/a bridgeport with PowerFC into my '86 gxl. I relocated the battery to the trunk and ran a 2-gauge wire from the + battery terminal up into the engine compartment to an insulated lug and then connected the original + cable and alternator + to that lug as well. Connected - terminal of battery to chassis and original - cable to chassis.
I then removed the stock ECU and using the Banzai s4 adapter plugged the PowerFC into my harness. Connected a wire from FRT wire on Banzai adapter to the signal wire on the full-range s5 TPS, spliced the +5V and ground wires of the two TPS together, cut the Brown wire on the bottom of the X-16 connector and connected it to the COR wire on the adapter, plugged the commander cable into the side and placed the PowerFC where the old ECU used to be and re-installed the ECU cover plate.
Since the S5 engine has high-impedance injectors I stole the connectors from a S5 harness and installed them in place of my old S4 low impedance clips on the harness. I removed the silver metal covered resistor pack from the passenger side of the engine compartment behind the headlight. I cut all the wires leading into the resistor and connected the 2 wires on the right side of this connector to each other and separately I connected the 2 wires on the left side of the same connector together. I left the middle wire alone and capped it. AFM is completely removed with the plug just hanging there.
After hooking up all the sensors, the ground on top of the engine from the harness, the ground from the top of the engine/bell housing to the firewall right under the VIN, I turned the key to the ON position. I did not hear the injector relay open in the engine compartment like usual (usually makes a metallic thunking/clicking sound), did not hear the fuel pump, power windows do not work, wipers do not work, turn signals do not work, blower motor does not work and get nothing from the starter when I push key to START position. However, headlights work, hazard lights work, dome lights work, brake lights work, little light on the hatch strut works. PowerFC commander does not light up or do anything.
I quickly checked some of the fuses and could not find any that were fried. Any ideas where I should be looking? Did I clip the correct side of the X-16 brown wire as noted in the Banzai S4 PFC install instructions? I noticed there is a sensor missing in the oil pan that was installed on my S4 engine but no spot for the sensor on the S5 pan so this plug is not connected to anything. Am I possibly missing a ground somewhere that would cause all those different things to stop working at the same time? Did I modify the injector resistor connector correctly to "bypass" straight to the injectors? I might have connected the 2 green wires going to the transmission backwards. (are these for the neutral start switch? Would that cause any of these issues?) I couldn't find any connectors that I missed but the new engine does not have any emissions equipment or BACV so there are connectors unplugged from all those things. I did not remove any of the starter motor wires while doing the swap, just let it hang there and reinstalled.
Any help would be much appreciated since there are a lot of people with much more knowledge than I on these forums. Any suggestions on which fuses, ECU pins, etc that I should begin checking would be much appreciated.
I've spent the last 2 months or so swapping in a s5 n/a bridgeport with PowerFC into my '86 gxl. I relocated the battery to the trunk and ran a 2-gauge wire from the + battery terminal up into the engine compartment to an insulated lug and then connected the original + cable and alternator + to that lug as well. Connected - terminal of battery to chassis and original - cable to chassis.
I then removed the stock ECU and using the Banzai s4 adapter plugged the PowerFC into my harness. Connected a wire from FRT wire on Banzai adapter to the signal wire on the full-range s5 TPS, spliced the +5V and ground wires of the two TPS together, cut the Brown wire on the bottom of the X-16 connector and connected it to the COR wire on the adapter, plugged the commander cable into the side and placed the PowerFC where the old ECU used to be and re-installed the ECU cover plate.
Since the S5 engine has high-impedance injectors I stole the connectors from a S5 harness and installed them in place of my old S4 low impedance clips on the harness. I removed the silver metal covered resistor pack from the passenger side of the engine compartment behind the headlight. I cut all the wires leading into the resistor and connected the 2 wires on the right side of this connector to each other and separately I connected the 2 wires on the left side of the same connector together. I left the middle wire alone and capped it. AFM is completely removed with the plug just hanging there.
After hooking up all the sensors, the ground on top of the engine from the harness, the ground from the top of the engine/bell housing to the firewall right under the VIN, I turned the key to the ON position. I did not hear the injector relay open in the engine compartment like usual (usually makes a metallic thunking/clicking sound), did not hear the fuel pump, power windows do not work, wipers do not work, turn signals do not work, blower motor does not work and get nothing from the starter when I push key to START position. However, headlights work, hazard lights work, dome lights work, brake lights work, little light on the hatch strut works. PowerFC commander does not light up or do anything.
I quickly checked some of the fuses and could not find any that were fried. Any ideas where I should be looking? Did I clip the correct side of the X-16 brown wire as noted in the Banzai S4 PFC install instructions? I noticed there is a sensor missing in the oil pan that was installed on my S4 engine but no spot for the sensor on the S5 pan so this plug is not connected to anything. Am I possibly missing a ground somewhere that would cause all those different things to stop working at the same time? Did I modify the injector resistor connector correctly to "bypass" straight to the injectors? I might have connected the 2 green wires going to the transmission backwards. (are these for the neutral start switch? Would that cause any of these issues?) I couldn't find any connectors that I missed but the new engine does not have any emissions equipment or BACV so there are connectors unplugged from all those things. I did not remove any of the starter motor wires while doing the swap, just let it hang there and reinstalled.
Any help would be much appreciated since there are a lot of people with much more knowledge than I on these forums. Any suggestions on which fuses, ECU pins, etc that I should begin checking would be much appreciated.
After reading Aaron Cake's "Proper RX-7 Grounding Procedures" I am going to start there. However, I will not be able to work on my car for another week or two. Any additional suggestions or input in the mean time would be greatly appreciated though.
not a grounding issue, it is in the auxiliary power feed up to the switch. i would start at he main fuse box in the engine bay and check for loose connections. also make sure your main relay is plugged in.. and physically in the car.
Ok that makes sense since I didn't hear the main relay click like it usually does. Looks like I will be getting out the volt meter this weekend and checking the relay connections, EGI fuse, and 15-amp engine fuse as suggested by Satch in the link below. Thanks for the info on which direction I should begin.
https://www.rx7club.com/2nd-generati...-help-1001897/
https://www.rx7club.com/2nd-generati...-help-1001897/
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