Engine Side Connector Wired
 

I wired up the engine side plug connector this evening - a few photo's to document my progress:

Electromotive Crankshaft Position Sensor

I routed the Electromotive Crankshaft Position Sensor wire(s) around the driver's side engine tin and and back to the connector. The crank sensor wires are bundled in a rugged, shielded insulation - as such, I didn't see any point in wrapping this part of the harness in Techflex sheathing:


http://forums.pelicanparts.com/uploa...1402282495.jpg


I had a bit of an UUUGH :confused: moment as I prepared to attach terminals to the crank sensor wires.

- The Electromotive instructions show the crankshaft sensor wires as a bundled RED, BLACK and BARE wire.
- The XDi controller wire harness included a RED, BLACK and BARE (bundled in a gray, shielded insulation wrap) wire for the crank sensor (very small wires BTW ~ 22 awg)
- Meanwhile my crank sensor wires were WHITE, BLACK and BARE (bundled in a black, shielded insulation wrap):

http://forums.pelicanparts.com/uploa...1402283016.jpg

The crank sensor wire harness came with a pre-installed connector. I probably would have never noticed the color scheme discrepancy if I would have used it. Meanwhile, since I cut the connector off to shorten the wires and connect to my multi-pin connector, I kind of freaked for a bit.

I went ahead terminated the sensor side WHITE wire to the XDi controller side RED wire.

Hopefully it will be OK - I'll give Electromotive or Clewett a call tomorrow about it.

Oil Pressure and Oil Temp Sensor Wires

I similarly ran the oil pressure and temperature wires around the passenger side engine tin. I wrapped these in Techflex:

http://forums.pelicanparts.com/uploa...1402283889.jpg

Interesting note - THAT DAMN OIL TEMPERATURE SENSOR CONNECTOR IS QUITE UNIQUE! I searched all over locally for a spade receiver big enough to fit the terminal but ended up cutting the old one off of the 3.2L harness and spliced it in...

Terminating the Engine Side Molex Connector

I also ran the alternator idiot light (blue wire) to the connector.

Once everything was routed to the connector I added the terminals put them in a long piece of shrink wrap and plugged them into the connector:

http://forums.pelicanparts.com/uploa...1402284295.jpg

Before I hit the shrink wrap with heat (that stuff's difficult to remove...) , I gave it a test fit:

http://forums.pelicanparts.com/uploa...1402284423.jpg

I've mounted the engine harness to a bracket and clamp - but will leave enough slack between the engine and the chassis connector to allow movement/flex. I want to make sure I don't have undue stress on the engine side wire connectors.

If everything works out - it's going to be a pretty clean set up, looking nearly wire free.

Inching along...

Gordo

Had the same problem when it was time to put my system back without using the connector... Fortunately I had took a photo.

Red to White is correct (was pin A on the connector)

For the 22 awg size, I end up folding the end a few time, twisting it and then crimping it.

Looking good.

I'm Obsessing
 

Yep, I'm quoting myself after waking from a dead sleep this morning - realizing a major flaw in my connection approach:

- I've actually isolated all of the engine harness movement/stress (due to engine torquing, vibrations etc) to the engine side pin connections / back-shell: not good...
(BTW the Molex connector isn't designed for / doesn't use an add-on back-shell protector/grommet since the connectors themselves are sealed).

A better approach would have been to mount the connector 90° offset from how I have it (parallel to the shock tower) and make the engine harness long enough to clamp onto the chassis thereby reducing stresses on the connector.

Hindsight - my harness is cut and I'm not extending it... Meanwhile, I can extend the chassis...

I think I can achieve the same wire stress releif by adding a chassis bracket that extends toward the engine. This would allow me to clamp the harness just beyond the connector.

Hard to describe, will post a pic once I make the bracket.

Yea - I've lost it :rolleyes:

Gordo

That should work.

At the end of the day, this is just a minor time set back!

Engine Harness Is Complete
 

I finished up the engine harness this evening:

As intended, it's "simple and uncluttered", or at least it appears simple... ;)


http://forums.pelicanparts.com/uploa...1402545339.jpg

That's it, exactly how it will look when installed.

http://forums.pelicanparts.com/uploa...1402545441.jpg


I still have a bit of wire work to do on the chassis side, but I did add a support bracket that will allow me to clamp the harness to the chassis to relieve stress on the connector:

http://forums.pelicanparts.com/uploa...1402545566.jpg


JJ - thanks again for the encouragement and wise words of patience.

Gordo

Looks great Gordo!! Get yourself a sound pad, will finish off the look and takes 10 minutes with engine out.

Todd

Great result.

Next winter during my "Biennial Engine Drop Event" I may borrow your spark plug wire routing idea :)

A foil finish engine sound pad would be a good contrast against the engine.

Sound Pad
 

Thanks guys,

I have the AppBiz foil pad - waiting until I'm done poking around with sharp tools back there to install it.

It's definitely going to make some of the black components stand out.

Hopefully firing the engine off for the first time this weekend - nervous and excited...

Gordo

Having BTDT, have a helper crank her up and you watch what is going in the engine bay with a fire extinguisher in your hand.

Having had too many cook in the kitchen, I sprung an oil leak from an hand tight oil hose fitting.

Best of luck with the start-up.

Looks great Gordo, can't wait to see it all installed and running. :)