Once I had a general idea as to ECU and relay wiring, I decided to make a wooden mock up of the knee space area. Then I could start the actual layout process.
Purchased the necessary wire stripping and crimping tools. A good ratcheting crimping tool was recommended. Saw one on the Summit site with interchangeable jaws for $109.97. Also purchased a Weather Pack ratcheting crimper from Pegasus for $139.99. And then picked up a basic crimper from a local hardware store for $19 just to make sure all the bases were covered. Also purchased a Milwaukee Heat Gun from a local hardware store for the heat shrinking tasks (Part Number 8975-6 for $70).
At this point I was wiring the relays with the in-line fuse holders.
The profusion of wires coming from the top of the PE-3 is due to the fact that Tom Habrzyk sent me the “fully populated” Main and Comm connectors. All the numbered wires from all of the pins were already crimped and in place. This saved a massive amount of time and effort. The Performance Electronics part number for the PE3 34 Pin Fully Populated Main Connector Harness (with 6 foot long pin numbered wires) is 99001001. The cost is $143. The part number for the PE3 26 Pin Fully Populated Comm Connector Harness (with 6 foot long pin numbered wires) is 99001004. This also includes a 4-pin comm connector pigtail. The cost is $99.
An ECU Sub Ethernet Cable is also necessary. The PE part number is 99002001. The cost is $30.
I rolled the engine, on its stand, over to the rear right side of the chassis and set up a work station in front of it. This, once again, was to aid the visualization process. It helped me see how things might line up and where the wires might go. That the wires coming from the PE-3 Main and Comm connectors bore their pin numbers all along the length of each wire was enormously helpful in making sure that the right pin number was connected to the right injector, coil pin or sensor.
I was not concerned with precise wiring lengths since those precise lengths (and the precise routings) would depend on whatever specific chassis the harness might be going into.
Note that I’ve given up on the in-line fuses and have re-wired the mock-up using the integral-fuse-holding relays from Del-City.
Junk Yard Zetec 