ITB Build – Part 6

This is a going to be a big-ish update, lots of photos, so please click through to see the rest of the post.

I spent the last couple of days building my custom fuse/relay panel. I've been looking forward to this part of the build šŸ˜€

Read more after the break...


ITB Build – Part 2

Some more progress today šŸ˜€

Had a friend come over to help strip out the interior since my cracked dash and ripped carpet will be getting replaced. Also makes it easier to get out the old wiring harness. Enjoy the madness below, sorry for the lack of photos.

Seats and center console out.

Steering column dropped and dash completely out.

Everything nearly out, just need some more free time to get the wiring harness out.


ITB Build – Part 1


Started pulling apart my car today, the head is being removed so I can get that ported. The AC, all wiring, intake, strut brace and fuse box will be removed to make way for my custom tucked wiring harness.

I was planning to port it myself but have decided to send it down to Warren Heath Performance down in Melbourne. The head will received an extensive porting job as well as largerĀ oversizedĀ valves, stronger valve springs and re-shimmed solid lifters. The camshaft going in will be 280degree duration and 10.5mm lift.

Didn't get too much done today but photos below.

The operating table where most of the work will be done.

Bonnet off, radiator out and headers moved aside.

Valve cover off to remove the head, full port job on the way with massive cams going in.

The AC condenser removed and a pile of parts that won't be going back in.

That's all for today, covered up and put to bed.


Engine Harness & Wiring Parts

So a few weeks back I started working on the ECU/engine harness, this was re-usingĀ old connectors and terminals. Was never happy about re-using those parts...

How it was with the re-used parts.

Fortunately I was able to find the part numbers for new parts, all sourced locally from RS Components too!Ā All parts are manufactured by Tyco/AMP and the part numbers are below:

I also found a very good source for automotive wiring in Brisbane, the company is CECA and located in Geebung. They stock Tycab's full range of automotive cabling.

All new connectors and terminals!

Also started on my Deutsch connectors, love these things!

All terminated... this connector is used for all coil and injector +12V wires.

As a precaution, I also didĀ continuity checks for every wire and terminal used.

These are the parts I picked up to do my dedicated fuse/relay panel. Includes terminal bar, bus bar, fuse block and a relay block.

On the left are the brand new terminals I used, and the right is the FD RX-7 battery fuse block. This is where I'll be relocating all my main fusible links, sits on the positive side battery clamp.


Wiring Update

Small update... some wiring parts arrived and picked up a white board to help me scribble down wiring stuff. It's been pretty handy šŸ˜€

According to the MegaSquirt manual, it's a pretty good idea to shield the TPS and trigger wires. So have been on the search for a flexible 2-core shielded cable, ended up deciding on a microphone cable from JayCarĀ (part no. WB1530).

Terminated the shielding into it's own BLACK wire, this will grounded at the ECU end and left floating on the sensor end. The BLUE wire will be used for sensor return and the WHITE for sensor ground. The +5V/+12V wire will be run externally to the shield.

My awesome PURPLE (and grey) Deutsch connectors, all solid terminals too.

This is the relay block I'll be using, it's all modular so you can expand if needed.


Build Update

Not much has been happening but some updates for the build so far.

I received my first batch of Brake Cylinder Braces, so took some photos of what it looks like installed. It's too hard to take photos of the install, so will be doing it on a bare chassis in a few weeks.

Excuse my dirty engine bay.

I've also decided to ditch the old style CAS and go with dedicated crank and cam angle sensors. They're used in later model BP4W engines as well as NB6 engines.

Started my ECU harness too. Re-used the ECU connectors and justĀ de-pinnedĀ the terminals so I could solder new wires on. Was a tedious process but well worth it, sensors/injectors/coils connectors will be installed later.

mmmm so fresh so clean.

Cleaned up all the connectors that I plan to re-use, de-pinned and bought new rubber seals.

Picked up this cool passenger foot well plate from MX-5 Plus. No idea what brand it is, but it looks useful as it'll give me more space for the MegaSquirt and fuse/relay panel.

Made a decision to get rid of the of standard coil/ignitors and go with the very popular "Toyota COPs". Coil-On-Plugs provide a much better spark as well as giving me sequential spark with the MegaSquirt.


Custom Wiring Harness – Part 2

Over the last couple of days I finished off the main body harness, it'sĀ basicallyĀ just wiring for the exterior lights and all in-cabin stuff plus fuses. It started out as a big mess but I think I did a pretty decent job in cleaning it up, also was able to relocate the engine bay fuse box to under the dash.

Another thing I did was remove all the stupid tape Mazda used on "wire splits" and replaced it with heat-shrink, I HATE TAPE!

I used zip ties instead of tape to bundle the wiring harness, all engine bay wiring will have convoluted tubing to protect it from stuff.

Removing the stupid tape and replacing it with heat-shrink.

Main body harness completed, now to start on the power and engine harness...


Custom Wiring Harness – Part 1

I decided that since my car would be off the road for a month or two as I work on the engine, it would be a great chance to do a custom wiring harness for the car. This would mean the body and engine/ECU wiring harnesses would beĀ separatedĀ andĀ independentĀ of each other. Try to keep it all as simple as possible, will be especially nice to have a dedicated harness for the Megasquirt =)

So I was lucky enough to pickup an entire wiring harness (body, main, power, dash) for a decent price and got started working on it.

I've stripped the following from the harness so far:

  • All engine wiring
    • Air Flow Meter
    • Ignitors & coils (going COPs for the Megasquirt)
    • IAC valve
    • Purge valve
    • O2 (going dedicated wideband)
  • AC stuff
  • Power-steering
  • Clutch switch
  • Neutral switch
  • Fan switch (Megasquirt will control fans)
  • probable more... can't remember

All engine/ECU related fuses and relays will be keptĀ separateĀ and located close to the ECU. The engine bay fuse/relay box will be made redundant and relocated under the dash as there will only be four fuses used at that location.

After a long day of peeling tape and cutting wires...

99% complete with the main harness, you can see the pile of tape and wires removed in this photo. Seems a bit excessive doesn't it?

This is the wiring kit from DIYAutoTune, pretty handy. Will be used for engine to ECU wiring.

I then spent the rest of the afternoon de-pinning the ECU terminals so I could salvage the pins to re-use. It sucks having a budget...