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Custom Engine Loom - Questions?


mwilkinson

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My engine is now down at AFR being rebuilt ready for my single install. I was going to do this all myself but I quite honestly just don't have the time to do this at the moment. John and the lads are more than capable and I'm just looking forward to the finished results and it's a weight of my mind.

 

I am now starting to think about the engine loom.

 

I am going to buy new plugs for all connections on the loom and as such decided to build a bespoke loom with new wiring etc..

 

Has anyone done this for a single and have any guides as to what wire to use?

 

I also want to get rid of the stock fuse box. I was thinking if there was anyway to use a digital fuse system as used on modern cars. That is to say trip switches instead of fuses. Could this be run from an ECU like the Syvecs which I will be using?

 

Has anyone used a more modern and streamlined fuse box? I have seen in Hodge's thread that he hid the fuse box in the glove box but I'm not keen on this.

 

I am also looking to install quick release connectors from the engine to the gearbox and the engine from the ECU loom. Anyone have any suggestions on what plugs to use?

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I got my hands on a second loom and stripped off what wasn't needed. I looked into the cost of making a loom with new plugs (for me) it wasn't cost effective.

 

As for quick disconnect connectors, only really one option - mil spec connectors, but be prepared for a shock of the cost of them. Saying that I'll probably putting some on mine - but I have access to some... ;)

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I got my hands on a second loom and stripped off what wasn't needed. I looked into the cost of making a loom with new plugs (for me) it wasn't cost effective.

 

As for quick disconnect connectors, only really one option - mil spec connectors, but be prepared for a shock of the cost of them. Saying that I'll probably putting some on mine - but I have access to some... ;)

 

Yeah, not expecting it to be cheap Si.

 

My concern is that you spend so much money on the engine and bling etc.. Then reinstall a butchered 16+ year old bit of wiring to run some very important things.

 

When you say expensive connectors what are we talking and are they commercially available?

 

Got any comments on the fuse box situation?

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If you want to do a proper job Tefzel insulated wire is the stuff to use. RS Components are one source of it online. Motec also sell it. Budget for crimping tools, some are seriously expensive, although some generic crimpers work fairly well. For none OE connectors I use DTM connectors from Deutsch, they are a LOT cheaper than the Motorport mil spec connectors, but are still superb quality. The ecu swill most likely come with its own connectors, again, have you got the right tooling to crimp the connectors on? 22 gauge is good for most sensors bar O2. The injectors and coil packs are best done with something a bit heavier like 20 or maybe even 18 gauge. Grounds need to be perfect, and supply protected with a fuse and I always add a diode in the ecu relay coil wiring to stop the relay even energising with a reversed polarity. M-Cal sell Deutsch connectors and tooling, as do Motec. pricing is pretty similar. Have fun, I find it a nightmare :)

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If you want to do a proper job Tefzel insulated wire is the stuff to use. RS Components are one source of it online. Motec also sell it. Budget for crimping tools, some are seriously expensive, although some generic crimpers work fairly well. For none OE connectors I use DTM connectors from Deutsch, they are a LOT cheaper than the Motorport mil spec connectors, but are still superb quality. The ecu swill most likely come with its own connectors, again, have you got the right tooling to crimp the connectors on? 22 gauge is good for most sensors bar O2. The injectors and coil packs are best done with something a bit heavier like 20 or maybe even 18 gauge. Grounds need to be perfect, and supply protected with a fuse and I always add a diode in the ecu relay coil wiring to stop the relay even energising with a reversed polarity. M-Cal sell Deutsch connectors and tooling, as do Motec. pricing is pretty similar. Have fun, I find it a nightmare :)

 

My brothers an auto electrician for the police and therefore has access to some funky kit. i'm sure I could piece most things together. They install all the radio equipment too so most connector tools should be available.

 

I will take a look at the RS stuff and see what I can find.

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The DT and DTM (miniature DT) connectors are a maximum, from memory, of 12 way, so unless you need to connect more than 12 wires together in one connector shell they should do. The proper round MIL spec stuff goes to 70 odd wires in one shell. I just had to buy one for my Lola, and it was about 140 quid, plus pins, plus VAT. plus carriage..... I can't see you needing them as the densest connector will be the ecu itself, and they have their own connectors if it's a Syvecs. Have a look here:

 

http://www.m-cal.com/

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The DT and DTM (miniature DT) connectors are a maximum, from memory, of 12 way, so unless you need to connect more than 12 wires together in one connector shell they should do. The proper round MIL spec stuff goes to 70 odd wires in one shell. I just had to buy one for my Lola, and it was about 140 quid, plus pins, plus VAT. plus carriage..... I can't see you needing them as the densest connector will be the ecu itself, and they have their own connectors if it's a Syvecs. Have a look here:

 

http://www.m-cal.com/

 

Good link there Chris +1 for you Sir.

 

Some very good connectors. I quite like the AS connectors. I could fabricate a plate and use a two hole connector straight from the bulkhead to the engine loom. Then create a custom loom from the connector in the car to the Syvecs.

 

I have a cunning plan M'Lord!!

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Trying to think of the stock engine connectors that you would keep be on a typical single turbo loom:

 

Cam position sensors x 2

Oil Level sensor

Crank Position sensor

Oil pressure sensor

Water temp sensor (Radiator)

Water temp sensor (Block)

Coil Pack connectors x6

Alternator

Injector connectors x 6

Ignitor pack x 2 (black box on suspension tower)

ABS actuator

Aircon pump

Oil pump? (Is there one I can't quite remember)

MAP Sensor

Plenum air temp sensor

Knock Sensors x 2

TPS

ICV

 

Additional sensors and wiring:

 

Oil pressure

AFR

Fuel Pressure

Wastegate Solenoid Control

 

Can anyone think of any others?

Edited by mwilkinson (see edit history)
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Radiator thermo switch (in bottom tank of rad, is it part of the engine loom, I can't recall?).

MAP sensor.

Plenum air temp sensor.

You may want to run a fuel pressure sensor and an oil pressure sensor, the stock sensor is just a switch for the warning light in the dash.

The engine loom also has, as stock, the wiring for the single wire water temp sensor for the dash gauge.

Knock sensors x 2

Throttle position sensor (+ the other stuff if you want to retain secondary throttle plate control, or convert to DBW).

Idle control valve.

Wastegate control solenoid.

 

Things I have forgotten... ;)

Edited by Chris Wilson (see edit history)
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MC04-768060.JPG

This is the MC04-768060 12 Way female kit DTM Series.

£16.50

 

MC04-768061.jpg

This is the MC04-768061 12 way male kit DTM Series.

 

They also supply rubber boots for either side of the connectors.

 

I think this is what I will go for.

 

They also do a two pin which is what I will use for the loom connector to the gearbox.

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Radiator thermo switch (in bottom tank of rad, is it part of the engine loom, I can't recall?).

MAP sensor.

Plenum air temp sensor.

You may want to run a fuel pressure sensor and an oil pressure sensor, the stock sensor is just a switch for the warning light in the dash.

The engine loom also has, as stock, the wiring for the single wire water temp sensor for the dash gauge.

Knock sensors x 2

Throttle position sensor (+ the other stuff if you want to retain secondary throttle plate control, or convert to DBW).

Idle control valve.

Wastegate control solenoid.

 

Things I have forgotten... ;)

 

Cheers Chris,

 

I've updated the list.

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The AS stuff is far worse, the main tool is very dear, plus each pin type needs a different adaptor turret at about £50 a shot. Unless you do a lot of connectors it sometimes pays to get a loom done by a specialist. I like to have the facility to repair or mod myself though, saves a lot of time and possible misunderstandings. If you prepped the loom all ready I could crimp the pins for you? BE AWARE the DTM pins will only take up to about 22 gauge, maybe 20 gauge wire, some OE loom stuff is pretty hefty. Deutsch have all the manuals on their site for downloading, or I can e-mail you the DTM one if you want?

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The AS stuff is far worse, the main tool is very dear, plus each pin type needs a different adaptor turret at about £50 a shot. Unless you do a lot of connectors it sometimes pays to get a loom done by a specialist. I like to have the facility to repair or mod myself though, saves a lot of time and possible misunderstandings. If you prepped the loom all ready I could crimp the pins for you? BE AWARE the DTM pins will only take up to about 22 gauge, maybe 20 gauge wire, some OE loom stuff is pretty hefty. Deutsch have all the manuals on their site for downloading, or I can e-mail you the DTM one if you want?

 

Thanks for the offer Chris. Can you send me the DTM manual by email. Will email you first.

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