Part 5: Wiring Block Diagram

Basic Circuits

Block Diagram

Wiring-BlockDiagram

The Block Diagram shows the basic connection paths used for successful operation. The arrows indicate the primary direction of the control or communication. It is important to consider the Engine & ECU Wiring harness complete with all associated sensors as a complete single unit. While some parts of the Engine & ECU Wiring Harness may need to be adapted to suit your vehicle configuration the overall harness should not be varied greatly. For details of individual sensor wiring refer to the electronic version of the Ford Focus Wiring Diagrams.

The OEM Engine Control Unit is designed to be located within the engine bay and only needs to be mounted with the connectors protected from direct water ingress.

Part 4: Connector Pinouts

Connector Pin-out Diagrams

C90 – Engine Loom to Main Junction Box

C90-Pinout

  1. 5-EC7D (BU/RD)
    5-EC7C (BU/RD)
    5-EC7A (BU/RD) – DURATEC 2.0L – HIGH CAN-
  2. 91S-RH15 (BK/YE)
  3. Not Used
  4. 31S-BB16 (BK/RD)
    31S-BB16B (BK/RD)
    31S-BB16A (BK/RD) – DURATEC 2.0L – Starter Relay Trigger Ground (PCM controls Ground for Starter Relay Coil, supplied from IGN Switch START position)
  5. 91S-RE8 (BK/YE)
    31S-FA11A (BK/YE)
  6. 91S-RH5 (BK/BU) – DURATEC 2.0 – Fuel Pump Relay Trigger (Grounds coil for fuel pump relay via inertia switch is fitted. Connects to PCM on C690 Pin 19)
    91S-RH5A (BK/BU)
    91S-RH5B (BK/BU)
    15S-PE8 (GN/RD)
  7. Not Used
  8. 15S-LG23 (GN/WH) – DURATEC 2.0L – Brake Pedal Detection (Ground for the Brake light Circuit connects to PCM via C690 Pin 39)
    15S-LG23B (GN/WH)
    15S-LG23A (GN/WH)
  9. Not Used
  10. 15-LG28 (GN/WH)
    15-LG28A (GN/WH)
  11. 50-BB12 (GY)
    50-BB14A (GY/RD) – DURATEC 2.0L – Starter Solenoid Power (via Transmission Selector switch to starter motor, Controlled by Starter Relay)
  12. 15-RJ15 (GN/BU) – DURATEC 2.0L – PCM +12v via Power Hold Relay
    15-RJ15A (GN/BU)
    15-RR1 (GN/RD) – DURATEC 2.0L – Ignition Coil Power (+12v via Power Hold Relay. Coils ground by PCM for ignition)
    15S-RL42 (GN/BU)
    15S-RL50 (GN/BU)
  13. 30-RE8 (RD)
    30-RE8A (RD)
    30-RE8B (RD)
    30-TA55 (RD) – DURATEC 2.0L – Transmission Control Unit +12v Battery (Connects to Transmission Control Unit via C117 & C414)
  14. 15-RN3A (GN/BU) – DURATEC 2.0L – Injector Power (via Power Hold Relay, injectors Ground controlled by PCM)
    15-RN3C (GN/BU)
    15-RN3 (GN/BU)
  15. 4-EC7D (GY/RD)
    4-EC7B (GY/RD) – DURATEC 2.0L – HIGH CAN+
    4-EC7A (GY/RD)
  16. 8-EE14 (WH/BU)
  17. 31S-FA11 (BK/YE) – DURATEC 2.0L – Wide Open Throttle Relay trigger (PCM grounds coil to activate)
    91S-RE8A (BK/YE)
  18. 15S-FA6 (GN/YE) – DURATEC 2.0L – A/C Compressor Clutch via WOT Relay
    15S-FA6A (GN/YE)
  19. 8-FA88 (WH/VT) – DURATEC 2.0L – A/C Pressure Sensor Signal (From PCM to pressure sensor)
    91S-PA13 (BK/BU)
    8-FA88A (WH/VT)
    8-FA88B (WH/VT)
  20. 30-BA10 (RD) – DURATEC 2.0L – +12v Battery to Alternator
  21. 91S-RH9 (BK/BU)
    91S-RH9A (BK/BU) – DURATEC 2.0L – Power Hold Relay Trigger (Grounds coil for Power Hold Relay) Connects to PCM at C690 Pin 35.
    91S-RH9B (BK/BU)
  22. 91S-LG45 (BK/GN) – DURATEC 2.0L – Reverse Light Relay trigger (Reverse light relay coil triggered when in Reverse by Transmission Control Unit)
  23. NOT USED
  24. 15S-RD15D (GN/OG)
    15-TA55 (GN/BK) – DURATEC 2.0L – Transmission Control Unit +12v via Power Hold Relay
    15-TA18 (GN/OG) – DURATEC 2.0L – Transmission Range Sensor +12 via Power Hold Relay
  25. 15S-RD15C (GN/OG)
    91S-BB6 (BK/YE)
  26. 15S-RD15B (GN/OG)
  27. 15S-RD15A (GN/OG)
  28. 10-RJ30 (GY) – DURATEC 2.0L – Accelerator Pedal Position Sensor Signal (From Accelerator pedal unit)
  29. 7-FA88 (YE/VT) – DURATEC 2.0L – A/C Pressure Sensor VCC (PCM to pressure sensor)
    7-FA88A (YE/VT)
  30. 8-PF36 (WH/GN) – DURATEC 2.0L – Auto Transmission Shift Up (Connects to Transmission Control Unit via C117 & C414)
    8-PF36A (WH/GN)
  31. NOT USED
  32. 9-FA88 (BN/WH) – DURATEC 2.0L – A/C Pressure Sensor Ground (Connects output of pressure sensor to PCM)
    9-FA88A (BN/WH)
  33. 10-PF36 (GY/OG) – DURATEC 2.0L – Auto Transmission Shift Down (Connects to Transmission Control unit via C117 & C414)
  34. 49-PA6 (BU) – DURATEC 2.0L – Radiator Fan Control trigger (PCM grounds coil of relay to trigger radiator fan)
  35. NOT USED
  36. NOT USED
  37. 15-RE17 (GN/BU)
    15-RE17A (GN/BU) – DURATEC 2.0L – PCM Power +12v IGN in RUN or START (Connects to PCM via C690 pin 46)
    15-RN2A (GN/BU)
    15-RN2B (GN/BU)
  38. NOT USED
  39. 15S-LG9 (GN/BK)
    15S-LG9A (GN/BK)
  40. 15-RJ14 (GN/YE) – DURATEC 2.0L – Rear O2 Sensor Power (+12v via Power Hold Relay)
    15-RJ25 (GN/RD) – DURATEC 2.0L – Front O2 Sensor Power (+12v via Power Hold Relay)
    15-RR4 (GN/BU)
  41. 15-RE21 (GN/OG)
    15-RE21A (GN/OG) – DURATEC 2.0L – PCM Power (+12v via Power Hold Relay)
    15-RE21B (GN/OG)

 C200 – On-Board-Diagnostic Port

 C200-Pinout

  1. Not Used
  2. Not Used
  3. 4-EC10B (GY) – HIGH CAN-
  4. 31-RA1 (BK) – Ground
  5. 91-RA1 (BK/OG) – Ground
  6. 4-EC7L (GY/RD) – HIGH CAN+
  7. Not Used
  8. Not Used
  9. Not Used
  10. Not Used
  11. 5-EC10B (BU) – MID CAN-
  12. Not Used
  13. Not Used
  14. 5-EC7L (BU/RD) – MID CAN+
  15. Not Used
  16. 29-RA1 (OG) – +12v Battery

C391 – PATS Key/Transponder Reader

C391-Pinout

  1. 15-GL37 (GN/BK) – +12v START / RUN from IGN Switch
  2. 91-GL1 (BK/YE) – Ground
  3. 10-GL37 (GY/OG) – Sensor (Connects to Instrument Cluster via C809 Pin 5)
  4. 8-GL37 (WH/GN) – Sensor (Connects to Instrument Cluster via C809 Pin 3)

C456 – Ignition Key Switch

C456-Pinout

  1. 15-DA1 (GN/YE) – +12v START/RUN (Distribution)
  2. 30S-LE29 (RD/GN)+12v Battery
  3. 31S-TA32 (BK/WH) – Ground Key Inhibit (Connects to C809 Pin25)
  4. 30-BB9 (RD) – +12v Battery (20A Fused Supply)
  5. Not Used
  6. 75-DA1 (YE) – +12 Accessory (Distribution)
  7. 50-BB16 (GY/BK) – +12v START Only (Connects to Starter Relay)

C648 – Accelerator Pedal Unit

C648-Pinout

  1. 7-RJ30 (YE) – +5v Constant Voltage (Connects to C809 Pin31)
  2. 8-RJ30 (WH) – Accelerator Pedal Position Validation Sensor+ (Connects to C809 Pin14)
  3. 9-RJ30 (BN) – Accelerator Pedal Position Validation Sensor- (Connects to C809 Pin 13)
  4. 91-RJ30 (BK/YE) – Ground
  5. 10-RJ30 (GY) – Accelerator Pedal Position Sensor (Connects to ECU Directly via C90 Pin 28)
  6. 15-RJ30 (GN/YE) – +12v START/RUN (Connects to IGN Switch via C456 Pin 1)

C732 – Fuel Pump Connector

C732-Pinout

  1. 15S-RG2 (GN/OG) – +12v START/RUN via Fuel Pump Relay (10A Fused)
  2. 8-GA7 (WH/RD) – Fuel Level Sensor+(Connects to C809 Pin 8)
  3. Not Used
  4. 9-GA7 (BN/RD) – Fuel Level Sensor Ground (Connects to C809 Pin 9)
  5. 31-RG2 (BK) – Ground
  6. Not Used

C809 – Instrument Cluster

C809-Pinout

  1. 15S-LD13 (GN/OG)
  2. 91S-GE56A (BK/YE)
  3. 8-GL37 (WH/GN) – PATS Key Reader (Connects to C391 Pin 4)
  4. 15-GG14 (GN/RD) – +12v START/RUN Cluster Power (Connects to C456 Pin 1)
  5. 10-GL37 (GY/OG) – PATS Key Reader (Connects to C391 Pin 3)
  6. 91-GG14 (BK/OG) – Ground
  7. 9-GA7 (BN/RD) – Fuel Level Sensor Ground (Connects to C732 Pin 4)
  8. 8-GA7 (WH/RD) – Fuel Level Sensor+ (Connects to C732 Pin 2)
  9. 29S-GG14 (OG) – +12v Constant Power
  10. 91S-BB6 (BK/YE) – Ground
  11. Not Used
  12. Not Used
  13. 9-RJ30 (BN) – Accelerator Pedal Position Validation Sensor- (Connects to C648 Pin 3)
  14. 8-RJ30 (WH) – Accelerator Pedal Position Validation Sensor+ (Connects to C648 Pin 2)
  15. 75-GG14 (YE/BU) – +12v Accessory Power (Connects to C456 Pin 6)
  16. 15S-LD7 (GN/BU)
  17. 5-EC7H (BU/RD) – MID CAN+
  18. 4-EC7H (GY/RD) – HIGH CAN+
  19. Not Used
  20. Not Used
  21. Not Used
  22. 5-EC10 (BU) – MID CAN-
  23. 4-EC10 (GY) – HIGH CAN-
  24. Not Used
  25. 31S-TA32 (BK/WH) – Ground
  26. Not Used
  27. 91S-GG6 (BK/RD) –
  28. Not Used
  29. 91S-PG6 (BK/YE) – Ground
  30. 91S-GE56 (BK/YE) – Ground
  31. 7-RJ30 (YE) – +5v Supply Constant (Connects to C648 Pin 1)
  32. 29-GG14 (OG) – +12v Battery Supply (Connects to C456 Pin 4)

Part 3: Donor Vehicle Connector Locations

Connector Locations

Due to the modular design of the Ford Focus wiring loom there are only a small number of connectors and components critical to independent engine operation.

C90

Located in in the main engine bay fuse box this is the link between the engine specific wiring and the power supply, fuses and relays to control engine ancillary devices.

C90 C200 & C809

C200 – Located on the drivers side, below the steering column.

C809 – Located on the back of the instrument cluster.

C200-C809

C391 & C456

C391-C456
C648

C648

 

Part 2: About the Duratec Wiring Guide

About this Guide

This guide has been developed to assist in converting the Ford/Mazda Duratec engines from standard factory configuration to other vehicles. It covers the methods and techniques used to perform a transplant keeping only as much of the donor vehicle wiring as required for successful operation of the engine. Chassis related systems such as donor vehicle lighting, ABS, Air-bags etc. are typically not required for most transplants and are not covered by this guide. The Passive Anti Theft System (PATS) is retained for simplicity and the lack of any proven low-cost techniques to bypass the system.

The guide is specifically based around the conversion of 2006-2009 Ford Focus wiring, however the majority of concepts, connectors and wire colours are the same in the Equivalent range of Mazda3 vehicles.

Benefits

All engine operating fail-safes are the same as the OEM installation

Engine emissions are controlled at OEM levels

Integrated immobiliser meeting all national standards

Turn-Key OEM reliability

Disclaimer

The author of this document and any agent providing this document provides this Document as a resource only. No warranty is offered on the accuracy or appropriateness of the information within this document to your particular circumstances.

As with any technical document many of the concepts described require an appropriate understanding and technical skill. If you do not understand the processes and information described it is recommended that you seek the services of a professional to complete the the procedures described.

Key Principles

The basic control of the vehicles electrical system is carried out by a separate chassis wiring loom. The chassis loom should the following functions;

Lighting (Headlights, Parkers, Indicators etc.)

Instrumentation

The Ford Focus/Mazda3 wiring loom is made up of a number of main segments with a number of design features that make it ideal for the conversion.

ECU & Engine sensor wiring are all on the same one piece wiring loom that can be removed from the Engine Bay of the donor vehicle in one piece.

ECU/Engine system wiring terminates via a single fuse/junction box in the engine bay of the donor vehicle.

Only three components in a matched set from one donor vehicle are required for trouble free operation with factory reliability and performance.

Engine Control Unit

Instrument Cluster

PATS Key

The Fuel Pump unit, Accelerator Pedal Unit and PATS Key Reader are not “coded” and can be sourced from an appropriate donor.

The addition of a basic power distribution panel with five relays and associated fuses are all that is needed for successful operation.

In this guide a relay is used in place of the donor vehicle Cooling Fan Control Unit. It is preferable to use the donor vehicle fan controller, however as this is mounted with the cooling fans at the front of the car it is likely to have suffered damage in any frontal impact. The Fan control unit would take the place of the Cooling Fan Relay in this guide.

Part 1: About the Duratec

DuratecQuads

Engine Description

The Ford/Mazda Duratec family of motors offer a lot of performance potential in a small and light package. The alloy head and block contribute to a bare weight of 90kg and lightweight plastic covers and intake components ensure the weight is impressively low when fully dressed..

The ~107kW output in factory 2.0L trim can be boosted with the addition of a wide range of performance parts but most important to builders of kit cars it’s also a “clean” motor easily meeting Euro4 emissions rules in its later Drive-by-Wire configuration.

Drive-by-Wire allows for a greater freedom to mount the accelerator pedal unit as well as introducing a number of fail safes not offered by traditional cable throttles.

6 Months in a Renault Megane GT220

Ok so we haven’t been living in the car since we picked it up on the 14s of June 2013, but we have covered almost 7000km!

Celeste wearing a smart bow for her delivery.
Celeste wearing a smart bow for her delivery.

Along the way we’ve covered a few highway trips, a lot of short round-town commuting and shared some interesting experiences like visits to the service centre and running out of fuel.

Operating Costs

I’ll be honest I track fuel use in a spreadsheet, each tank is carefully entered and the average cost per kilometre is calculated.  Sure it’s dependent on fuel pricing and the driving style but over time provides a real understanding of the “variable” costs.

It’s easy to say I’ve visited petrol stations 14 times in the past 6 months, but the numbers below (up to the last refuel a few days before the 6month mark) tell us the real story.

Total Distance (km): 6531.6
Total Fuel (l): 610.7
Average Consumption (l/100km): 9.28
Average Fuel Price: $ 1.72
Average Cost/KM: $ 0.16

I should say for the record that I have been “driving like I stole it” for about 90% of this distance.

On the servicing front we had a basic Oil and Filter change done at around 3000km to ensure any crude from the run-in process was flushed out.  This was carried out by our local dealer, and not without it’s own quality glitches with oil spilt into the under-engine panelling and ultimately pouring out over my garage floor.  The service itself was just shy of $300 – the main cost being the genuine oil filter and the Elf oil, which accounted for over half the bill.

The next three future services at 10000km/12 month intervals are capped at $299.

It’s a Renault, What’s fallen off it?

OK You got me.  I’d love to say that my experience has been flawless, and it hasn’t been.  All said though I have some minor issues.

  • The roof rail cover fell off, the clips broken, I had flashbacks to my old RenaultSport Clio at that point.
  • The bonnet is missing its leading edge seal, it never had it, I’m still waiting for it.  So much for Renault having parts in Australia.
  • There’s a rattle in the passenger side area of the cabin.  Maybe something loose in the door, I’m not sure.
  • The felted door seals make noise unless they’re heavily lubricated.  I’m dealing with this myself, the Goss Dri-Lube stick works wonders for about 8 weeks at a time.

Other than that there’s been no issues, not mechanical maladies and no weird “Starts second time every time” annoyances.

Is it hard to live with?

I don’t think so, it’s a wagon and immediately that makes it way more useable than just about every size comparable sedan.  When we started out car hunt we were frustrated that most sedans had boot openings that made us feel that we were “posting” our luggage into the dark unreachable corner and recovery required a rope tether to climb in and get it.

In a way stuff can still end up way deep in the back against the rear seats but at least large, odd shaped or long things can be slid straight in.

The rest of the car is just conventional, the Keyless system is truly Keyless, a few times the proximity unlock function hasn’t as it’s been snug against a mobile phone in a pocket, but it’s never failed to lock, nor failed to start.

The stereo is functional, it works and sounds OK in the “driver” mode, but just about every other sound field adapting mode is useless.  The fact that the tweeters are only driven in Driver mode probably has a lot to do with this.  Renault doesn’t have a fix, “they’re all like that” isn’t really a good enough response but that’s what we got.

The real annoyance was running out of fuel.  Yeah something that can be averted by the addition of well aged liquid dinosaur to the tank, however I do partly blame the car for it.  See it gives distance to empty down to a 50km range.  From that point it doesn’t give indication of range.  So making a decision on which petrol station to fill up at isn’t really about choice, it’s about what’s closest.

Interestingly as it died and tried to auto-start a few times it came up with “ESC” disabled, something that isn’t possible to do as a driver, only the traction control can be turned off.  I’ve got to investigate this more.

There's nothing to see here!
There’s nothing to see here!

Is it really a RenaultSport?

It’s definitely more than “just a regular wagon”.  Despite the ESC that cannot be over-ridden there’s lift-over oversteer available on-tap, the lateral grip on flowing corners is outstanding and when the curves tighten into tight bends there’s enough “slip” available before the traction control cuts the fun that careful throttle application can keep things moving.

On the highway it’s a competent almost effortless cruiser.  This is naturally aided by our relatively low speed limits keeping the engine slightly “on the boil” at the expense of fuel consumption.  At a steady 130km/h (the French national limit) consumption drops off by about 10% compared the 110km/h we have here in Australia.

On country roads – that is the kind that traverse the majority of rural Australia something spectacular happens and the chassis absorbs the lumps and bumps firmly but with a edge of suppleness that even Australian designed large cars haven’t delivered when fitted with their factory “sports” suspensions.  The harsher ride around city potholes and undulations isn’t as pronounced with the addition of speed, the somewhat “on stilts” stance of the car is now working in our favour with the longer suspension travel suddenly coming into play.

Incidentally even with a few hundred kilograms of cargo in the back the suspension doesn’t seem to sink into a “dog-with-worms” bum dragging stance that many Japanese and Korean wagons do, it’s obvious that a despite the very limited nature of the production the RenaultSport engineers have managed a pretty good balancing act between a practical family tourer and a “hot hatch”.

Inside the car there isn’t an excess of noise, the engine has a gruff note that becomes a melodic bellow at higher rpms, it’s not unpleasant but I suspect removing the intake resonator which transmits some of this into the cabin could be a good thing.  The exhaust is very muted, the large pipe dumping well under the car, roughly half way between the rear axle one and the rear bumper.

Tyre noise on the other hand is noticeable, partly this will be the Dunlop SportMax, a tyre not known to be a quiet runner and partly reflecting a lack of luxury car-like sound deadening.  A $30 roll of deadener in key areas and some quieter rubber would probably not hurt.  On smoother (concrete & hot mix) the noise is very well suppressed and the noise of the air swirling around the roof-rails becomes far more obvious, it’s not unpleasant, yet it does make me wonder what the car would be like without them.

Would the car need an LSD?  Certainly it would help with the grip under power, as would the PerfoHub arrangement (which would also bring Brembos to the party) but I’m not sure I would have found the extra $10000 Renault Australia would probably charge for a car with that.  Naturally I’d hope that they’d find more than 220hp for it too once those grip and traction matters were addressed.

Speaking of power, we did run Celeste up on the dyne at Ultimate Tunes here in Canberra and got a very respectable 147kw at the front wheels.  I’m happy enough with that for now.

So where to from here?

Driving, more driving and some more driving.  At the moment we’re not considering modifications, by the 30000km/3 Year mark we will have to make plans for servicing that avoid cost blowouts.  To this end there are a number of high-quality Renault approved oils available that aren’t the relatively hard-to-get Elf (nor are they as expensive), Genuine “Service Kits” are available from the UK and mainland Europe for very reasonable prices and there are at least two good French specialist workshops in town.

But swinging back to the modifications topic.  I’d be lying if I said I haven’t done research, but considering the car is largely a bespoke combination of RS265 driveline and GT-Line Estate/Wagon/Sports Tourer some things will require custom fettling.  Cat-back exhausts don’t deliver major power, and changing the cat will bring up the power levels but like most emissions controlled vehicles that will likely trigger warning lights, boost cuts and other weirdness.  The only remedy for that being a tune.  The tunes themselves delivering up to 80hp more than stock on the GT220 are already proven (basically it’s a RS265 power tune) and there’s a few companies that can do it.  Shame all of them invoke locking the ECU to a specific tuner or tuning tool.

Intake modifications seem to deliver nothing of value, Blow-Off-valves etc certainly can help manage higher boost levels but lets be honest, the factory unit will be fine for a modest boost increase (and the reality is that at least half of my power gain is simply in extending the current boost level further up the rev range as it tapers off quite significantly compared to the RS265 boost map.

Anyway there you have it.  6 months of living with a Renault Megane GT220.