Until I can afford a Standalone ECU, I decided to revamp my very worn and BRITTLE TII Emmissions harness (Engine). The exisiting harness covering was missing/brittle/worn beyond belief. The injector connections were trash.



The goal of this endevor are:

a. Replace all broken connections

b. Replace all brittle wiring

c. Remove all un-needed connections (ie "Rats Nest Wiring")

d. Protect the wiring from future damge



In the past 2 evenings I have the following progress.



1. Removed existing harness covers and wraps. Temporary Tie-wraps are used to maintain harness branch locations.

2. Solenoid Valve Connections and wiring have been deleted from the harness back to the ECU plugs



This has resulted in a large quantity of trash by the workbench.



The next stage is to place the harness on the engine to determine optimum routing and branch lengths.



Then the individual runs will be replaced with Tefzel Mil Spec Wire MS-22759/16 and new connectors. The branches will be wrapped in High Temperature Silicone Tape. Then a vinyl protective cover will be placed over it.



Pics to come soon



Connectors and Pins hi-lighted in yellow have been BANISHED from the harness

you have way too much free time https://www.nopistons.com/forums/pub...DIR#>/wink.png

I agree w/ the big man https://www.nopistons.com/forums/pub...#>/biggrin.png

if you need it i have a new harness i can measure up, so you know the lengths of stuff



mike

I am changing the routing of the Injector/Throttle branch so it no longer goes near the exhaust. Its not a matter of free time, Its a matter of my cars never get finished https://www.nopistons.com/forums/pub...IR#>/smile.png

haha, i know i have projects until 2010 :bigthumg:



mike

Cool! :bigok:

Here is he pile of CRAP I have removed so far....

its amazing how much harness is "extra" you might want to double up the ground wires, just a thought



mike

Here is the new location of the injector resistor pack. I have also relocated the boost sensor and he mixture adjustment...

cool, i moved all the suff out of the way when i did mine, it looks a lot better



mike

Here is the "bare harness" at the injector end. The new plan is to re-route this whole harness to the rear of the engine. The AFM is also being relocated to the TB inlet. This removes ALL of the harness from the turbo area!!!!!!!

Thats quite a project you have there.Thankfully the rats nests on FB is easier to pull. https://www.nopistons.com/forums/pub...DIR#>/wink.png I already modified the harness and rewrapped it in tape.

if you need any connectors lemme know, some of them are available new



mike

thanks

where can you get new connectors? i have no idea where you get them

I use weatherpak or metricpak connectors. The Injector connectors are available at Autozone if you just want to do a crimp install

mazda lists a bunch in the 97 bulletin book, but they didnt tell anyone. i have the book, and have ordered a bunch of the connectors so i kinda know whats what, the pictures are really bad



mike

Mike, I need:

Water Temp Switch

Water Temp Gaguge Unit

Knock Sensor

o2 Sensor

AFM



I also need 20 pins for the ECU connections



Are the connectors "bare" or do they come terminated with a length of wire attached?

I would prefer bare with the terminals supplied of course John

they come bare with the pins. all this stuff is 87-88 right? cause 89 is different



mike

hey mike do you know if the S5 thermo switch is a different size from the S4 (NA)



the hole in my SR motorsports radiator is too small for my S4 thermo switch, I'm thinking they might have made it for S5... lemme know if you can https://www.nopistons.com/forums/pub...#>/biggrin.png





sorry it's off topic, banzai reminded me of my problem with his list...

Yes this is for a 87-88 Thanks again!!

hey mike do you know if the S5 thermo switch is a different size from the S4 (NA)



the hole in my SR motorsports radiator is too small for my S4 thermo switch, I'm thinking they might have made it for S5... lemme know if you can https://www.nopistons.com/forums/pub...#>/biggrin.png





sorry it's off topic, banzai reminded me of my problem with his list... [/quote]

the 89 doesnt have the switch in the radiator at all.



mike

hey mike do you know if the S5 thermo switch is a different size from the S4 (NA)



the hole in my SR motorsports radiator is too small for my S4 thermo switch, I'm thinking they might have made it for S5... lemme know if you can https://www.nopistons.com/forums/pub...#>/biggrin.png





sorry it's off topic, banzai reminded me of my problem with his list... [/quote]

the 89 doesnt have the switch in the radiator at all.



mike [/quote]

argh.



then this hole will probably get plugged. What exactly does the thermoswitch do on the s4's? I thought it was basically the controller for the AWS solenoid... is that correct? Someone told me it also switches the maps in the ecu so it's rich when cold...

it like turns on the emisions system, out here it barely gets cold enough to open



mike

Sorry for the stupid question, but can you pass emission without all of that stuff that you eliminated?

to pass smog you need the air control valve and the 2 solenoids that run it + the airpump main cat and a working tps



mike

The short answer: NO!



I live in a state that does not have emissions testing https://www.nopistons.com/forums/pub...IR#>/smile.png

i live in a state with tree hugging nazis



mike

I'll eat a Granola Bar in your honor sir: NOT!

I live in a state of confusion, but I know that if you have the right conects and Money.. Smog is A-OK.. :bigthumg:

I've heard you can pass smog with just the air pump and the hose going directly to a cat (full time air injection), just won't pass visual.



We don't have visual here and I planned on going this route, you don't think it will work?

i dunno, we have a visual. ive never tried it



mike

thats a **** load of work uve been doing

Man i remember all the crap I removed, looks so much better now! I shoud get some more pixs up tonight, looks sexy :yum:

water temp switch (in the tstat housing) is GD4L-76-MF3

water temp guage (under the oil filter) is GD4R-76-MF1

for the knock sensor and 02 sensor they list the 89+ style GD4V-76-MF1 (female) and GD4V-76-MF2 (male)

they only have the 89+ afm connector GD4R-76-MF4

they dont list anything like the ecu connectors, you may want to contact k2rd, paul has connecotr sources



mike

https://www.nopistons.com/forums/pub...#>/biggrin.png Thanks!

:bigthumg:

HOLY ****!!! My Mazda dealer had a CLUE!!!! He faxed me the 18 page supplement!!!!!! Kewl!

wow cool, around here that book is a secret :bigthumg:



mike