Single turbo FD harness mod (PICTURES)
 

Well here it is, i finally decided to do it, i hacked a wiring harness to remove all the unnecessary stuff when you go single turbo and remove all the emission stuff. That was one heck of a job, took a whole day but i am happy. I decided to do it the right way, not only cut the wires that were unused but remove them completly, including the pins that go in the connectors to the ecu. I had to strip the harness completly and tape everything back. You got to be carefull with such a job because some wires are spliced and splited at different places in the harness, like grounds and powers. You got to make sure you don't cut a wire or remove a spliter that will still be used.

So what i have removed is the complete rat's nest (twins and emission), the ACV connectors, wastegate and precontrol solenoid, AWS, fuel thermosensor, air pump and egr connector

I am going to order some stuff to prevent the heat from harming the electrical tape and the wires, some DEI stuff i guess, i'll order that tomorrow.

Here are a couple of pictures to show the before and after. You can also see the difference in the ecu connectors as far as how many wires are left. I also took a pic of all the wires and connectors i removed from the harness. Sorry for those bad quality pics, i am a better mechanic than photographer...

BEFORE
http://img.photobucket.com/albums/v3...IMG_5033-2.jpg

AFTER
http://img.photobucket.com/albums/v3...IMG_5032-2.jpg

In the harness there is some sort of silicon to hold all the wires together, that was the biggest PITA, those were stuck really good, no clue why they did that. Looks like they put silicon in just before they taped eveything together.

http://img.photobucket.com/albums/v3...IMG_5036-2.jpg
http://img.photobucket.com/albums/v3...IMG_5037-2.jpg

Here is all the stuff removed
http://img.photobucket.com/albums/v3...IMG_5039-2.jpg

finally, pics of the ecu connectors before (can't see really well)
http://img.photobucket.com/albums/v3...IMG_5035-2.jpg

and after
http://img.photobucket.com/albums/v3...IMG_5073-2.jpg

I'll take some pics when the harness is installed in the car.

Nice.

would there be people interested in getting the same thing done for their harness? I could get some brand new harness and modify them for around 1000, would there be some interest?

A new harness when doing a single turbo projet is always a good idea, after 15 years of getting heated up in the engine bay, they become very fragile and brittle, not counting the electrical resistance that went up at the same time.

let me know

hey guys. i know this thread is a few months old, but i was wondering if anyone knows of (or could create for me) a list of all the emissions solenoids and their colors/pins back at the ECU plug. it is taking me forever to trace down every wire from the wiring diagram to the harness. I am hoping someone else has taken the time to do this and document it for the rest of us to use.

my plan is to just pull every emissions/sequential solenoid wire out of the harness and hook up the 330ohm 1/2watt resistors to each wire back at the ECU to clean up the harness.

http://img.photobucket.com/albums/v4...lx/wire4dr.jpg

http://img.photobucket.com/albums/v4...ireharness.jpg

I'd be interested, seems like a fair price of a *new* modified harness

Already have a new harness but will eventually like it slimmed down.

id pay 5 bucks for a full picture tutorial of how to diy. but with the posts above and how much I have already started on maybe just posting for people on here.

You mean like this one.....I advertised the mod for $300 shipped long time ago. It was your working harness to me, and looks like this one back. Loom is very nice. Something like 24 connectors and 16 wires total.


Also the purpose of the Sealant is to seal off the wiring harness from the engine bay to the Cockpit :)

ALWAYS include several spare signal wires for gauges and spare grounds.



Later

For $1,000 that some person can build a harness 60x better.
The harness shown hasn't been modified for EMI, heat, gas/oil, etc. The GND's could be better too.

Anyone looking to do this can spend half the money and end up with a harness worth twice as much as a stock harness by using 55A cable and DR25.

Apex Speed Tech (apexspeedtech.com) would be an ideal place to build that harness per your spec and 60x better.

If you cut off the solenoid connectors the idle air control will not function. It shares a power with the gray solenoid connector. What I do for single turbo/non sequential cars is open the harness and rewire it.

He's right, I've done that a few times (open the harness and rewire & de-pin).

Gotta be careful.

Meh, do you really need the idle air control? All of the ls1 engines I put in sandrails don't come with them (well until emissions controls were mandatory).

After doing some thinking I might offer this as a service. Not crap either, full shrink wrap covered with a braided sleeve. My only issue is I'd have to remove the connectors and that is possibly something I could only feel comfortable doing with a new harness. So I would sell a new modified harness. Not sure if there is much interest. I'm not new to wiring, I wired this $185,000 dollar sand rail front to back.

I didn't see any 55A cable in those photos... What did you write it up with?

of course you didn't, its standard primary wiring for the chassis. The engine is in the back of the car. There is no need for it. The engine itself uses thermal cross-linked wire TXL. The wrap for the chassis where the wires aren't seen is standard heat shrink and the wrap for the engine is a braided wrap. Anything more for these is not needed at all.

As far as the rotary stuff I would use the stock wires, possibly throw a heat shrink for the first layer and finish up with a fiberglass sleeve, I haven't really explored my options yet. It could end up being a high temp shrink with a nice braided top layer for a nice look.

You should start a thread in the group buy interest section. The stock harness sucks, I'd be interested.

no interest in recreating a stock harness. think about that for a min.. you could copy the structure / branching, etc then reproduce that with wire worth paying for 55A.

Trust me, 55a is very useful jacketed or non jacketed... braided or not. given the jacket type, etc you can surely run much smaller cable (F1 & Indy Car are using 22awg - 26awg) for typical small draw / low voltage and signal producing a much lighter weight harness and easier to work with. even throw in a autosports connector on the subharnesses (injector branch, coils etc) making for a modular design for upgrading, etc... that is something people would pay for.
but no one will would pay $700 - $800 for a new harness then pay you another $500+/- on top of that for crap plastic-jacketed cabling. it would be an overpriced harness.


If you are really looking for a replacement harness, try Neel @ ApexSpeed - I'm sure he can help you get in the right direction.

The problem is you can't buy the connectors, at all, ever, people have tried looking. I would have made a harness from the ground up for myself already if this was possible.

What connectors are you missing?

I built a harness for an SQ6 on my 3rotor, - I didn't have your luck, I was able to buy all the connectors needed.

was this new or used? New ones are what I'm after for an entire harness.

This would definitely be awesome and worthwhile. I'd definitely buy a custom made harness.

well once I have no job in a few weeks I will look into this more thoroughly.

update?

still have a job, lol. I may end up going to junk yards and getting some connectors out of 90's mazdas, hopefully I can get just about everything. I would imagine the OMP connector would be impossible. I would also put fresh new pins in the connectors.

i would reccomend that you use some heat wrap. i got some from thermo tek.

here are some pics of mine

http://i12.photobucket.com/albums/a2...3/DSCN0497.jpg

Update:
I've been sourcing new connectors and things look promising. I have some coming in the mail. Some are on an 8 week back order. I won't know for certain until I get them if they will work. I haven't found everything yet, but I've been finding things like the OMP connector that I thought was going to be an impossibility. I even tracked down the ECU connectors. Once I know I can get everything I'll start stocking parts, get a shit ton of wire and get a harness in the works. I'd like to test one out first myself. I'm not sure if I can get every color of tracer wire out there so I may have to make a conversion chart or a guide for diagnostics.

Nothing is set in stone at this time, but I just wanted to let some of you know that I am working on it and it won't be garbage. I plan to keep you updated as progress is made. It will be a COMPLETE replacement harness that is superior to OEM with a professional look. Depending on material cost, I hope to be lower than what Malloy would charge.

You can use the OEM connectors too ;)

I think the hardest part will be locating the proper pins for the OEM connectors... but it'll work though the connector would be used. :(

These are the OEM connectors I'm getting. You can't get them at the dealer.

you missed my point. AMP (and DTM) wont sell YOU 10 connectors for the OMP. Maybe if you bought 5k or so. I was suggesting to re-use the old ones if you cant source 'em.

if you ask nicely i might let you know where i bough mine. :)

I'm not buying directly from AMP. I have a bunch on order through a distributor and a few coming in from AMP directly as "samples" to see if they match up. It also looks like you can order 100 directly through amp as a minimum.
There are a couple I may have to re-use and the ones I have on hand come from an 80k mile car and they seem to be holding up fine. It depends which plastics the connectors are made of as some are crunchy and some are still flexible.

I still need to rip the harness out of one of my cars so I can get all on order. So far there are a few oddball connectors that don't seem to come from AMP or they were a proprietary design for Mazda from AMP. The TPS connector and the air intake connector come to mind as they are ever so slightly different. If you have found them and you would like to share, by all means. If you don't want to share, I understand also as this is painful research to find all of these.

Well now I see what some are saying. It has already been noted in this forum that half of the connectors are made by a different company. Sumitomo. I am trying to make contact with some distributors who have some of these connectors, pins, and plugs. I'm mainly going after the one connector that seems to be all over this harness. The crank sensors for example. I will buy these in bulk and not only use these in my harnesses, but I am open to selling these individually for those that just need one or two connectors. It appears that the Sumitomo connectors hold up better than the AMP connectors. If I can't get the Sumitomo connectors I will have to re-use your connectors. I will track down new pins. It seems like Tyco has Sumitomo equivalent pins. Just trying to keep you guys updated. If all else fails, I have contacts with someone that can actually make new connectors, but I don't know the legality of it.

Semi victory, I have some Sumitomo connectors in possession:
http://content.imagesocket.com/images/P1010152771.JPG

Nice, good luck man.

hi,
can you please give more info about that? witch grey solenoid? i checked the ISC diagram in the F-section Page-226 from the workshop manual and the two wires from the isc is the ecu 4Q and the other is ground. the groun B/W wire is shared with that " gray solenoid"? so all i need is to ground again at some other B/W wire ?
thanks

correction : the B/W wire is NOT Ground , is the + from main relay. that wire must rerouted?
thanks!!!

I know I haven't updated in a long time, mainly because of the frustration of trying to get certain connectors. It looks like I have almost everything now. ALMOST. The most frustrating ones to get have been the TPS connector, IAC, water temp, and the gray trans connectors. There is no hope on those. I'm also having a hard time getting one of the ECU connectors. I have some mill spec wire on the way, and I'll be slowly building up my supply of wire. Once I build my first single turbo harness I will see if anyone else wants one. If you guys want one I'll need your old harness as a core for the above connectors, as long as those select ones are in good shape you should be good to go as I'll be putting fresh pins in them. It seems that the gray Sumitomo connectors hold up fairly well, its the damn AMP connectors that blow up into a million pieces and it seems like I can get most of them.

I know I said there is no hope on the last few connectors, but it looks like I have some hope. I have a source on the TPS connector, and the gray transmission connectors as well, I'm in the process of getting a quote. I MIGHT even have some luck on the IAC connector as well.

It may be down to needing a core harness for the water temp connector, one ecu connector, one trans connector, and possibly the IAC connector. If there are connectors that are in great condition they will be reused (but will get new pins) strictly because of quantity stock concerns.

I hope to get one done in a month so I can show a product here soon if there is interest in a product. It all depends on how quick Sumitomo is as I have a guy with a direct line to them. These will strictly be a single turbo or non-seq harnesses with emissions delete. However I can add the purge control, air pump, OMP, and possibly some other extra stuff depending on what it is. There will be no rats nest connectors on these harnesses. You will also get the correct injector connectors for your application. :icon_tup:

For those of you wondering about Raychem. I've looked into the Raychem stuff the Honda guys are using and I believe it is blown out of proportion hype and just plain overkill. On a Honda you can see the wires so It seems more like a bragging rights thing. On an RX7 you don't get too see too many wires. the cost of that stuff alone can jump the price by 500 dollars. I'm trying to make something affordable but solid and reliable at the same time. Maybe in the future I will offer Raychem, but not now. I'm also looking into the aircraft bulkhead connectors to have a quick disconnect on the firewall, they look nice, and are handy, but definitely something for the future, not now.

I am interested in this. Keep us posted.

-AzEKnightz

I'll be interested in this too next year when I get around to doing the engine part of my build. :)

Hopefully by then you'll have everything sorted out. :-)

Welp, looks like I'm gonna have some competition, just noticed a new thread in the 3rd gen section.
I'm just waiting for some connectors to come in from Sumitomo and I should be starting on my first new harness soon. Just a reminder this will be mill spec wire (not automotive grade) to handle the heat, no splicing, new connectors (except for about 2 or so), new pins. Heat shrunk (not electrical tape) Pretty much 99% brand new. It has taken me quite a while to get this far and I'm getting excited to finally be able to offer a product.

It's not competition it's just a big country. I mean we are doing the same thing after all. Nice to meet someone else that does this professionally though. Email me and maybe we can work something out with sumitomi together. I've got the catalogue and I'm debating if I want to get an account and put their connectors on my webpage.

I'm sure we can work together, you just caught me off guard was all =)
I've got connectors on the way. In the future if working together can help us I'm open to that, but for now I'm just concentrating on getting a product out, its been a long road. My past wiring experience has been off road stuff (I've wired around 100 sand rails) and I have never had to deal with Tyco or Sumitomo.

would be nice to have a new custom made wiring harness with all new connectors, wires and pins. However I've waited for WAY too long for you to update on getting those connectors. I havent yet decide what to do yet, hopefully you can get the product out asap =)

-AzEKnightz

emailed

Yeah getting this stuff has been a huge ordeal. Mainly because the connectors I'm getting have to come direct from Sumitomo and I just recently found a contact a month ago or so who has been able to help me with "small" quantities. I'm still waiting on the parts and I would hate to take orders only to have your stuff waiting on a bench.
Before I was just scrounging up what I could get and was going to reuse a bunch of connectors, and I probably would have had a product out , but I want most of everything to be new, so the drawback has been a huge wait for everyone and a huge chunk out of my pocket.

I can understand your position and I'm not telling you who you should get your harness made by. I'm getting antsy myself over this stuff.

Just a quick update. I have been extremely busy with personal things but I have finally been able to start on a harness. This one will go in my car for testing, after that I will start making more.

http://i31.tinypic.com/2uzxikk.jpg

The hard part is locating the long connectors from the transmission .

got the main layout done, just started mocking up the lengths so I can make a proper jig.

http://i27.tinypic.com/16gc45x.jpg