MAZDA MP5T Haltech Sport 1000

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BRIAN MP5T
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MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Sun Feb 01, 2009 6:03 pm

Hello, I am Brian. I have been working on my Mazda Protege5 (Astina Sport 20) since I bought it in 2002.

It's been a long journey so far and my next logical step involved Full Stanalone Engine Managament.

there isn't really any parts that were not specifically made for the car. There are hardly any Bolt-Ons, and even if they were bolt on, they were either prototype parts or the only one made.

I have just bought a Haltech Sport 1000 with racepack display, I am very interested to discuss engine management to learn what I can.

Here is a basic rundown of the car.

It can be viewed at http://www.cardomain.com/ride/503974 in better detail.

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    • 2002 Mazda MP5 Turbo
    • HALTECH PS1000 Full Standalone
    • RACEPACK Street Display
    • Garret Custom GT-28s
    • 8.5:1 CP Pistons (Engine#1) 8.5:1 ARIAS Teflon/Ceramic Pistons (Engine#2)
    • Oliver Rods (Engine#1) PAUTER Rods (Engine#2)
    • TOGA Rod Bering (Engine#1) Cleavite Bearings (Engine#2)
    • TOGA Mains (Engine#1) Cleavite Bearings (Engine#2)
    • ARP Rod Bolts.
    • LS1 Coil Convesion
    • Full Crank Balance, Deck/Head, Deglaze, Align Hone.
    • Intake Manifold Extrudehoned, VCTS Disabled
    • Head Extrudehoned, ARP Head Studs
    • FOCUS Adjustable Timing Gear
    • Custom Sidewinder 304 Stainless Turbo Manifold
    • DEI Header Wrap
    • 2.75" Turbo Back Exhaust
    • Apex-I N1
    • Spearco Full Front Intercooler
    • T-6 Ron Davis Prototype Triple Pass Radiator
    • K-SPORT 14" (8 Piston) Big Brake Kit
    • Sparco Torino Seats w/4 Point
    • Sparco Steering Wheel
    • K-Sport 4 corner balanced coil overs.
    • AWR Motor Mounts
    • AWR Adjustable End Links
    • AWR 21 MM Anti Sway
    • ACT Stage IIR Clutch
    • Turbo XS Bov-RFL
    • Tial 35mm Wastegate
    • BRAILE 11 Lb Battery
    • NO Audio System
    • NO Air Conditioner
    • NO HEATER
    • NO Power Steering
    • NO Stock ECU

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Sun May 03, 2009 12:25 pm

Here are some parts that were made for the car,

The Plate that holds the Coils is about 40% done..

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I had to make a Cam gear that has a single magnet that would trigger 5 teeth before the Crank Gear missing tooth..

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I removed and covered the stock Idle control motor.

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I modified the intake manifold, making a hole for the IAT directly in the canter of the manifold, just before it splits into 4 runners.

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Wed May 13, 2009 10:16 pm

Ok, So the Spring Install continues..

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Finally found an 14x1.5 Tap so I could install my Intake Air Temp Sensor.

Rather than installing it in the intake pipe and adding restriction, I installed it in the collector of the intake manifold. Should be a very accurate representation of what is actually going into the engine.

The Brass fitting to the right of it is for the Idle Step Motor that. It's function is to regulate the idle based on a target RPM (Set By The User)

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This was the last part of the intake manifold, before I could install it on the car for good.

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Still have to do the wiring.. Should not take too long..

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Thu May 14, 2009 3:54 am

UPDATE LS1 Coil Conversion:

Got all the positive leads done for the battery, 1x8ga to the Alternator, 1x8ga to the starter, 1x8ga to the car (Built a fuse panel)


Also was working on the Coil bracket to verify it's feasibility..When it's done it will get polished..

Aside from being a pain in the C*CK to remove, it will work great. the coils are very high on the engine but there is still 1" of clearance under the hood. Away from water and away from the high heat of the exhaust system. The Coils are not attached... I know...

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Mike_R
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Re: MAZDA MP5T Haltech Sport 1000

Postby Mike_R » Thu May 14, 2009 4:49 am

Good work on this car, looks like a really clean setup.
Mike Roberts
Accounts / Data Acquisition Specialist USA
mike@haltech.com
(760)-598-1941

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Fri May 15, 2009 5:32 am

^^ Thanks, It's been a long time since I started.

Good Progress today..

Got the Wiring done for the Lights and got the Haltech to connect to the PC for the first time.

None of the sensors are connected yet which is why the screen looks like a Christmas Tree..

The IQ3 Dash is AWESOME!

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Tomorrow I will start to hook up all the sensors..

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crispeed
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Re: MAZDA MP5T Haltech Sport 1000

Postby crispeed » Fri May 15, 2009 8:29 am

Nice work Brian.
Can't wait to see the final results.
AWD MOTORSPORTS EVO8 GSR 8.75@167 E85
CHARLES/RAW 2JZ S2000 7.77@194 E98
NeillAutoWorks 2JZ S13 7.49@188mph E98 275 radials
MedicineManRacing R32 7.31@188mph E98 275 radials

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Sat May 16, 2009 7:43 am

Ok, this is the final prototype for the Ignition system. It will be used to make the final part once I get some more aluminum.

I cleaned it up a bit more than the original which hung over the belt, (Yuck)

All there is left, is everything else...

Still working on Wiring...

Bought gas so I could test out the pump and fuel pressure sending unit..


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crispeed
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Re: MAZDA MP5T Haltech Sport 1000

Postby crispeed » Sat May 16, 2009 6:07 pm

BRIAN MP5T wrote:Ok, this is the final prototype for the Ignition system. It will be used to make the final part once I get some more aluminum.

I cleaned it up a bit more than the original which hung over the belt, (Yuck)

All there is left, is everything else...

Still working on Wiring...


Looking good.
AWD MOTORSPORTS EVO8 GSR 8.75@167 E85
CHARLES/RAW 2JZ S2000 7.77@194 E98
NeillAutoWorks 2JZ S13 7.49@188mph E98 275 radials
MedicineManRacing R32 7.31@188mph E98 275 radials

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Mon May 18, 2009 1:57 pm

Finished all the wires around the engine.

There is only one main wire (Split loam) that comes from the firewall.

All wires that go to sensors or engine components are contained within a single 2" conduit.

It splits cleanly to only two smaller parts.

1 Runs along the injectors.
2 Runs in front of the coils.

The result is an almost surgical looking engine bay. Almost everything is visible.


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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Wed May 20, 2009 2:57 am

I wanted to post this up in Two Places so it can easily be searched.

Wiring for Haltech Sport 1000/2000 ECU to a Mazda Protege (America) Astina Sport 20 (Australia) with FS Engine 2.0L

Throttle Position Sensor
TPS

Haltech Orange to Blue with Red Line on stock sensor harness wire
Haltech Black to Black on stock sensor harness wire
Haltech White to Green with Black Stripe on stock sensor harness wire

Remember to calibrate the sensor with the software.

Cam Position Sensor.
(HOME)
RELUCTOR.

Haltech Yellow to Green on stock sensor harness wire
Haltech Green to Grey on stock sensor harness wire


CRANK Position Sensor.
(TRIGGER)
RELUCTOR.

NOTE: There are only two wires that are used by the Haltech, The third is a Shield that goes to ground.

Haltech Yellow to Red on stock harness wire
Haltech Green to Green on stock harness wire

Here is reading on Reluctors
http://www.megamanual.com/ms2/pickups.htm


RISING RATE Reluctor for Trigger with No GAIN, No Filter.
RISING RATE Reluctor for HOME with No GAIN, No Filter.


EDIT: and NOTE.

It is so cool, I had another sensor attached to the Haltech that was not attached to the car. I was able to fool it with a ferrous metal part (Ratchet Handle) to see the counter rise on the Laptop. As soon as the Haltech detects movement on the sensor it fires the fuel pump. If you only trigger it once, it fires the pump and shuts off, if you trigger it over and over, the pump stays on (Like it's supposed to, you guys are awesome!)

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Wed May 20, 2009 4:34 am

SUCCESS!


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I just hooked up the starter to verify that the Trigger and Home sensor work on the car.

If I had the Fuses in for the Coils and Injectors, it would have tried to start for real.

See Picture, Home Counter, Trigger Counter near Bottom Middle..

The 4 Home, means that the engine did 8 Revolutions or four full cycles.
The 255 Triggers is divided by 8 as 31 and some decimal. Which is fine because it should be around 245 - 280 (Due to when I stopped cranking the starter)

This means that the math that the ECU is doing, is exactly the math I was expecting.

The Cam gear modification work, a Reluctor sensor has a unique property, the signal becomes stronger as speed is increased. So if this low speed test has no trouble, then it will only get better when the car is actually running.

I am still waiting on a WBO2 controller to run the engine..

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Sat May 30, 2009 2:47 am

UPDATE: Went For a Drive Just now.

Did some basic mapping around the block, then went for a drive down a straight 10Km road. (Farm Area)

Then finished off with a spurt on the highway.

No leaks yet, no problems and the spark plugs are probably looking normal again.

The more I drive, the better it gets. AWESOME!

Thanks so much to the staff here!

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Sat May 30, 2009 6:31 am

Progress.

I have taken the car for a total of 100 Km.

I have had help with the map, a friend riding shotgun with he laptop. We return and have a look at the map, estimate the values based on the slope and then apply them and go for a drive again.
Here is what I got so far..

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BRIAN MP5T
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Re: MAZDA MP5T Haltech Sport 1000

Postby BRIAN MP5T » Sat May 30, 2009 9:01 am

Back from another 60Km trip.

It still unloads fuel a bit in some places, but It will probably be less once I activate the throttle pump.
It is a setting that compensates for quicker throttle changes.

I have also not put Automatic O2 Control on, and even without it, it is maintaining AFR quite nicely.

I will continue to refine the lower parts of the map. Probably take the wife for a cruise tonight.


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