Universal Chassis Wiring Harness
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Table of Contents
- Reverse Light and Fog Light - CH053 (LH) & CH054 (RH)
- Rear Tail Lights Brake and Indicators - CH052 (LH) & CH053 (RH)
- Headlights & Side Lights – CH001 & CH007
- Nose Cone / Front Indicators – CH002
- Steering Wheel – 4 Button Control
- Steering Wheel – 8 Button Control
- Mazda MX-5 Steering Stalk Controls – CH059 & CH060
- Hazard Switch
- Starter & Alternator Circuit - CH003 or CH009
- Ignition Start Circuit - CH059
- Dashboard - CH004
- Dashboard Senders / Engine Connection - CH012
- Fog Light
- Fuel Pump
- Reverse - CH048
- Horn
- Immobiliser
- Side Light Switch
- Dip Beam Switch
- All Dashboard Switches
- Bike Engine Reverse Circuits
- Mazda Smart Alternator
- ECU Connections - Engine Connection 2
- Dashboard Plug Examples
- Troubleshooting
- Loom Pin Outs
- CH003 - Alternator & Starter
- CH004 - Dashboard & Instruments warning lights
- CH008 - Blink Stop
- CH009 - Alternator & Starter
- CH012 - Engine Connection 1
- CH016 - Flasher Unit
- CH022 - Engine Connection 2
- CH048 - Reverse Box
- CH049 - Fuse Box
- CH059 - Dashboard Switches 1
- CH060 - Dashboard Switches 2
1. Reverse Light and Fog Light - CH053 (LH) & CH054 (RH)
This is a 3 pin econoseal plug. There is one of these on both sides of the rear section of the loom to allow for LHD and RHD vehicles.
| Pin | Purpose | Wire Colour |
| #1 | Reverse + | Green / Brown |
| #2 | Fog Light + | Blue / Red |
| #3 | Ground | Black |
2. Rear Tail Lights, Brake and Indicators - CH052 (LH) & CH053 (RH)
This is a 4 pin econoseal plug. There is one of these on both sides of the rear section of the loom CH055 is the
RH, CH052 is the LH side.
2.1 Standard Rear Lights
| Pin - CH053 - RH | Purpose | Loom Wire Colour | Light Wire Colour |
| #1 | Ground | Black | Black |
| #2 | Side Light | Red / Orange | Red |
| #3 | Stop Light | Green / Purple | Green / Purple |
| #4 | Indicator RH | Green / White | Green |
| Pin - CH052 - LH | Purpose | Loom Wire Colour | Light Wire Colour |
| #1 | Ground | Black | Black |
| #2 | Side Light | Red / Orange | Red |
| #3 | Stop Light | Green / Purple | Green / Purple |
| #4 | Indicator LH | Green / Red | Green |
2.2 LED Rear Light - 4 Wire
| Pin - CH053 - RH | Purpose | Loom Wire Colour | Light Wire Colour |
| #1 | Ground | Black | White |
| #2 | Side Light | Red / Orange | Blue |
| #3 | Stop Light | Green / Purple | Red |
| #4 | Indicator RH | Green / White | Green |
| Pin - CH052 - LH | Purpose | Loom Wire Colour | Light Wire Colour |
| #1 | Ground | Black | White |
| #2 | Side Light | Red / Orange | Blue |
| #3 | Stop Light | Green / Purple | Red |
| #4 | Indicator LH | Green / Red | Green |
2.3 LED Rear Light - 5 Wire
These light clusters are the same as the 4 wire modules, however they have the reverse light built into them. When fitting the plugs, it is our recommendation to fit the 4 way plug to the earth, side, brake and indicator lights, extend the green/black reverse wire by 20cm and fit this to the 3 pin plug. All of these 4 way and 3 way mating half plugs are included in loom.
| Pin - CH053 - RH | Purpose | Loom Wire Colour | Light Wire Colour |
| #1 | Ground | Black | White |
| #2 | Side Light | Red / Orange | Blue |
| #3 | Stop Light | Green / Purple | Red |
| #4 | Indicator RH | Green / White | Green |
| Pin - CH054 - RH | |||
| #1 | Reverse | Green / Brown | Green / Brown |
| Pin - CH052 - LH | Purpose | Loom Wire Colour | Light Wire Colour |
| #1 | Ground | Black | White |
| #2 | Side Light | Red / Orange | Blue |
| #3 | Stop Light | Green / Purple | Red |
| #4 | Indicator LH | Green / Red | Green |
| Pin - CH053 - RH | |||
| #1 | Reverse | Green / Brown | Green / Brown |
3. HEADLIGHTS & SIDE LIGHTS – CH001 & CH007
The headlights are wired into the loom to chassis harness connection CH007 and CH001 (Right Hand and Left Hand respectively).
Note: Pin out is viewed looking at the terminals of the plug and not the wires
| Pin | Purpose | Wire Colour |
| 1 | Earth | Black |
| 2 | Side Light + | Red / Black |
| 3 | Dip Beam | Blue / Red |
| 4 | Main Beam | Blue / White |
| 5 | Indicator | Green / Red (L) |
| 6 | Indicator | Green / White (R) |
Note : Pins 5 and 6 are swapped on the (L)eft CH001 and (R)ight CH007
4. Nose Cone Indicators / Side Indicators – CH002
The nose cone and front indicators beneath the headlights are wired into the 4 – way male plug using the following wiring pin outs.
Note: Pin out is viewed looking at the terminals of the plug and not the wires
| Pin | Purpose | Wire Colour |
| 1 | Earth | Black |
| 2 | Earth | Black |
| 3 | Indicator (RH) | Green / White (R) |
| 4 | Indicator (LH) | Green / Red (L) |
If wiring the front indicators beneath the headlights, you will need to extend the wires from each indicator tail.
5. Steering Wheel – 4 Button Control
The Steering wheel buttons are configured by default to be
| Position | Purpose | Button Colour |
| #1 | Indicator (LH) | Green |
| #2 | Indicator (RH) | Green |
| #3 | Headlight Flash / Latch | Blue |
| #4 | Horn | Red |
This is integrated into the “blinkstop” econoseal plug directly into the loom.
Using the following diagram, it is possible to integrate this into the wiring loom in minutes.
| Pin | Wire Colour | Description | Loom Connection | Loom Wire Colour |
| #1 | White | Indicator Common | Blinkstop Plug SW003-6 | Green |
| #2 | White | Indicator (L) | Blinkstop Plug SW003-4 | Green / Red |
| #3 | White | Join to Pin #1 | ||
| #4 | White | Indicator (R) | Blinkstop Plug SW003-3 | Green / White |
| #5 | ||||
| #6 | White | Horn | Horn Switch Earth – CH059-1 | Black |
| #7 | Red | +12v Ignition | Blinkstop Plug SW003-2 | White / Green |
| #8 | Black | Earth | Blinkstop Plug SW003-1 | Black |
| #9 | Green | Brake Light Input | Blinkstop Plug SW003-5 | Green / Purple |
| #10 | White | Horn | Horn Earth Feed – CH059-2 | Black / Green |
| #11 | Blue / Brown | Dip / Main | Dip / Main Beam – CH059-11 | Blue / Red * |
| #12 | White / Brown | Main Beam | Main Beam Switch - CH059-8 | Red / Green * |
| #13 | Blue / Red | Main / Dip | Main / Dip Switch – CH059-11 | Blue / Red * |
| #14 | White / Blue | Main / Dip | Main / Dip Switch – CH059-9 | Blue / White |
*Note: these pins are looped into the switches controlling the side lights and main beam, so you cannot put 2 wires into CH059 as the pins are only large enough for 1 wire.
** Note: the indicator may not function until you connect the Hazard Switch as this uses a bypass wire for the 12v load on the indicator relay. This is connected into SW003-6.
You may need to configure the behaviour of the relay box using the USB cable. The controller does come complete with it’s own indicator circuit, but in this installation we have turned this off.
5.1. Expected Behaviour
If wired correctly the following behaviour should be seen.
Indicate left, then indicate right – Left indicators should operate, left indicator should automatically cancel and right indicator should operate.
Indicate both left and right – Hazard operation – this is not yet IVA compliant.
Horn – work on demand.
Headlight should operate main beam or Flash when ignition is on.
Side lights on – Headlight should operate main beam or flash.
Dip Beam on – headlight should latch between main beam and dip beam.
6. Steering Wheel – 8 Button Control
The Steering wheel buttons are configured by default to be
| Position | Purpose | Button Colour |
| #1 | Indicator (LH) | Green |
| #2 | Indicator (RH) | Green |
| #3 | Headlight Flash / Latch | Blue |
| #4 | Horn | Red |
| #5 | ||
| #6 | ||
| #7 | ||
| #8 |
Using the following diagram, it is possible to integrate this into the wiring loom in minutes.
| Pin | Wire Colour | Description | Loom Connection | Loom Wire Colour |
| #1 | White | Indicator Common | Blinkstop Plug SW003-6 | Green |
| #2 | White | Indicator (L) | Blinkstop Plug SW003-4 | Green / Red |
| #3 | White | Join to Pin #1 | ||
| #4 | White | Indicator (R) | Blinkstop Plug SW003-3 | Green / White |
| #5 | Blue / Brown | Main /Dip | Dip / Main Beam – CH059-11 | Blue / Red * |
| #6 | White / Brown | Main Beam | Main Beam Switch - CH059-9 | Blue / White |
| #7 | Blue/Red | Dip / Main | Dip / Main Beam – CH059-11 | Blue / Red * |
| #8 | White / Blue | Main / Dip | Main / Dip Switch – CH059-9 | Blue / White |
| #9 | White | Side lights Feed | Side Lights - CH059-8 | Red / Green *** |
| #10 | Red | +12v Ignition | Blinkstop Plug SW003-2 | White / Green |
| #11 | Black | Earth | Blinkstop Plug SW003-1 | Black |
| #12 | Green | Brake Light Input | Blinkstop Plug SW003-5 | Green / Purple |
| #13 | ||||
| #14 | ||||
| #15 | White | Horn | Horn Switch Earth – CH059-1 | Black |
| #16 | White | Side Lights Out | Side Lights Out - CH059-10 | Red/white *** |
| #17 | White | Main / Dip | Join to Pin 9 – CH059-8 | |
| #18 | White | Main / Dip | Main / Dip Out – CH059-11 | Blue / Red * |
| #19 | White | Wash | Wash/Wipe IGN - CH060-1 | White / Green |
| #20 | White | Wash | Washer – CH060-2 | Yellow / Black |
| #21 | White | Wiper | Join to Pin 19 | |
| #22 | White | Wiper | Wipers Slow – CH060-3 | Blue / Green |
| #23 | White | Horn | Horn Earth Feed – CH059-2 | Black / Green |
*Note: these pins are looped into the switches controlling the side lights and main beam, so you cannot put 2 wires into CH059 as the pins are only large enough for 1 wire.
** Note: the indicator may not function until you connect the Hazard Switch as this uses a bypass wire for the 12v load on the indicator relay. This is connected into SW003-6.
*** With this configuration, this is not IVA compliant.
You may need to configure the behaviour of the relay box using the USB cable. The controller does come complete with it’s own indicator circuit, but in this installation we have turned this off.
7. MAZDA MX-5 Steering Stalk Controls – CH059 & CH060
The MX-5 steering stalk controls can be integrated into the standard wiring loom. Using the colours of the wires and location in the stalk plug, we can integrate this as follows.
| Location | Colour | Purpose | CH059 Pin | CH059 Colour | CH060 Pin | CH060 Colour |
| A2 | Green / Yellow | Indicator + 12v (Hazard Switch Yellow) | ||||
| A3 | Green / White | Indicator Right | 16 | GW | ||
| A4 | Green / Black | Indicator Left | 17 | GR | ||
| A5 | Blue | Wipers +12v | 1 | WG | ||
| A6 | Blue / Red | Wipers High | 3 | PG | ||
| A7 | Blue / White | Wipers Low | 4 | UG | ||
| A8 | Blue / Yellow | Wipers Intermittent | 5 | NG | ||
| A9 | Light Green | Side Lights | 10 | |||
| E1 | Black | Main Live | 8 | RG | ||
| E2 | Green / Red | Dip Beam +12v | 11,7 | U | ||
| E3 | Light Green / Red | Dip Beam +12v | 11,7 | U | ||
| E4 | Yellow / Red | Main Beam +12v | 9 | UW | ||
| E5 | Blue / Orange | Wipers Squirt | 2 | YB | ||
| F2 | Red | ** Remove From Plug ** |
This should seamlessly connect into the MK wiring harness so it’s possible to use the Mazda stalks with our harness. Further pin-outs for the switch controls can be found below.
Note 1: If you are using a single pole hazard switch, you will need to loop pins CH059-12 and CH059-15 in order to power the indicator relay correctly.
*Note 2: 2x diodes are required to feed CH059 pin 7 (join the band of the diodes together) which is the fog light feed +12v. Pin 7 is fed from the Dip Beam and Main Beam +12v from Pin 11 and 9 respectively.
**Note 3: These pins are looped into other switches, so make sure you are aware of which inputs are required before fitting the pin into CH059.
CH059 – As viewed from the plug
CH060 – As viewed from the plug
Note 4: Ensure the + and – of the flasher relay correspond to the correct + and – on the loom. You may need to swap over pins 49 and 31. 49 = Black, 31 = Green/Purple.
7.1. Mazda MX-5 Steering Stalks Wiring Diagram
Note : The colours on this diagram are not necessarily the colours of wires on the stalks, they are just for information only
7.2 Mazda MX-5 Clocks Wiring Diagram
Note : The colours on this diagram are not necessarily the colours of wires on the stalks, they are just for information only
8. Hazard Switch
8.1 Single Pole Switch
With the single pole switch, you will need to use diodes to allow the Hazard switch to operate the indicators. The band on the diode is a wall and will not allow current to flow through in this direction.
Note: Indicators left and right are connected to a permanent live, therefore if you operate the indicators without the ignition on, they will operate as if the ignition is powered on.
Using one of our single pole switches, the outputs are as follows on the plug for the switch:
Green – Feed
Yellow – Normally Closed
Blue – Normally Open
Red – Switch Bulb +
Black – Switch Bulb -
In the diagram below, you will see we have made a slight adjustment from the feed to the indicator switch.
8.2 Single Pole Switch Pin Connectivity to CH059
8.3. Double Pole Savage Switch
Even with the double pole switch you will still need to use diodes. This is a very similar setup to the single pole switch with the only difference being that when you operate the indicators without the ignition powered on, the indicators will not work. Only the hazards will work when the ignition is switched off.
| Chassis Harness Pin | Wire Colour | Switch Pin | Purpose |
| CH059 / 12 | Green / Purple | D1 | Flasher Unit Feed |
| CH059 / 15 | Red / Green | D2 | +12v |
| CH059 / 14 | White / Green | D3 | Ignition Live |
| CH059 / 13 | Lt Green / Brown | C1 | Flasher Unit Trigger |
| CH059 / 16 & 17 | Gn / Red & Gn / White | C2 | RH & LH Indicator |
| C3 | |||
| C2 | A | Switch Illumination | |
| CH059 / 1 | Black | B | Earth |
*There must be a diode in here to prevent feedback
9. Starter & Alternator Circuit - CH002 or CH009
Wire the 4 way plug for the starter and alternator circuit as following with 16 gauge wire. This is either plug CH003 or CH009 which are the same just located on different sides of the engine bay depending on where your starter motor and alternator is.
9.1 MX-5 Engine
Start by connecting the main power for the alternator and starter motor. These connections are looped so that you only need a single power lead coming from the battery direct to the starter motor.
• Connect the Alternator to the starter motor using “thick” red cable – length 380mm
• Connect the Starter Motor to the battery using “thick” red cable – length 1300mm
• The starter motor has a trigger connection which is a spade terminal. Make a fly lead with a spade terminal on it (Size 1.5) and connect this into the UK Drivers side of the vehicle (CH003) pin #1.
• The standard MX-5 mk2 alternator has a 3 way plug on it. Cut this off the standard Mazda loom and connect the following coloured wires into the male plug of CH003:
| Mazda Plug Wire Colour | Purpose |
CH003 (Male) |
| ?? | Alternator Warning Light | 2 |
| ?? | Ignition | 3 |
| Grey / Red | Alternator Sense | 4 |
9.2 S2000 Engine F20C
Start by connecting the main power for the alternator and starter motor. These connections are looped so that you only need a single power lead coming from the battery direct to the starter motor.
• Connect the Alternator to the starter motor using “thick” red cable – length ???mm
• Connect the Starter Motor to the battery using “thick” red cable – length ???mm
• The starter motor has a trigger connection which is a spade terminal. Make a fly lead with a spade terminal on it (Size 1.5) and connect this into the UK Passengers side of the vehicle (CH009) pin #1.
• The standard S2000 alternator has a 4 way plug on it. Cut this off the standard S2000 loom and connect the following coloured wires into the male plug of CH009:
| S2000 Wire Colour | Purpose |
CH009 (Male) |
| "L" - White / Red | Alternator Warning Light | 2 |
| "S" - Black / Yellow | Ignition | 3 |
| "IG" White / Green | Connect to FR with 1K Resistor | |
| "FR" - White / Blue | Connect to IG with 1K Resistor |
If you have an aftermarket plug with different colour wires, use the diagram in figure 8.2.a to work out the colour of the wires on your plug.
9.3 Duratec / Durapower Engine 2.0
Start by connecting the main power for the alternator and starter motor. These connections are looped so that you only need a single power lead coming from the battery direct to the starter motor.
• Connect the Alternator to the starter motor using “thick” red cable – length ???mm
• Connect the Starter Motor to the battery using “thick” red cable – length ???mm
• The supplied alternator plug comes with 3 wires and some tails. These tails are the correct length, just connect them into a 4 way econoseal plug in the following way
| Alternator Pin # | Purpose |
CH009 (Male) |
| 1 | Alternator Warning Light | 2 |
| Remove this from the plug | ||
| 3 | Ignition | 3 |
10. Ignition Start Circuit - CHO59
The MK Loom start circuit is connected to the loom via a large 20 way white plug.
It has been designed like this so you can disconnect your dashboard from the vehicle should you require. The pin out for the plug (viewed from the plug) is shown in the diagram below.
Note : The start circuit is one of the circuits broken by the immobiliser.
Depending on which option you have selected when you specified your vehicle, you will be able to connect it as follows:
10.1 MX-5 Ignition Barrel - CH059
The MX-5 ignition barren has 6 wires (shown in the table below).
Note: There are two White / Red wires on the ignition barrel which are connected together. We use these individually, so you will need to probe out with a meter to find out which one powers the correct side of the ignition switch (white / red* and white / red in the table below).
| Colour | Purpose | Pin | CH059 |
| White / Red* | 12v Positive Feed | #4 | Red / Green |
| Green / Red | Accessory | ||
| Red / Black | Run | #3 | White / Orange |
| White / Red | 12v Positive Feed | #6 | White / Green |
| Black / Red | Run | ||
| White / Black | Start | #5 | White / Red |
Connect the wires in the table above into the white dashboard plug CH059
10.2 Universal Ignition Switch - CH059
The Universal ignition switch is an single position “on / start” switch.
| CH059 | Colour | Purpose | Ignition Switch |
| #5 | White / Red | Start Relay Drive | #1 |
| #4 | Red / Green | Ign Switch Batt + | #2 |
| #3 | White / Orange | Ignition Relay Drive | #3 |
10.3 Motorsport Off-On-Monentary Switch - CH059
The motorsport switch is an on / off / momentary switch. On is the ignition, momentary is the start procedure.
Wire this in the following way
| CH059 | Colour | Purpose | Motorsport Switch |
| #5 | White / Red | Start Relay Drive | B5 |
| #4 | Red / Green | Ign Switch Batt + | A3 and B6 |
| #3 | White / Orange | Ignition Relay Drive | A2 |
If using this with a CUP car, a 1.2m length of wire needs connecting into the Hayabusa relay (black / yellow) which controls the start signal from CH003 or CH009 white / red wire. CH003 or CH009 is the 4 pin plug located near the headlights on either side of the vehicle.
Connect the Hayabusa relay Black / White wire to ground to complete the circuit.
For more information, refer to the “Starter - Alternator Circuits.pdf”
11. Dashboard - CH004
The dashboard and clocks are connected to the vehicle via the white plug CH004 (Chassis Harness 004). The
pin outs for this plug are shown in the table below and the reference for the plug is facing towards you.
11.1 Digi Dash-2 Lite
|
Plug |
DD2 Wire Colour |
Function |
Pin Number |
CH Wire Colour |
|
Red |
Black |
Ground |
1 |
B |
|
Red |
Red |
Ignition +12v |
3 |
WG |
|
Red |
Yellow |
Tacho |
8 |
WB |
|
Red |
Light Brown |
Neutral Switch |
|
|
|
Yellow |
Black |
Coolant Temp |
7 |
GU |
|
Yellow |
Blue |
Oil Temp |
4 |
NU |
|
Yellow |
Orange |
Oil Pressure (G) |
5 |
WN |
|
Yellow |
White |
Low Oil Pressure (WK) |
17 |
|
|
Yellow |
Pink |
Fuel Level |
6 |
GB |
|
Yellow |
Grey |
Main Beam |
13 |
UW |
|
Yellow |
Purple |
Rear Fog |
16 |
RU |
|
Yellow |
Green / Grey |
Indicator Left |
15 |
GR |
|
Yellow |
Green / Red |
Indicator Right |
14 |
GW |
|
Yellow |
Dark Brown |
Handbrake |
12 |
BW |
11.2. Analogue Clocks
For a standard Mazda MX-5, the number of pulses for the speedo should be set to xxxx
For a standard Honda S2000, the number of pulses for the speedo should be set to xxxx
|
Clock |
Clock Wire Colour |
Function |
Pin Number |
CH Wire Colour |
|
Speedo |
Black |
Ground |
1 |
B |
|
Speedo |
Green |
Ignition +12v |
3 |
WG |
|
Speedo |
White / Brown |
Low Oil Pressure (WK) |
17 |
|
|
Speedo |
Brown / Yellow |
Ignition Charge |
11 |
NY |
|
Speedo |
Black / White |
Handbrake |
12 |
BW |
|
Speedo |
Red / White |
Illumination |
2 |
RO |
|
Speedo |
Red / Blue |
Mazda Speed Signal |
9 |
O |
|
Speedo |
Black? |
Mazda Speed Signal |
10 |
Y |
|
Speedo |
Purple |
Speedo Link Cable |
Tacho |
Purple |
|
|
|
|
|
|
|
Tacho |
Black |
Ground |
1 |
B |
|
Tacho |
Green |
Ignition +12v |
3 |
WG |
|
Tacho |
Red / White |
Illumination |
2 |
RO |
|
Tacho |
Red / Blue |
Tacho |
8 |
WB |
|
Tacho |
Green / Red |
Indicator Left |
15 |
GR |
|
Tacho |
Green / White |
Indicator Right |
14 |
GW |
|
Tacho |
Blue / White |
Main Beam |
13 |
UW |
|
|
|
|
|
|
|
Fuel |
Terminal B |
Ignition +12v |
3 |
WG |
|
Fuel |
Terminal Earth |
Ground |
1 |
B |
|
Fuel |
Terminal T |
Fuel Level |
6 |
GB |
|
Fuel |
Terminal Lamp |
Illumination |
2 |
RO |
|
|
|
|
|
|
|
Oil Pressure |
Terminal B |
Ignition +12v |
3 |
WG |
|
Oil Pressure |
Terminal Earth |
Ground |
1 |
B |
|
Oil Pressure |
Terminal T |
Oil Pressure (G) |
5 |
WN |
|
Oil Pressure |
Terminal Lamp |
Illumination |
2 |
RO |
|
|
|
|
|
|
|
Oil Temp |
Terminal B |
Ignition +12v |
3 |
WG |
|
Oil Temp |
Terminal Earth |
Ground |
1 |
B |
|
Oil Temp |
Terminal T |
Oil Temp |
4 |
NU |
|
Oil Temp |
Terminal Lamp |
Illumination |
2 |
RO |
|
|
|
|
|
|
|
Water Temp |
Terminal B |
Ignition +12v |
3 |
WG |
|
Water Temp |
Terminal Earth |
Ground |
1 |
B |
|
Water Temp |
Terminal T |
Coolant Temp |
7 |
GU |
|
Water Temp |
Terminal Lamp |
Illumination |
2 |
RO |
|
|
|
|
|
|
|
Switch |
Purple |
Rear Fog |
16 |
RU |
|
|
|
|
|
|
12. DASHBOARD SENDERS / ENGINE CONNECTION – CH012
The senders for the dashboard are connected to the engine connection plug in the chassis harness plug 012. The other end of these wires are located on the dashboard plugs. CH004
|
Sender |
Wire Colour |
Function |
Pin Number |
CH Wire Colour |
|
Water Temp |
GU |
Water Temperature |
7 |
GU |
|
Oil Pressure (G) |
WN |
Oil Pressure |
8 |
WN |
|
Low Oil Pressure (WK) |
GB |
Low Oil |
12 |
NW |
|
|
|
|
|
If you are using either Analogue Clocks or the Digital dashboard, the sender unit looks like the picture 11.a.
Note : On some vehicles, you will need a thread adapter to convert the 1/8 npt thread into most likely an M10 x 1 thread.
13. Fog Light
Note : The fog light needs to obtain a signal from the switch on the dashboard to tell it the headlights are active. This is done by connecting CH059-7 to CH059-11
13.2 Fog Light Unit
The fog light uses a switched earth switch to control the management module. The pin outs are labelled 1 to 6 when viewed from the top down. Towards the left are the screw connections.
| Module Pin | Module Function | Pin Number | CH Wire Colour |
| 1 | +12 v Load | 4 | WG |
| 2 | +12v Switched Feed | 5 | RU |
| 3 | |||
| 4 | Lights + 12v | 3 | U |
| 5 | Ground | 1 | B |
| 6 | Switch | 2 | UB |
See figure 12.2.a should be the end result of the wiring of the IVA fog light module.
13.2. Fog Light Switch Single Pole – CH059
This document outlines how to install the fog light using a single pole switch with a light on it. The light will be illuminated when the side lights are on.
Note: When using the IVA Compliant Fog light wiring module, we switch the earth feed to control the fog light and not a conventional positive feed.
| Switch Plug | Switch Function | Pin Number CH059 | CH Wire Colour |
| Green | Ground | 1 | B |
| Yellow | |||
| Blue |
Switch |
19 | UB |
| Red | Light +12v | 18 | RO |
| Black | Ground | 1 | B |
In the MK Wiring harness at the rear of the loom there are 3 wires:
|
Colour |
Purpose |
|
Purple / White |
Fuel Pump +12v |
|
Black |
Fuel Pump Earth |
|
Black / Green |
Fuel Level |
It is possible to connect this into any particular fuel pump and sender.
14.1 MX-5 Fuel Pump
|
The Mazda fuel pump is a grey 4 way plug. Viewed from the plug, connect the following loom wires into the plug.
You can cut this plug from your Mazda loom and fit some female spade terminals for connectivity into the MK loom. |
||||||||||||||||
Note: If you’re using the Mazda fuel pump with the ETB DD2 Lite Digital dashboard, you will need to fit a 22ohm resistor on the fuel sender wire. This will make the resistance to the dashboard read 0% with the float at its lowest position and 100% at its highest – you also need to set the dd2 general 2 (132ohm empty - 52ohm full).
14.2 Universal Fuel Pump and ETB Sender
|
Colour |
Purpose |
|
Purple / White |
Fuel Pump +12v |
|
Black |
Fuel Pump Earth |
|
Black / Green |
Fuel Level |
15. Reverse - CH048
15.1 Mazda NB Gearbox
There are 3 senders on the Mazda gearbox. The one we are interested in is the reverse which is positioned on the near side of the gearbox with 2 green wires coming from it with a 2 way spade connector (same as the cooling fan) This is the switch which is furthest forward towards the engine on the gearbox.
Cut the female plug from the loom and allow 100 mm of wire.
Connect this into pin1 and pin 2 of the 6 way connector of CH048
15.2 Honda S2000 Gearbox
The sender for the reverse switch is located in the picture below.
Cut the female plug from the loom and allow 100 mm of wire.
Connect this into pin1 and pin 2 of the 6 way connector of CH048
16. Horn
The Horn is position at the front of the vehicle. There is a tail already in the loom with 2 female spade connectors on it to power the horn. This is controlled by a relay beneath the dashboard. The circuit to control the relay can be configured through any switch which is connected one side to earth, the other to CH059-2
16.1 Single Pole Switch
Connected one side to earth (CH059-1), the other to CH059-2 (Horn)
16.2 Mazda Steering Column
Remove the Mazda steering column plug from the standard Mazda loom which looks like this.
Wire this into pin CH059-2
For the standard steering boss we use, you can then utilise the instructions in the RX-5 Manual Book 3, section 1.5.5
17. Immobiliser
The MK wiring harness is designed to have two forms of immobilisation, it inhibits the fuel pump & starter motor. The below instructions use the “Toad Sterling Excel Engine Immobiliser” with the MK wiring harness.
The Sterling immobiliser connection details into plug CHxxx are as follows;
| Wire Colour | Description | Pin | Loom Wire Colour |
| Blue #1 | Starter Motor Immobiliser (in) | #1 | White / Red |
| Blue #2 | Starter Motor Immobiliser (out) | #2 | White / Red |
| White #1 | Fuel Pump Immobiliser (in) | #3 | White / Dark Green |
| White #2 | Fuel Pump Immobiliser (out) | #4 | White / Dark Green |
| Green #1 | Earth | #5 | Black |
| Green #2 | Earth | #6 | Black |
| Red | Power Supply + 12v | #7 | Red / Green |
| Orange | Ignition Input | #8 | White / Light Green |
| Yellow | Door Switch (tie down to earth) |
The immobiliser wired into the plug and mounted into the ECU panel should look something like the below;
The immobiliser fob key detector will need to be mounted behind the dashboard so that when the ignition switch is engaged, the user can touch the fob onto the dashboard and the immobiliser will detect and allow the car to start.
The below location is directly next to the key switch, so that the immobiliser fob can be fitted to a keychain and touch the dash when required to disable the immobiliser on startup.
18 Side Light Switch
18.1 Double Pole
This document outlines how to install the side light using a double pole switch with a light on it. The light will be illuminated when the side lights are on.
|
Savage Switch Pin |
Switch Function |
Pin Number 059 |
CH Wire Colour |
Notes |
|
D1 |
Lights Battery + |
8 |
RG |
Loop to Flash |
|
D2 |
Side Lights* |
10 |
RW |
Loop to Dip Beam |
|
D3 |
|
|
|
|
|
C1 |
|
|
|
|
|
C2 |
|
|
|
|
|
C3 |
|
|
|
|
|
A |
Light +12v |
18 |
RO |
Loop to other switches |
|
B |
Gnd |
1 |
B |
|
19. Dip Beam Switch
19.1 Double Pole Savage Latching
This document outlines how to install the side light using a double pole switch with a light on it. The light will be illuminated when the side lights are on.
|
Savage Switch Pin |
Switch Function |
Pin Number 059 |
CH Wire Colour |
Notes |
|
D1 |
Side Light + |
10 |
RW |
Loop to Flash |
|
D2 |
Headlights Input |
7 |
U |
Loop to Main Beam |
|
D3 |
|
|
|
|
|
C1 |
|
|
|
|
|
C2 |
|
|
|
|
|
C3 |
|
|
|
|
|
A |
Light +12v |
18 |
RO |
Loop to other switches |
|
B |
Gnd |
1 |
B |
|
20. All Dashboard Switches
20.1 Single Pole
|
CH059 |
||||
|
Pin |
Colour |
Signal |
Switch |
Terminal |
|
1 |
B |
Ground |
Horn Switch |
Green |
|
|
|
Horn Switch |
Black |
|
|
|
|
Side Light |
Black |
|
|
|
|
Dip Beam |
Black |
|
|
|
|
Main Beam |
Black |
|
|
|
|
Fog Light |
Green |
|
|
|
|
|
Reverse Latching Hazard Switch |
Black Black |
|
2 |
BG |
Horn Output |
Horn Switch |
Blue |
|
3 |
WO |
Ignition Relay Drive |
Ignition Switch |
Pin #3 |
|
4 |
RG |
Ignition Switch Batt + |
Ignition Switch |
Pin #2 |
|
5 |
WR |
Starter Relay Drive |
Ignition Switch |
Pin #1 |
|
6 |
WG |
Ignition Start Switch |
|
|
|
7 |
U |
Fog Light +12v Input |
Dip Beam |
Blue (also CH059 #11) |
|
8 |
RG |
Lights Batt + |
Side Light Main Beam |
Green Green |
|
9 |
UW |
Main Beam |
Main Beam |
Blue |
|
10 |
RW |
Side Lights |
Side Light |
Blue |
|
|
|
Dip Beam |
Green |
|
|
11 |
UR |
Dipped Beam |
Dip Beam |
Blue (also CH059 #7) |
|
12 |
LGP |
Flasher Unit + |
|
Loop to Pin 15 |
|
13 |
LGN |
Flasher Unit Trigger |
Hazard Switch |
Green |
|
14 |
WG |
Hazard Switch Ignition |
|
|
|
15 |
RG |
Hazard Switch Batt + |
|
Loop to Pin 12 |
|
16 |
GW |
RH Indicators |
Hazard Switch |
Blue, Diode Band Away |
|
|
|
|
Indicator Switch |
RH |
|
17 |
GR |
LH Indicators |
Hazard Switch |
Blue, Diode Band Away |
|
|
|
|
Indicator Switch |
LH |
|
18 |
RO |
Illumination |
Horn Switch |
Red |
|
|
|
Side Light |
Red |
|
|
|
|
Dip Beam |
Red |
|
|
|
|
|
Main Beam |
Red |
|
19 |
UB |
Fog Light Switch |
Fog Light |
Blue |
|
20 |
|
Spare |
|
|
|
Y |
Hazard Switch |
Indicator Switch |
Middle |
|
|
B |
Hazard Switch |
Hazard Switch |
Red |
|
|
CH004 |
||||
|
Pin |
Colour |
Signal |
Switch |
Terminal |
|
1 |
B |
Ground |
Fog Light |
Black |
|
2 |
RO |
Illumination |
|
|
|
3 |
WG |
Instruments Ignition |
|
|
|
4 |
NU |
Oil Temp |
|
|
|
5 |
WN |
Oil Pressure |
|
|
|
6 |
GB |
Fuel Level |
|
|
|
7 |
GU |
Water Temp |
|
|
|
8 |
WB |
Rev Counter |
|
|
|
9 |
O |
Mazda Speed Signal |
|
|
|
10 |
Y |
Mazda Speed Signal |
|
|
|
11 |
NY |
Alternator Warning Light |
|
|
|
12 |
BW |
Brake Fail Warning Light |
|
|
|
13 |
UW |
Main Beam |
|
|
|
14 |
GW |
RH Indicator |
|
|
|
15 |
GR |
LH Indicator |
|
|
|
16 |
RU |
Fog Light W/Light |
Fog Light |
Red |
|
17 |
NW |
Oil Pressure Warning |
|
|
|
18 |
|
|
|
|
21. Bike Engine Reverse Circuits
This is designed for use with two single pole switches. 1x latching and 1x momentary.
It works in such a way that the reverse circuit is not active unless the bike engine is in neutral.
|
Bike Engine Reverse |
||||
|
Pin |
Colour |
Signal |
Switch |
Terminal |
|
|
Green / Brown |
Bike Engine Reverse |
Reverse Momentary Switch |
Green |
|
|
Green / Brown |
Bike Engine Reverse |
Reverse Momentary Switch |
Blue |
|
|
White / Green |
|
Reverse Latching |
Green |
|
|
Green / Brown |
|
Reverse Latching |
Blue |
|
|
|
|
Reverse Latching |
Red |
Located in the transmission tunnel is a plug labelled "Reverse Switch". This is referred to as "ch048"
22. Mazda Smart Alternator
The smart alternator on the MX-5 mk2 has 3 terminals.
The grey / red wire is the signal for the smart alternator from the MX-5.
Connect the grey / red wire is connected to pin#4 of the starter alternator plug which in turn is connected to pin #6 on engine connections #2.
If you are unsure of the pins, check continuity against pin#6 on engine connection 2.
23. ECU Connection - Engine Connection 2
This loom is designed for use with several different engine configurations and their respective looms. To check you have the correct wiring setup for the chassis loom and the engine loom, please refer to the following tables for your engine specific installation
23.1 ME 360 Mazda MX-5 NB
|
MK LOOM - Female 6 Way |
|
ME LOOM - Male 6 Way |
||
|
Pin |
Wire Colour |
Purpose |
Pin |
Wire Colour |
|
1 |
Red / Green |
Engine Batt + |
1 |
Red 32 |
|
2 |
White / Green |
Engine Ignition |
2 |
Red 16 |
|
3 |
Black / Yellow |
Cooling Fan Relay Drive |
3 |
Green / Light Blue |
|
4 |
Black / Purple |
Fuel Pump Relay Drive |
4 |
Green / Yellow |
|
5 |
White / Black |
Rev Counter |
5 |
Brown |
|
6 |
Yellow / Red |
Alternator Sense |
6 |
|
23.2 OMEX Honda S200 F20c
|
MK LOOM - Female 6 Way |
|
OMEX LOOM - Male 6 Way |
||
|
Pin |
Wire Colour |
Purpose |
Pin |
Wire Colour |
|
1 |
Red / Green |
Engine Batt + |
1 |
Red 32 |
|
2 |
White / Green |
Engine Ignition |
2 |
Red 16 |
|
3 |
Black / Yellow |
Cooling Fan Relay Drive |
3 |
Blue / Black |
|
4 |
Black / Purple |
Fuel Pump Relay Drive |
4 |
Blue / White |
|
5 |
White / Black |
Rev Counter |
5 |
Blue / Green |
|
6 |
Yellow / Red |
Alternator Sense |
6 |
|
23.3 ME 360 Honda Civic Type R K20
|
MK LOOM - Female 6 Way |
|
OMEX LOOM - Male 6 Way |
||
|
Pin |
Wire Colour |
Purpose |
Pin |
Wire Colour |
|
1 |
Red / Green |
Engine Batt + |
1 |
Red 32 |
|
2 |
White / Green |
Engine Ignition |
2 |
Red 16 |
|
3 |
Black / Yellow |
Cooling Fan Relay Drive |
3 |
Blue / Black |
|
4 |
Black / Purple |
Fuel Pump Relay Drive |
4 |
Blue / White |
|
5 |
White / Black |
Rev Counter |
5 |
Blue / Green |
|
6 |
Yellow / Red |
Alternator Sense |
6 |
|
24. Dashboard Plug Examples
24.1 Analogue Clocks, 4 Way Steering Wheel Buttons, 22mm Dashboard Switches
24.2 Digital DD2 Clocks, 4 Way Steering Wheel Buttons, 22mm Dashboard Switches
25. Troubleshooting
25.1 Headlights Not Latching On Using the Freewheel
Pin 11 on the Freewheel should be connected to CH059 #11 along with several other wires.
25.2 Fog Light Not Working
There is no +12v input to the relay when headlights are on. Check CH059#7 is connected to CH059#13.
26. Loom Plug Pin Outs
CH003
CH004
CH008
CH009
CH012
CH016
CH022
CH048
CH049
CH059
CH060