RX-5 Aftermarket Mazda Electrical Manual
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The Information and descriptions described herein are the property of MK Sportscars. Such descriptions and information may not be copied or reproduced (duplicated) by any means (in any form) or disseminated or distributed without the express prior written permission (consent) of MK Sportscars. The information contained in this document is subject to change without notice. MK Sportscars assumes no responsibility for any errors that may appear in this document.
Copyright Notice
This document contains propriety information, which is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced by any means, or translated into another language without the prior written consent of MK Sportscars.
Table of Contents
- Introduction
- IVA
- Safety First
- ME360 Harness Connections
- Daughter Loom Connections
- Power and Earth Leads
- Troubleshooting
1. Introduction
MK Sportscars has produced thousands of cars since the company launched the MK Indy in 2000. We are constantly striving to improve our cars and options list available to further enhance the affordability and desire of the car our main goal driver behind the RX-5 project. The enjoyment of the car should be in its actual construction, This Build manual has been produced to assist with this part of the project. The purpose of building a MK RX-5 140 is to realise a car that will suit the purpose for which it is intended. If this is a Road car or Track-based car, we have many thousands of satisfied owners in all categories both here and overseas who have had the enjoyment of building a MK. MK Sportscars will continue to offer the support to help deliver to you the means and advice of building a car, simply and quickly, with minimum complication and a maximum amount of fun. This manual is for the guidance of building the MK Indy and should also be used alongside the current IVA manual if you are looking at building a road registered car. If at any stage of the build you are unsure, please contact MK Sportscars for guidance or seek professional mechanical knowledge from a reputable and qualified company or individual. MK Sportscars hope you enjoy the experience.
1.1. Manual Conventions
Throughout this manual there are important details which must be followed. These are highlighted with the following icons.
2. IVA
For amateur build IVA compliance, you will need to have photographic evidence throughout the whole build process. Please ensure you take sufficient photographs of each step in the build. These will need to be submitted with your IVA application form. Each section where you need to take photographs will be marked in the manual – but you can never have too many pictures of your build, it’s great to look back on in years to come.
3. Safety First
ALWAYS WEAR:
• GOGGLES OR PROTECTIVE GLASSES AND SUITABLE FOOTWEAR IF YOU ARE USING WELDING OR GRINDING EQUIPMENT, THERE MAY BE OCCASIONS FOR THIS IF YOU ARE OUTSIDE OUT BUILD PARAMETERS,
• PROTECTIVE GLOVES WHEN HANDLING FIBREGLASS OR CARBON.
• DUST MASK AND EAR PROTECTION WHEN WORKING WITH FIBREGLASS OR CARBON.
IT IS ESSENTIAL THAT THE SUPPORTS YOU USE UNDER THE CHASSIS DURING THE BUILD PROCESS ARE SUITABLE AND SAFE FOR USE.
DO NOT CONNECT THE BATTERY +VE LEAD UNTIL THE WIRING LOOM HAS BEEN FULLY INSTALLED AND ALL EARTH CABLES HAVE BEEN CONNECTED.
THE BATTERY MUST NOT BE CONNECTED UNTIL ALL TESTS HAVE BEEN COMPLETED.
DO NOT FILL THE FUEL TANK UNTIL THE CAR IS COMPLETE.
PLEASE TAKE CARE WITH BRAKE FLUID AND BRAKE FLUID SPILLAGE AND ALWAYS FOLLOW THE MANUFACTURES GUIDELINES.
IT IS ADVISABLE TO HAVE A SUITABLE FIRE EXTINGUISHER AT HAND.
ENJOY YOUR BUILD AND BE SAFE AND MOST IMPORTANTLY HAVE FUN
4. ME360 Engine Harness Connections
The Motorsport Electronics Wiring harness is designed as a plug and play system to connect your Mazda MX-5 engine to the ME360 stand alone ECU.
This is achieved by connecting the following components from the loom to the Engine.
Before making an attempt to wire this in, remove the top of the inlet plenium so you can lay in the loom to prevent any of the wires from showing, thus making you a tidy installation.
4.1. IAT (Intake Air Temp)
Specific for the Turbo build, this is positioned in the top of the inlet plenium. This is a blank which is then tapped out. Please refer to our turbo manual for more details.
4.2. IDLE + TPS
Positioned on the inlet of the engine.
4.3. CAM
Located at the front of the engine at the top.
4.4. CRANK & BOOST SOLENOID
Specifically for the turbo installation, the boost controller is mounted on a bracket towards the front of the engine.
4.5. COILS
Positioned towards the rear of the engine.
4.6. COOLANT
Positioned towards the rear of the engine.
In the kit there is a purple wire with a terminal on the end. This plugs into this coolant sender in the hold with no wire in it.
The other end of the coolant sender is connected into pin #7 of the “Engine Connections” plug located beneath the bulk head panel.
| Pin # | Wire Colour | Signal |
| 1 | Black | GND |
| 2 | Red / Green | Engine Batt + |
| 3 | White / Green | Engine Ignition |
| 4 | Black / Yellow | Cooling Fan Relay Drive |
| 5 | Black / Purple | Fuel Pump Relay Drive |
| 6 | White / Black | Rev Counter |
| 7 | Green / Blue | Coolant Temperature |
| 8 | White / Brown | Oil Pressure |
| 9 | Brown / Blue | Oil Temperature |
| 10 | Brown / Orange | Neutral Switch |
| 11 | ||
| 12 | ||
| 13 |
4.7. MAP
Located under the bulk head panel.
5. Daughter Loom Connections
It’s possible to build your own daughter loom using the following
5.1. Indicator Stalks & Ignition Barrel – CH059 & CH060
CH059
|
Cov ID |
Colour |
Signal |
Mazda Ignition Key Plug |
Mazda Column Plug |
Mazda Horn Plug |
Hazard Switch |
Fog Light Switch |
Heater Switch |
|
1 |
B |
GND |
|
Black (B8) |
|
Black |
Black |
Black |
|
2 |
BG |
Horn |
|
|
Green / Yellow |
|
|
|
|
3 |
WO |
Ignition Relay Drive |
Red / Black |
|
|
|
|
|
|
4 |
RG |
Ign Sw Batt + |
Red / White (x2) |
|
|
|
|
|
|
5 |
WR |
Starter Relay Drive |
Black / White |
|
|
|
|
|
|
6 |
WG |
Ignition Start Switch |
|
|
|
|
|
|
|
7 |
U |
Headlights Input |
|
Red / Orange (E2), (E3) |
|
|
|
|
|
8 |
RG |
Lights Batt + |
|
Black (E1) |
|
|
|
|
|
9 |
UW |
Main Beam |
|
White (E4) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
10 |
RW |
Side Lights |
|
Light Green (A9) |
|
|
|
|
|
11 |
|
Dipped Beam |
|
Red / Orange (E2), (E3) |
|
|
|
|
|
12 |
|
Flasher Unit + |
|
Loop to Pin #15 |
|
|
|
|
|
13 |
|
Flasher Unit Trigger |
|
|
|
Green |
|
|
|
14 |
|
Hazard Sw Ignition |
|
|
|
|
|
|
|
15 |
|
Hazard Sw Batt + |
|
Loop to Pin #12 |
|
|
|
|
|
16 |
|
RH Indicators |
|
Green / White (A3) |
|
Diode, Blue |
|
|
|
17 |
|
LH Indicators |
|
Green / Black (A4) |
|
Diode, Blue |
|
|
|
18 |
|
Illumination |
|
|
|
|
Red |
Red |
|
19 |
|
Fog Light Sw |
|
|
|
|
Blue |
|
|
20 |
|
|
|
|
|
|
|
|
CH060
|
Cov ID |
Colour |
Signal |
Mazda Plug |
Heater Switch |
|
1 |
WG |
Washer / Wipe Ignition |
Blue |
|
|
2 |
YB |
Washers |
Blue / Pink |
|
|
3 |
UG |
Slow |
Blue / Red |
|
|
4 |
PG |
Fast |
Blue / White |
|
|
5 |
NG |
Park |
Blue / Yellow |
|
|
6 |
WG |
Heater Switch Ignition |
|
Green |
|
7 |
GY |
Slow |
|
Blue |
|
8 |
GO |
Medium |
|
|
|
9 |
GS |
Fast |
|
|
|
10 |
|
|
|
|
|
11 |
|
|
|
|
|
12 |
|
|
|
|
5.2. Dashboard Cluster / Warning Lights – CHOO4
CH004
|
Cov ID |
Colour |
Signal |
Mazda Plug |
Fog Light Switch |
Hazard Switch |
|
1 |
B |
GND |
Black / Blue (1N) |
|
|
|
2 |
RO |
Illumination |
Grey / Red (3H) |
|
|
|
3 |
WG |
Instruments Ignition |
Black / Yell (1C) |
|
|
|
4 |
NU |
Oil Temp |
|
|
|
|
5 |
WN |
Oil Pressure |
Yellow / Red (3E) |
|
|
|
6 |
GB |
Fuel Level |
Brown / Black (1A) |
|
|
|
7 |
GU |
Water Temp |
Violet / White (2A) |
|
|
|
8 |
WB |
Rev Counter |
Green / Orange (2K) |
|
|
|
9 |
O |
Mazda Speed Signal |
Orange (2M) |
|
|
|
10 |
Y |
Mazda Speed Signal |
Yellow (1M) |
|
|
|
11 |
NY |
Alternator W/L |
Brown / Red (3B) |
|
|
|
12 |
BW |
Brake Fail W/L |
Blue / Yellow (3C) |
|
|
|
13 |
UW |
Main Beam |
Red (1H) |
|
|
|
14 |
CW |
RH Indicators |
Green White (3I) |
|
Blue * |
|
15 |
GR |
LH Indicators |
Green / Black (3A) |
|
Blue * |
|
16 |
RU |
Fog Light W/L |
Pink / Blue (2O) |
Blue |
|
|
17 |
|
|
|
|
|
|
18 |
|
|
|
|
5.3. Alternator & Starter Solenoid
5.4. Fuel Pump & Sender
5.5. Speedo Sender
5.6. Reverse Sender
6. Power and Earth Leads
6.1. Starter Motor Power Lead
The starter motor power lead is xx long with and M6 eyelet on both ends.
Connect this directly to the Starter motor from the battery
6.2. Engine Earth Lead
The engine earth lead is 300mm with M10 eyelets on both ends.
Connect one side to beneath the engine mount on the UK drivers side, the other into the bolt in the side of the block.
7. Troubleshooting
7.1. Mk 2.5 Dashboard Issues
On the mk 2.5, the headlight flash doesn’t work straight out of the box. There is an additional earth wire required on the white plug which goes into the stock dashboard.
Splice into wire A and connect this into wire B in the drawing below to resolve.
7.2. CANchecked Canbus Gauge – No Data
In the event of data loss when installing the CANchecked gauge and receiving zero readings from the ECU, you need to install a 60ohm resistor across the output like this:
