E11v2 Installation Document for Mazda Rx-7 FC3S 86-91 by Brian D. Cain Mar 29 2004 http://bdc.cyberosity.com All wiring colours in CAPITAL letters. Please refer to the Haltech wiring diagram and manual for assistance. [Removing factory harness & ECU] Remove factory engine wiring harness and ECU Remove air flow meter, stock air pressure sensor, and fuel pump resistor/relay pack at passenger side headlight Cut the orange plug that has the wiring to the water temp cockpit gauge and wiper motor near factory ECU Wiper motor has 5 or so blue leads; remove the connector clip to the wiper motor and cut leads (give several inches of length); extend and re-splice those leads back to the orange connector Run a lead back to the water temp cockpit gauge lead (male spade) located on the rear iron housing near #1 heater hose Make all of the above a separate harness for the orange plug; feed plug in to passenger side from engine bay [Mounting E11v2 ECU and routing harness] Mount E11v2 ECU in stock location. The hole in the firewall for the old wiring harness is large enough to pass the connectors for the ECU. No need to run wires, relays, and fuseblocks from the passenger side, through the firewall, to the engine bay. [Relays and FuseBlocks] Mount all three relays to the fender well above wiring harness hole in firewall Mount fuseblocks side-by-side next to relays FuseBlock 1 (with wiring colours for reference) -- - Top 20A fuse is fuel pump ORANGE - Top/Middle 10A fuse is for fuel injectors power RED/BLUE - Bottom/Middle 20A fuse is ECU power RED/WHITE - Bottom 15A fuse is for sensor (CAS, etc.) power GRAY/RED FuseBlock 2 (with wiring colours for reference) -- - Top 20A fuse is for ign +12vdc power (if used) RED - Top/Middle empty fuse is spare BROWN/ORANGE - Bottom/Middle empty fuse is spare BROWN/BLACK - Bottom empty fuse is spare BROWN/RED [Flying Lead harness] ORANGE #1 to fuel pump +ve (BLACK/WHITE lead on factory fuel pump harness; run it back through the firewall) ORANGE #2 to battery terminal constant +12vdc or main fuse block +ve RED (long lead on harness) to battery terminal constant +12vdc BLACK to battery terminal -12vdc or chassis ground - Wire up main ECU power first, power on the ECU and go online, then wire up all sensors afterwards to ensure they're working properly RED/BLUE - Injector power (used for all injectors; parse off of this lead for all +ve injector leads) - Bundle back into main harness RED/YELLOW can either be cut and left off (remove the ignition fuse to relay) or parse off for powering the ignitor/coil packs (two to trailing TAN +ve leads and one to leading TAN +ve lead) GREY for switched +12vdc for all three relays (ECU/Injectors, Fuel Pump, and Ignition) - Switched lead at 6-prong green connector (female spades) near leading ignitor/headlight assembly (top-centre spade) - BLACK/WHITE w/ RED notches lead on 2-lead, white-coloured, cylinder-shaped main ignition relay connector RED (short lead on harness) to battery terminal constant +12VDC for ignition power relay (if factory ignition power harness isn't being used) Six spare fused leads (short leads on harness) (three pairs; one pair each for spare fuse in second fuseblock) - BROWN/ORANGE, BROWN/BLACK, and BROWN/RED (two leads each) -- Parse these off and keep them for later if desired [Map Sensor] BLACK/WHITE Ground YELLOW Sensor Signal ORANGE +5vdc Run vacuum source for MAP sensor and FPR alone from bottom of three nipples on front of TB Mount MAP sensor as high as possible and away from heat source (passenger side near relays or wiper motor); not on engine [Air Temperature Sensor] GREY Sensor Signal (do not confuse with switched gray lead on flying lead harness) BLACK/WHITE Ground [Coolant/Water Temperature Sensor] VIOLET (Purple) Sensor Signal BLACK/WHITE Ground [Injector Wiring] Injector ECU Ground Leads: INJ1 (Front Primary Injector) BLUE INJ2 (Rear Primary Injector) BLUE/BLACK INJ3 (Front Secondary Injector) BLUE/BROWN INJ4 (Rear Secondary Injector) BLUE/RED Additional Injector ECU Ground Leads (usually not needed): INJ5 BLUE/ORANGE INJ6 BLUE/YELLOW INJ7 BLUE/GREEN INJ8 BLUE/VIOLET Use one ground lead per injector clip. Label each injector clip (numbered 1, 2, 3, etc. etc.) RED/BLUE lead from the flying lead harness is used for all injector power. Parse off of this lead once for each injector. Once injector clips are made, test for +12vdc on each power lead to verify. [Throttle Position Sensor (TPS)] Haltech/GM TPS: - BLACK/WHITE Ground - WHITE Sensor Signal - ORANGE +5vdc Series 5 ('89-'91) factory TPS Stock TPS -> Haltech E11 harness: - BLUE BLACK/WHITE Ground - PINK ORANGE +5vdc - YELLOW WHITE Sensor Signal Stock Series 4 ('86-'88) sensor cannot be used. If using Haltech/GM TPS, custom bracket must be made for the throttle body. [Oxygen (O2) Sensor] GRAY/RED +12vdc supply to sensor (not needed with single wire sensor) BLACK/WHITE Ground to sensor (not needed on single wire sensor) WHITE/ORANGE (Shielded) Sensor Signal (only lead used on single wire sensor) [Crank Angle Sensor (CAS)] There are two trigger harnesses used on the E11v2. Use both for the factory FC3S CAS wiring. Trigger Input and Home Input harnesses: Trigger Input Harness (WHITE, thickly Shielded) - WHITE/ORANGE +12vdc Unused - WHITE/BLUE Ground WHITE on CAS (WHITE on connector side) Trigger - - WHITE Trigger RED on CAS (RED on connector side) Trigger + - WHITE/GREEN Unused n/c Unused Home Input Harness (WHITE/BLACK, thickly Shielded) - WHITE/ORANGE +12vdc Unused - WHITE/BLUE Ground WHITE/BLACK on CAS (BLUE on connector side) Home - - WHITE/GREEN Home GREEN on CAS (GREEN on connector side) Home + - WHITE Unused n/c Unused [Factory Leading and Trailing Ignitors/Coil Packs] IGN1 (YELLOW/BLACK) Leading Ignitor Signal PINK IGN2 (YELLOW/RED) Trailing Ignitor Signal PINK IGN3 (YELLOW/ORANGE) T1/T2 Toggle Lead for Trailing Ignitor WHITE [PWM Outputs] (bundle and reserve these leads for later use if desired or cut from harness) PWM1 VIOLET/BLACK PWM2 VIOLET/BROWN PWM3 VIOLET/RED PWM4 VIOLET/ORANGE [Spare A/D Outputs] (bundle and reserve these leads for later use if desired or cut from harness) Spare A/D 1 WHITE/YELLOW (shielded) Spare A/D 2 ORANGE/BLACK Spare A/D 3 ORANGE/RED Spare A/D 4 ORANGE/YELLOW Spare A/D 5 ORANGE/GREEN Spare A/D 6 ORANGE/BLUE Spare A/D 7 ORANGE/VIOLET [Aux-In and Timed Inputs] (bundle and reserve these leads for later use if desired or cut from harness) Aux-In 1 GREY/GREEN Timed Input 1 WHITE, Shielded (small) Timed Input 2 WHITE/BLACK, Shielded (small) Timed Input 3 WHITE/BROWN, Shielded (small) [Additional Sensor Inputs] (bundle and reserve these leads for later use if desired) GREY/RED +12vdc (5 flying leads) BLACK/WHITE Ground, bundle additional, unused ground leads [Wires to be cut from main harness] Idle Speed Motor - GREEN/RED, GREEN/BROWN, GREEN, and GREEN/BLACK Injectors 5-8 - BLUE/ORANGE, BLUE/YELLOW, BLUE/GREEN, BLUE/VIOLET +8vdc Sensor Supply - ORANGE/WHITE (two leads)