This document serves as a quick start guide for the Haltech Elite 2500 GM Gen IV LS2 & LS3 Non-DBW Terminated Engine Harness, model HT-141365, designed for OEM EV6 injector connectors. It provides essential information for installation, initial setup, and understanding the various components and their functions.
Function Description
The Haltech Elite 2500 GM Gen IV LS2 & LS3 Non-DBW Terminated Engine Harness is a plug-and-play engine management solution. It is designed to integrate seamlessly with General Motors Generation IV LS2 and LS3 engines that do not utilize a Drive By Wire throttle system. When installed in conjunction with a Haltech Elite 2500 ECU, this system allows for extensive performance modification and precise tuning of the vehicle. The primary function of this harness is to provide the necessary electrical connections between the engine's sensors, actuators, and the Elite 2500 ECU, ensuring accurate delivery of fuel and ignition timing for optimal engine performance across all operating conditions.
The system includes a comprehensive set of inputs and outputs to manage various engine parameters. Key functions include:
- Engine Control: Manages ignition outputs (IGN1-IGN8) and injector outputs (INJ1-INJ8) to control engine firing and fuel delivery. These outputs connect directly to the factory ignition harness and injectors, respectively, with specific allocations for cylinder banks and individual injectors.
- Sensor Integration: Connects to critical engine sensors such as the Crank Angle Sensor (CRANK) for crankshaft position and engine speed, Camshaft Position Sensor (CAM) for crankshaft position and stroke, Engine Coolant Temperature Sensor (ECT) for engine temperature, Intake Air Temperature Sensor (IAT) for intake air temperature, Manifold Absolute Pressure Sensor (MAP) for engine load and RPM changes, Fuel Pressure Sensor (Fuel-P, AVI 3) for current fuel pressure, Oil Pressure Sensor (Oil-P, AVI 4) for current oil pressure, and Throttle Position Sensor (TPS, AVI 10) for throttle position.
- Auxiliary Control: Provides Spare Digital Pulsed Outputs (DPO 1, DPO 2, DPO 4) for controlling auxiliary devices such as boost control, auxiliary fuel pumps, intercooler fans, shift lights, thermo fans, and reverse lockout solenoid valves. These outputs switch to ground when activated by the ECU and can be used to directly run solenoid valves and shift lights, or to activate relays for high-current devices like thermo fans and additional fuel pumps.
- Knock Detection: Integrates with OEM knock sensors (Knock 1, Knock 2) to detect knock events within the engine, feeding this information to the ECU's Knock Control function.
- Vehicle Speed Sensing: Features an optional Vehicle Speed Sensor Input (VSS-Input) to provide vehicle speed information to the ECU, which can be used for displaying speed, detecting gears, or controlling switches.
- Wideband O2 Integration: Designed to integrate with Haltech WBC2 wiring harnesses and optional wideband O2 sensors (HT010714) for accurate Air/Fuel ratio measurement, crucial for precise engine tuning and control.
- Power Management: Includes a fuse box with six fuses and six relays to protect the ECU and various outputs, ensuring a stable and protected power supply for the ECU, injectors, ignition, fuel pump, and accessories.
Usage Features
The Haltech Elite 2500 Terminated Engine Harness is designed for ease of use and installation, particularly for racing applications.
- Plug-and-Play Design: The harness is pre-terminated with correct lengths and clearly labeled wires, simplifying the installation process. It is intended to plug directly into the OEM ignition loom, eliminating the need for a separate ignition loom.
- Comprehensive Documentation: The quick start guide, along with a full service manual on a provided USB key, offers detailed instructions for installation, configuration, and tuning.
- Software Integration: The system utilizes the Haltech Elite Software Programmer (ESP) for initial setup, basemap upload, and calibration. Users can connect to the ECU via ESP to upload a suitable basemap, check and configure non-OEM performance parts, and calibrate sensors like the Throttle Position Sensor.
- Customizable Inputs: Analogue Voltage Inputs (AVIs) are versatile, accepting variable voltage inputs from 0V to 5V, as well as switch inputs. These can be programmed within the ESP Software to read various inputs such as O2 sensors, pressure sensors, temperature sensors, switches, and trim modules.
- Flexible Outputs: Digital Pulsed Outputs (DPOs) offer flexibility in controlling auxiliary functions, allowing users to tailor engine management to specific needs.
- Engine Compatibility: Specifically designed for GM Gen IV LS2 & LS3 engines without Drive By Wire, ensuring compatibility and optimized performance for these engine types.
- Optional Accessories: Supports optional accessories like the Dual Channel Wideband Controller (HT059980) with O2 sensors and weld-on bungs (HT010702), and DTM4 CAN Cables for enhanced functionality and data communication.
Maintenance Features
While the document primarily focuses on installation and initial setup, it also provides important guidelines for maintaining the integrity and safety of the system.
- Proper Grounding: Emphasizes the critical importance of proper engine grounding directly to the vehicle's chassis using a heavy-gauge ground strap. Failure to do so can result in damage to the harness and/or ECU. The harness itself does not ground the engine.
- Battery Connections: Clear instructions are provided for connecting the harness directly to the battery, including +12V connections for various circuits (Red/Green, Red, Red/White) and a -VE/Ground connection (Black).
- Power Supply Integrity: Warnings are issued against charging the battery with a 24 Volt truck charger or reversing battery polarity, as this can expose the ECU to unregulated power, potentially destroying the ECU and other electrical equipment. It also advises against charging the battery with the engine running.
- Heat Management: Instructs users to keep all wires away from the exhaust manifold and other extreme sources of heat to prevent damage.
- Welding Precautions: Advises disconnecting the Haltech ECU from the electrical system by unplugging the wiring harness connector whenever performing arc welding on the vehicle to prevent damage.
- Safety Procedures: Highlights general installation warnings such as avoiding open sparks, flames, or electrical devices near flammable substances, always disconnecting battery cables during electrical work, ensuring no fuel leaks, and no un-insulated wiring after installation to prevent fire hazards. It also stresses the importance of following proper workshop safety procedures, including using safety stands when working underneath a jacked-up car.
- Professional Installation Recommendation: Strongly recommends that installation and tuning be carried out by a professional with expertise in engine management systems to prevent misuse that could damage the engine.
- Limited Warranty: The product comes with a 12-month limited warranty covering defects in material or workmanship, with specific conditions for obtaining warranty service and limitations on liability. This encourages proper handling and installation to avoid issues not covered by the warranty.
- Fuse Box Protection: The integrated fuse box protects the ECU and various outputs from overcurrent, with specific fuse ratings for each relay output. Users are advised to ensure that auxiliary devices, fans, and fuel pumps do not exceed the supplied fuse current limits to prevent damage to the fuse box.
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