Ford Performance 3.5L EcoBoost Controls Pack Installation Manual (M-6017-35CNTRL)

Important Information

No part of this document may be reproduced without prior agreement and written permission of Ford Racing Performance Parts.

For the most current instruction and warranty information, please visit www.fordracingparts.com.

Please read all of the following instructions carefully prior to installation. At any time you do not understand the instructions, please call the Ford Performance Techline at 1-800-367-3788.

Factory Ford shop manuals are available from Helm Publications, 1-800-782-4356.

1.0 Introduction

This kit was developed by Ford Performance to allow performance enthusiasts the ability to install the 3.5L EcoBoost Crate Engine (Ford Performance P/N: M-6007-35T) into the application of their choice. The system supports use of a manual transmission only.

Note:

• Cruise control is not available with this system.

2.0 Overview

This booklet provides a step-by-step guide for the preparation and installation of the controls pack. Please read the instructions thoroughly before starting the installation. For questions, contact Ford Performance Technical Support at (800) 367-3788.

3.0 Included Components

3.1 Powertrain Control Module (PCM) – CMDL3Z-12A650-ZF

• The PCM is the central processing unit for engine operation. Input data/engine operation feedback is provided from each of the engine's sensors connected to the PCM via wiring leads. This input data is used to perform calculations that in turn adjust fuel quantity, turbo pressure, and spark timing according to varying driver demand (i.e., accelerator pedal input).
• The wiring that plugs into the PCM is integral to the wiring harness that was included with the 3.5L crate engine; the length of these wiring leads dictates that mounting location be in close proximity to the engine itself.
• The PCM in this Controls Pack has custom software and calibration dataset specifically modified/developed by Ford Performance engineers to provide peak performance and reliability with the 3.5L EcoBoost Crate Engine (Ford Performance P/N: M-6007-35T).

Visual description: A rectangular electronic control unit (PCM) with multiple connectors and a label indicating "3.5L ENGINE RUN STAND" and part numbers like "FoMoCo MK5-12-" and "BOSCH 261 S10 39813-40-2".

PCM Calibration Application Notes:

• The calibration provided in this PCM will NOT work with the ‘Returnless’ fuel system as used on factory vehicles. Use of a return style fuel system is required. Refer to Section 7 of this manual for more information on fuel system requirements for this PCM.
• The Air Filter Assembly with Integral Mass Air Flow Sensor included with this kit must be used to achieve acceptable engine performance. If the air filter assembly provided is not used, calibration may be required. Refer to Section 3.7 for more information about Air Inlet System requirements.
• Premium Fuel Only (91 Octane or higher).

NOTE:

• Due to the fuel system requirement described above, installation of this PCM in ANY Production vehicle will result in a no-start condition!

3.2 Accelerator Pedal Position Sensor (APPS) – DL3Z-9F836-A

• The accelerator pedal assembly includes a pair of integrated pedal position sensors (APPS1/APPS2). This pedal has electrical properties designed specifically for correct interface with PCM: CMDL3Z-12A650-ZF and is required for proper engine operation.

Visual description: An accelerator pedal assembly, showing the pedal arm and the electronic sensor housing.

3.3 Clutch Pedal Position Switches:

• Bottom Travel (CBT) - 6G9Z-11A152-A (Gray Plunger)
• Top Travel (CTT) - 4M5Z-11A152-A (Black Plunger)
• The switches translate the clutch pedal position to the PCM. The bottom travel switch also acts as a starter safety interlock. The starter motor will not energize until the clutch has been fully depressed.
• CBT switch is Normally Open (i.e., Clutch Pedal NOT fully depressed); Closed with Clutch Pedal fully depressed.
• CTT switch is Normally Open (i.e., With Foot off Clutch Pedal); Closed Otherwise.
• Clutch pedal assembly P/N: DV6Z-7519-A is available through an Authorized Ford Parts dealer. Includes a clutch pedal and mounting bracket with provisions to hold both the Top and Bottom of Travel switches in the appropriate locations.

Visual description: Two separate clutch pedal position switches. One (CBT) has a gray plunger, and the other (CTT) has a black plunger.

WARNING:

• Do not bypass the starter interlock. Doing so creates a hazard to those in and around the vehicle as the starter can operate with the transmission in gear and the clutch pedal engaged.

3.4 Universal Exhaust Gas Oxygen Sensor (UEGO) – 8F9Z-9F472-H

• Two UEGO sensors provide wide range feedback to the PCM for closed loop air fuel ratio control by measuring the quantity of oxygen present in exhaust leaving the combustion chamber.
• Each UEGO is supplied with a light coating of anti-seize lubricant on its threads. Please use caution when installing as this lubricant will damage the sensor element, so make sure no lubricant comes in contact with the sensor element (tip).
• Tighten to 48 Nm (35 lb-ft).
• NOTE: Do not splice, lengthen or otherwise modify the UEGO wiring. Doing so will adversely affect the sensor performance & reliability of the signal.

Visual description: A Universal Exhaust Gas Oxygen Sensor (UEGO) with its threaded end and electrical connector.

Moving the UEGO sensors to alternate locations can result in the need to recalibrate the PCM. Do not install sensors with harness on a downward angle.

It is required to locate the sensor so it is sampling from all 3 cylinders and at a distance of 2 to 6 inches beyond the turbocharger outlet flange.

NOTE:

• Modification of the UEGO harness can affect function of UEGO sensor and should not be attempted.

3.5 B+ to FPPDB Cable Assembly

• Provides B+ from Battery "+" Post to in-line fuse and then to the Ford Performance Power Distribution Box (FPPDB).
• It is extremely important that the ground eyelet connection (discussed later) is attached to a solid grounding location.

Visual description: A coiled cable assembly with a large inline fuse holder and a power distribution box (FPPDB) with multiple terminals.

3.6 Plastic Bag of Assorted Items

• Zip-ties
• 4 AWG Jumper Cable
• Buss 250A In-line Fuse and Fuse Holder
• Malfunction Indicator Light
• Small diameter heat shrink (red)
• Large diameter heat shrink (black)
• Large diameter eyelet terminal
• Small diameter eyelet terminal
• Two battery terminal lugs

Visual description: A clear plastic bag containing various small components including zip-ties, heat shrink tubing, terminals, and a fuse.

3.7 Air Cleaner Assembly - DL3Z-9V456-A, CL3Z-9661-A DL3Z-9C623-A, DL3Z 9R530-A

Visual description: A disassembled air cleaner assembly, showing the air box, intake tubes, and associated sensors.

IMPORTANT NOTE:

• The calibration of the PCM received requires use of this air box system exactly as received. Any changes to the air inlet system will result in changes to how the air entering the engine is measured and will require modification to the PCM's calibration.

Ford Performance recognizes that it may not be practical to package this Air Box sensor system in some vehicle applications. The recommendations listed below are intended to serve as guidelines for designing an air inlet system that will provide good control system performance once the control system calibration has been modified to work with the new Air Inlet System:

1. MAP sensor contamination: Install sensor in upper half of cross sectional area to minimize possibility of condensation coming in contact with the MAP sensor element. If a clock is superimposed on a cross section of the zip tube, the sensor should be installed somewhere equal to or above the 9:00 and 3:00 positions. Most OEM applications have the sensor located at the 9:00 or 3:00 location.
2. MAP sensor locations: MAP sensors will have to be mounted in two separate locations. One will be located between the air filter and the turbo charger inlet. If using a y-pipe the sensor should be located in the pipe prior to the split. The second sensor should be 8 to 10 inches from the throttle body to prevent flow pulsations.

3.8 Controls Pack Wiring Assembly - CM-14A006-35LA

• Connects to vehicle battery and inline connector on engine harness.
• Contains Ford Performance Power Distribution Box (FPPDB) and High Power 250A inline fuse.
• Electrical connections to Accelerator Pedal (APPS) and Clutch Switches (CBT/CTT).
• Wire leads for Ignition Switch & Starter.
• Data Link Connector for reading Diagnostic Trouble Codes (DTCs).
• Check Engine/Malfunction Indicator Lamp (MIL) for visual indication of engine control system fault code presence.
• MIL will stay illuminated when the ignition is ON and the engine is NOT running; therefore this condition does not indicate a system fault. Not all DTCs will cause the MIL to illuminate.
• MIL on stock instrument panel will not work—only the MIL included in this kit will illuminate if a fault exists.

4.0 Pre-Installation of Harness and Parts

4.1 Planning

The following is a list of key factors to consider before any installation takes place:

• PCM mounting location is limited by the lengths of the (2) corresponding leads into which the PCM is connected. These leads are an integral part of the CRATE ENGINE HARNESS (not included with Controls Pack).
• Inline Fuse Holder must be mounted within 12” of the vehicle battery “+” post when using the supplied 4AWG Jumper Cable.
• Ford Performance Power Distribution Box must be mounted within 60" of the engine powertrain controls module (carefully layout complete system prior to attaching any components).
• Lay out the harness and components first to ensure that the wiring leads will reach everywhere intended. This is a good reality check before drilling any holes or mounting any components!

4.2 Connector ID

Visual description: A complex wiring harness with various connectors labeled with letters (A-S) corresponding to the table above. Key points on the harness are labeled M, DD, CC, CCA, H, G, D, E, BB, BBA, AA, N, F, B, EE.

4.3 Tools Required

• Wire Cutter/Stripping Tool
• Crimper
• Digital Volt/Ohm Meter
• Solder Gun / Solder
• Center Punch
• Cordless Drill / Drill bits / Hole saw / Screwdriver bits

4.4 Engine Harness Routing

Visual description: Front and rear views of a 3.5L crate engine with a yellow overlay indicating the routing of the ENGINE harness. This is explicitly noted as NOT the Controls Pack wiring harness.

Note: The wire harness shown in yellow is the ENGINE harness that comes standard with the 3.5L Crate Engine (Ford Performance P/N: M-6017-35CNTRL); THIS IS NOT THE CONTROLS PACK WIRING HARNESS.

5.0 3.5L Controls Pack Harness Installation Instructions

NOTE:

• To avoid electrical shock and/or damage to sensitive electrical control system components, before beginning any work, remove the vehicle's Negative Battery Terminal and place a rag or towel between it and the Battery Negative Post. The Negative Battery Terminal is not to be reinstalled until the last step of installation.

1. Locate harness that comes on engine then locate a large black PCM connector that hangs off the engine.
2. From the PCM connector traveling towards the engine, locate the first takeout AA, then traveling further down the harness, locate takeout BB, which is between the intake and the valve cover.
3. Locate PCM connector on control pack harness which is C1551 (referring to Figure 1).
4. Traveling up the harness, locate takeout AA, continuing up the harness, locate takeout BB. Locate C1260, C100, C1588, BLUNT CUT FAN CIRCUITS and starter solenoid eyelet and make sure they are routed towards the front of the motor.
5. Place takeout BB on top of takeout BB of the engine harness and zip tie together.
6. Route the red wire (not included with engine, visual example only) correctly under the vacuum lines. Carefully route C1260, C100, C1588, BLUNT CUT FAN takeout and starter solenoid eyelet under vacuum lines located in the top of engine. Zip tie controls pack harness along the same routing as the engine harnesses.
7. Route C1260, C100, blunt cut fan and solenoid eyelet down front of cylinder head.
8. Locate takeout C1588 and connect to sensor in front of throttle body on air intake tube.
9. Connect eyelet to starter solenoid; takeout must be routed away from the exhaust.
10. If using OEM air conditioning compressor, plug C100 into compressor and C1260 into A/C pressure transducer. If not using A/C, cut these takeouts off the harness, use shrink tube to seal all circuits separately, and tape all circuits together.
11. A blunt cut FAN takeout is provided for custom cooling FAN set up. The orange wire is positive and the black wire negative.
12. Locate takeout BB again, moving towards the back of the motor following engine harness routing. The controls pack harness will come to takeout CC; carefully apply zip ties along on both harnesses to tie them together.
13. Locate ground eyelet GD200 and place on ground stud, carefully route behind engine harness.
14. At takeout CC, continue routing control pack harness along engine harness and zip tie together. Then locate takeout CCA which is the FAN ground eyelet; place eyelet on ground stud on the back side of the left head of the engine.
15. Locate C1667, C1622 and C102A and carefully route under vacuum lines and rubber hose on engine. As in step 6, the red wire shows the proper routing. Carefully apply zip ties along on both harnesses to tie them together until takeout CCB is reached. Takeout C102A routes down to the alternator and plugs to the alternator.
16. Route C1667 to sensor on top of air cleaner.
17. Route C1622 to sensor on inner cooler near bottom left of radiator; take care so harness will not come in contact with cooling fan movement.
18. Return to takeout CC on the back of the motor. Traveling down the harness, locate takeout DD and the PDB.
19. Choose a mounting location for the PDB and route the rest of the harness inside of the vehicle. Remove the small cover of the PDB. An eyelet is loosely attached to the PDB; it is CRITICAL that this eyelet remains at the same location after installation.
20. Locate the long battery cable. Place both eyelets of the battery cable and the eyelet from takeout DD on the PDB stud. Replace the small PDB eyelet on top of the large eyelet. Re-install nut and washer onto PDB stud and torque down. Replace small cover. The owner can route the rest of the battery cable to the desired location of the battery. The battery cable can be shortened (an extra eyelet and shrink tube are provided).
21. Locate the short battery cable jumper and assemble into the mega fuse.
22. Attach the long battery cable onto the other side of the mega fuse. Do not install battery eyelet to battery until installation is complete.
23. Please note negative cable is not provided in the controls pack installation kit. Cable must run from battery negative to engine block for best results.
24. Continuing down the main line away from Takeout DD, a loose/floating grommet will be found. This grommet needs to be properly installed in the firewall of the vehicle to protect the controls pack harness routing that passes through to the passenger compartment. All takeouts and connections previously mentioned are located under hood; all takeouts and connections mentioned from this point on are located in the passenger compartment.
25. Identify the most appropriate location for the controls pack wiring harness to pass through the engine compartment/passenger compartment bulkhead. Use a center punch to mark the location of the center of the hole to prevent the drill bit from 'walking'. Use a hole saw to create a hole large enough (~2") for the remaining portion of the controls pack harness to pass through. It is strongly recommended to file/smooth the sharp metal edges created by the hole saw and install a rubber grommet in the hole to prevent metal edges from perforating the harness and causing damage. Feed the controls pack harness through the opening and route to the appropriate locations.
26. Identify proper mounting location for the Accelerator pedal, Clutch pedal (purchased separately) and Ignition Switch (purchased separately). Lay each component on its own piece of cardboard and use a pencil to create a template of the footprint. Use the templates to drill holes in the proper location/orientation within the vehicle passenger compartment. Attach components to vehicle.
27. Identify mounting location for the Bracket with OBDII connector. Complete Step 26 first as harness lead length will be a limitation. Use a piece of paper or cardboard and a pencil to create a template of the bracket footprint. Use the template to drill holes in the proper location/orientation within the vehicle passenger compartment. Attach the bracket to the vehicle.
28. Moving down the main line of the controls pack harness from the loose grommet is "Takeout EE," which consists of one routing off of the mainline:
    • Instrument Panel Pigtail connector (C160A)
29. Route C160A to approximately the base of the steering wheel to be connected as explained in a later step (Step 34).
30. Connect the ground eyelet to a reliable ground point on the chassis or engine block, away from dirt and water.
31. Located approximately 1 foot down the main line of the controls pack harness from Takeout EE is "Takeout FF" and "Takeout GG", which consist of five routings off of the mainline:
    • Accelerator Pedal Position Sensor (APPS) (C2040)
    • Ground Eyelet (GD100)
    • Clutch Bottom of Travel (C257)
    • Clutch Top of Travel (C277)
    • Data Link Connector (C251)
32. Connect C2040 to the base of the accelerator pedal module.
33. Connect each of the connectors to their respective locations.
34. Locate the 16-way I/P Pigtail connector with blunt leads and continue to Section 6.

* Removal Procedures for Unused Connectors:

If 100% sure a connector is not currently needed and will not be needed in the future, cut routing leading-up to unused connector and individually heat shrink each wire. To ensure wires are completely isolated from one another and the outside environment, wrap the heat-shrinked wire in electrical tape for additional protection from moisture and dirt.

6.0 16-way I/P Pigtail Connection Details

Visual description: A diagram of the 16-way I/P Pigtail connector (C160B) with numbered pins (1-16).

The 16-way pigtail is to be connected according to the chart below. See also the diagrams on the following pages for illustrations of wire connection points, based on the ignition/starter switches that you intend to use. Setup A uses separate toggle switches for ignition and starter inputs, while Setup B uses an ignition cylinder with a key.

6.1 Locate Blunt Leads

Locate each of the Blunt Leads. This is where all soldered connections for the harness will be made. Before soldering any wires, decide which set-up (A or B on pages 19 and 20) will be pursued. Once decided, continue to Step 6.2.

6.2 Connect REQUIRED Blunt Leads

6.2.1 Blunt Lead 1 - Fuel Pump Relay Out (Dark Green):

• Connect to Fuel Pump positive. Separate ground for fuel pump must be provided. The fuel pump will be running any time key is on.

6.2.2 Blunt Lead 3 - Starter Motor Request (Red-Light Blue):

• Set-up A: Connect to input node of starter momentary switch so that 12 volts is provided when engine starting is requested.
• Set-up B: Connect to 'Start' output node of ignition cylinder so that 12 volts is provided when engine starting is requested.

6.2.3 Blunt Lead 5 - Ignition Relay Trigger (Red-Light Green):

• Set-up A: Connect this wire to the output side of the ignition toggle switch so that 12 volts is provided when the key is in the 'Start' (cranking) and ‘Run' positions. It is imperative that this circuit be reliable; the PCM will interpret an intermittent voltage on this signal as a request to shut down the engine! (Hint: if the engine shuts down after a hard launch, check here first).
• Set-up B: Connect to the 'Start/Run' output node of ignition cylinder so that 12 volts is provided when engine starting is requested. It is imperative that this circuit be reliable; the PCM will interpret an intermittent voltage on this signal as a request to shut down the engine! (Hint: if the engine shuts down after a hard launch, check here first).

6.2.1 Blunt Lead 6 - Malfunction Indicator Light (Blue):

• Connect this blunt lead to the negative (black) lead on the MIL (provided in the kit bag). Provide 12V for the positive (red) lead of the MIL.

6.2.2 Blunt Lead 8 - Hot At All Times (Red):

• Set-up A: Connect this lead to three different locations as needed: 1) the input node of the A/C toggle switch, 2) the input node of the Starter momentary switch, and 3) the input node of the Ignition toggle switch.
• Set-up B: Connect this lead to two different locations as needed: 1) the input node of the A/C toggle switch, 2) the input node of the ignition cylinder.

6.2.3 Blunt Lead 9 -Chassis Ground (Black-Grey):

• Connect this blunt lead to the negative (black) lead on the MIL (provided in the kit bag).

6.2.4 Blunt Lead 16 – Key On 12V/10A (Yellow):

• Set-up A: This lead is not needed and may be wrapped in heat shrink and electrical tape as described at the end of Section 5.
• Set-up B: Connect to the ‘Accessory’ output node of ignition cylinder so that 12 volts is provided when key is in 'Accessory/Run' mode with engine off.

6.3 Connect OPTIONAL Blunt Leads

• 6.3.1 Blunt Lead 2 - CTO (Orange): Optional tachometer output signal if desired.
• 6.3.2 Blunt Lead 4 - A/C Request (Violet): Connect to the output of an A/C toggle switch (if desired). Sends a request to the PCM to energize the A/C Clutch Solenoid when 12 volts is applied.
• 6.3.3 Blunt Lead 7 - AUX 1 (Green): Optional 12 volt power supply for additional aftermarket items. If use is desired, an additional fuse must be added to the FPPDB.
• 6.3.4 Blunt Lead 12 – HS CAN (-) (White): Optional CAN line for additional aftermarket items.
• 6.3.5 Blunt Lead 13 - HS CAN (+) (White-Blue): Optional CAN line for additional aftermarket items.
• 6.3.6 Blunt Lead 14 – AUX 2 (Green): Optional 12 volt power supply for additional aftermarket items. If use is desired, an additional fuse must be added to the FPPDB.
• 6.3.7 Blunt Lead 15 – AUX 3 (Green): Optional 12 volt power supply for additional aftermarket items. If use is desired, an additional fuse must be added to the FPPDB.

6.4 Final Connection

Once all of the blunt lead connections have been soldered onto their appropriate location, insert the 16-way I/P Pigtail connector into C160A.

* Important Note on the Starting System

This kit includes connections and installation instructions for PCM controlled engine starting; however, it is not required that the customer utilize this option. Customers may choose to use their existing non-PCM controlled starting system if desired. If non-PCM controlled starting is used, Step 6.2.2 may be omitted, and any unused blunt leads should be cut to ~2” length and sealed using heat shrink.

7.0 Fuel System

The PCM is calibrated for a return style fuel system as shown below.

Visual description: A diagram illustrating a return-style fuel system. It shows a fuel tank, a primary fuel pump, fuel flow from the pump to an OEM fuel rail, a fuel pressure regulator (not included in kit) with a reference to intake manifold vacuum/pressure, and a fuel return line back to the fuel tank. The fuel pressure regulator is set to maintain 50-55 psi delta fuel pressure across the injector (50-55 psi at fuel rail with engine off). Only AN type fuel fitting should interface with the OEM fuel rail. The fuel pressure regulator must have reference to manifold vacuum.

• Set regulator to maintain 50-55 psi delta fuel pressure across injector (50-55 psi at fuel rail with engine off).
• Use only AN type fuel fitting to interface with OEM fuel rail.
• Fuel pressure regulator must have reference to manifold vacuum.

Fuel pump requirements:

• 155L/Hr minimum at 55psi

Fuel pump location:

A common and often overlooked problem is the location of the fuel pump or pumps. Optimally, the fuel pump should be mounted IN THE TANK to reduce the possibility of pump cavitation. Cavitation is essentially localized boiling caused by a reduction in pressure, generally occurring on the inlet side of a pump. This localized boiling results in fuel vapor bubbles which will reduce the volume of fuel the pump is capable of delivering to the engine. Any reduction in pressure or increase in temperature at the inlet side of the pump increases the chances that cavitation will occur. For this reason, it is always best to either have the pump inside the tank immersed in fuel or (in the case of an external pump) gravity fed, which will increase the pressure on the inlet side of the pump. If the fuel pump has to “pull” the fuel, this will result in a reduction in pressure at the fuel pump inlet potentially allowing cavitation and, thus, vapor bubbles to develop. These vapor bubbles are then drawn into the fuel pump and exit the high-pressure side of the fuel pump as compressed vapor.

They travel the entire length of the fuel system and are expelled through the fuel injector. This can cause issues ranging from stumbles and hesitations to engine damage due to insufficient fuel delivery and lean A/F ratios. Sometimes this problem can characterize itself by only appearing when the weather gets warmer, which can confound the diagnosis of the issue. In certain cases, it may seem to only develop when driving on certain surfaces, because pavement reflects more heat than an off-road 4x4 trail. Remember, more heat and lower pressure on the inlet side of the pump means a greater chance of cavitation, which is to be avoided whenever possible.

If an external mounted fuel pump is used, run a very coarse (typically around 100 micron) filter on the inlet side of the fuel pump, and a finer (typically around 10 micron) filter on the outlet side of the pump. A paper filter is NOT recommended on the inlet of the fuel pump because it can cause a restriction in fuel flow which, as mentioned previously, can lead to cavitation.

Warning:

• It is highly recommended that an inertia switch is incorporated into the fuel pump wiring to turn off the fuel pump in event of an accident.

8.0 Initial Start-Up

Note:

• The following information assumes completion of each of the previous steps of this installation manual.

1. Check all fluid levels, electrical and fluid connections.
2. Pressurize the fuel system by turning the key on. Inspect the entire fuel system (from tank to engine) for leaks.

!!! NOTE: If any leaks are found, do not proceed further until these have been corrected !!!

3. Start Engine.
4. Check for leaks and/or noises that may indicate a problem.

CAUTION:

• Be certain to run the vehicle in a well ventilated area.

9.0 Wire Usage Schematics

The following two pages detail the two most common wiring configurations—please choose one to complete installation of your controls pack kit.

Setup A Wiring Diagram

Visual description: A schematic diagram for 'SETUP A' showing connections for Ignition, Starter, A/C, Fuel Pump, and Battery. It illustrates three toggle switches (Ignition, Starter, A/C) and their inputs/outputs connecting to the C160B connector. The Ignition toggle switch output connects to 'Ignition Relay Trigger (Light Green)'. The Starter momentary switch output connects to 'Starter Motor Request (SMR) (Light Blue)'. The A/C toggle switch output connects to 'A/C Request (VT)'. All three switches receive input from 'HAAT B (RD)'. The Fuel Pump is connected to 'Fuel Pump Relay Out (GN)'. The Battery is shown with a positive terminal connected to 'HAAT B (RD)' and a negative terminal connected to 'GROUND 14AWG'. Components marked with an asterisk (*) are not included in the kit.

Setup B Wiring Diagram

Visual description: A schematic diagram for 'SETUP B' showing connections for Ignition Cylinder/Switch, A/C, Fuel Pump, and Battery. It illustrates an ignition cylinder/switch with 'INPUT', 'START', 'START/RUN', 'ACCESSORY/RUN', and 'OFF' positions. The 'START' output connects to 'Starter Motor Request (SMR) (Light Blue)'. The 'START/RUN' output connects to 'Ignition Relay Trigger (Light Green)'. The 'ACCESSORY/RUN' output connects to 'Key On 12V/10A (YE)'. The 'INPUT' and 'HAAT B (RD)' are connected. An A/C toggle switch is shown with its output connected to 'A/C Request (VT)' and input connected to 'HAAT B (RD)'. All these connections lead to the C160B connector. The Fuel Pump is connected to 'Fuel Pump Relay Out (GN)'. The Battery is shown with a positive terminal connected to 'HAAT B (RD)' and a negative terminal connected to 'GROUND 14AWG'. Components marked with an asterisk (*) are not included in the kit.

10.0 Fuses & Relays

Visual description: A diagram showing the layout of fuses and relays within the controls pack wiring harness. It includes J-Case fuses (JC1-JC8) and Minifuses (F1-F12), along with Power Mini Relays (R1-R2) and High Current Micro Relays (R3-R6).

• The following diagram outlines the array of fuses and relays included in the controls pack wiring harness, and the function of each.
• NOTE: Do NOT replace any of the fuses with a higher value than those specified below.

11.0 Connector Faces

Visual description: Diagrams of various connector faces, showing pin layouts and numbering for: C257 (2-pin), C277 (2-pin), C2040 (6-pin), C251 (16-pin), C100 (2-pin), C102A (3-pin), C1260 (2-pin), C1667 (3-pin), C1588 (4-pin), C1622 (2-pin), C1551B (multiple pins), C146 (10-pin), C160A (16-pin), and C160B (16-pin). These diagrams illustrate the physical appearance and pin configuration of each connector mentioned in the manual.