Tuesday 1 October 2024

Engine wiring

 There's no two ways about it, this is probably the biggest job remaining. The main loom is about two inches thick, and I reckon maybe half of it is redundant. More importantly it's designed to go down both sides of the engine bay, whereas I think I only need maybe one or two wires to go down the passenger side. In fact it may just be the O2 sensor on the manifold.

So the plan will be to take out each sensor individually, route them as required, shorten the wire if needed, then bundle them back up. I'm planning on doing this in stages, and I'll tick them off as I go;

Stage 1: High current

This includes;
  • Starter motor. Partly complete as I left it in place.
  • Alternator. Similarly partly complete.
  • Ground to chassis. Big wire to be connected.
  • Ignition switch. Done. 
  • Fuse box. This is more about physically locating it in the right place.
  • Battery. As above, getting it physically located and connected.

Stage 2: Engine sensors

This will include all of the following, traced out individually and then taped up once they're all complete. I'll need to put the ECU in place before I start here, as basically all of this connects to the ECU. Depending on what is required I might also need to put the fuse boxes in the relevant locations as well. 
  • Igniter (C4) Now extracted. 
    • White (to ignition coil)
    • Brown/Yellow (to ECU)
    • Blue (Ignition switch)
    • Yellow/Blue (to ECU and to rev counter)
    • Black/White (to ECU)
    • Black (Ground)
    • Brown (to ECU)
    • Red (to ignition coil)
  • Ignition coil (D4)
    • Spark plug leads
    • Red (to igniter)
    • White (to igniter)
    • Blue (to ignition switch and capacitor to ground)
  • Main relay (E4)
    • White/Green (Relay and main fuse block)
    • White/Red (to ECU)
    • Black (Ground)
    • Black/White (Engine Fuse)
    • Black/White (Cooling fan relay)
  • Crank Angle Sensor (D7)
    • Black/Light Green (Ground)
    • White/Red (to ECU)
    • White (to ECU)
    • Yellow/Blue (to ECU)
  • Throttle sensor (D7)
    • Light Green/White (to ECU)
    • Black/Light Green (Ground)
    • Red (to ECU)
  • Airflow meter (C7)
    • Light Green/Red (to ECU)
    • Red (to ECU)
    • Black/Light Green (Shield/Ground) x 2?
    • Red/Green (to ECU)
    • Light Green (to fuel pump relay)
    • Black (ground)
  • Coolant temp sensor (B7)
    • Blue/White (to ECU)
    • Black/Light Green (Shield/Ground)
  • Fuel injectors (B7)
    • Yellow/Black (to ECU)
    • Yellow (to ECU)
    • White/Red (to ECU)
  • Idle speed control valve (A7)
    • Blue/Orange (to ECU)
    • White/Red (to ECU)
  • Purge solenoid valve (A7) I think this has been deleted?

Stage 3: Non-engine sensors and switches

  • Fuel pump relay (C4)
    • Blue/Red (to Fuel tank)
    • Light Green (to AFM)
    • White/Red (to ECU)
    • Violet (ST SIGN FUSE?)
    • Black (Ground)
  • O2 sensor on exhaust (B7)
    • Red/Blue (to ECU)
  • Clutch Switch on pedal (E7)
    • Brown/White (to ECU)
  • Neutral switch on gearbox (E7)
    • Brown/White (to ECU)
  • Cooling fan via relay (E10)
    • Yellow (to relay)
    • Black (to Ground)
  • Coolant thermostat (E9)
    • Black/Green (to ECU and relay)
    • Black (Ground)
  • Horn and relay (C17)
    • Green/Orange (to horn switch inside combination switch)
    • White/Green (STOP FUSE)
    • Green/Red (Horn)

Stage 3: Connection to steering column switch gear

Mainly lights and indicators, as the ignition switch will have already been wired in stage 1.

Stage 4: Connection to gauges and tell-tales

Once things have been wired from the controls and sensors it'll be fairly straightforward to wire them back to the dash. 

No comments:

Post a Comment