Welcome to the North American Subaru Impreza Owners Club Thursday March 28, 2024
Home Forums Images WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Go Back   NASIOC > NASIOC Technical > Water/Methanol Injection, Nitrous & Intercooler Cooling

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.







* As an Amazon Associate I earn from qualifying purchases. 
* Registered users of the site do not see these ads. 
Reply
 
Thread Tools Display Modes
Old 11-10-2015, 01:37 AM   #1
KornShaDoW097
Scooby Specialist
 
Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default Hfs-3 connectors

I noticed my brown wire on the ECU plug connector is somehow melted...it kept triggering safe mode.

What type of connector is used? It looks like a 10 pin RJ45 ethernet male connector. But pin 1 and 10 are not used. So I bought a 8 pin RJ 45 but the wire guides seem smaller than the wire diameter.

Anyone know what connector this is? Is a 10 pin RJ45 larger diameter wire btw?

Thanks
* Registered users of the site do not see these ads.
KornShaDoW097 is offline   Reply With Quote
Sponsored Links
* Registered users of the site do not see these ads.
Old 11-10-2015, 12:27 PM   #2
Aquamist
Former Vendor
 
Member#: 110029
Join Date: Mar 2006
Location: Sussex, England
Vehicle:
2004 Citroen Picasso
Silver

Default

How do you come to this conclusion? I have never seen this before.
Aquamist is offline   Reply With Quote
Old 11-10-2015, 02:36 PM   #3
KornShaDoW097
Scooby Specialist
 
Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default

I kept blowing fuses on the line leading to the relay. I found a short and fixed it. Which was making the pump not come on.

My battery was low so i hooked up a second battery to help it out. The system ran fine during testing but on the second run the fav and pump stayed ON, even after the SYS jumper was disconnected and the amber thresh light stayed on.

I tested every harness to isolate the issue. First trunk, then fav. I figured out how the wiring worked on the Fav and figured out It relays power to the trunk. Which triggers the magnetic coil on the relay.

It was somehow receiving signal and after activation it would not stop. At first i noticed a click of the black coils on the hfs. But after a few resets and disconnecting harnesses depending on if i wanted the coils to trigger or not. I found the only time the amber light (gauge also showed w injection and sometimes both ambers) was if the ecu wire plug was unplugged. Then i saw the brown melted wire on the inside of the rj45 or 10P10C connector. At first it looked like 3 wires were bad but i saw pin 1 and 10 were there for possibly future/different applications. The wire after the connector is fine. So it must have been not making a good contact or arching on the black wire causing an issue after start up.
KornShaDoW097 is offline   Reply With Quote
Old 11-10-2015, 02:59 PM   #4
KornShaDoW097
Scooby Specialist
 
Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default

Anyway, The 10pin RJ45, do you know the gauge the wires are? Or the Category? (5,5e,6)

22,23 or 24AWG? Because they dont seem to fit in Cat5e 24AWG connectors.

Do you think dielectric grease would help them slide?

Cat5/5e is 24AWG, Cat6 is 23AWG...

If nothing else I'll use Cat6 connectors next.

Jon
KornShaDoW097 is offline   Reply With Quote
Old 11-12-2015, 08:00 PM   #5
KornShaDoW097
Scooby Specialist
 
Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default

Booklet says RJ48 24AWG. However there is a manufacturer defect. I dont think the wire was burned. I think it was made this way on purpose.

The ECU plug brown wire, its insulation is out of spec. It is NOT 24AWG as all other wires are. This causes a Rj45/48 with 24AWG spec even a CAT6 23AWG capacity connector NOT to fit. All other wires fit fine (black is a bit tight too but still capable of fitting).

So I believe when being built by Aquamist the builder had no choice but to strip the insulation completely off on the connector. (I have pics) in order to not have to re order the correct spec. This could be a reason why i and many others receive interference and have the failsafe kick in at random and cause shorts.

The wire is completely exposed, can arc on neighboring wires and cause interference.
KornShaDoW097 is offline   Reply With Quote
Old 11-12-2015, 08:02 PM   #6
KornShaDoW097
Scooby Specialist
 
Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default

Even mess with the Boost Controller and potentially damage it.
KornShaDoW097 is offline   Reply With Quote
Old 11-13-2015, 08:22 PM   #7
KornShaDoW097
Scooby Specialist
 
Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default

I replaced the connector with a EZRJ45 connector (shielded) CAT 6, 8P8C.

The brown wire requires substantial trimming of insulation but you can twist the wire and add dielectric to keep it from contacting other wires. To slip the rest in just add dielectric grease to help everything else fit.

Done.
KornShaDoW097 is offline   Reply With Quote
Old 11-14-2015, 03:48 AM   #8
Aquamist
Former Vendor
 
Member#: 110029
Join Date: Mar 2006
Location: Sussex, England
Vehicle:
2004 Citroen Picasso
Silver

Default

I advise you to seek help to have the system installed, so far you are getting nowhere. From previous communications, you have had the system for 1.5 years and still struggling to make it work. Blaming the system every step of the way.

The term "little knowledge is dangerous" describes you perfectly.
Aquamist is offline   Reply With Quote
Old 02-02-2016, 06:46 PM   #9
KornShaDoW097
Scooby Specialist
 
Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default Hfs-3 connectors

Wrong. I had it working day 1, but these low quality connectors and relays keep the system acting strange.

You guys use the RJ45 or 8P8C yet the wires in question are the incorrect insulation thickness. Brown being most obvious since they stripped the insulation.5" from factory. I bet if others look at the 8pin harness on ECU connector they will have the same stripped wire I mentioned.

Plus the relay broke apart at the fuse terminal like a year in . So those two factors have nothing to do with me.

And those are the only problems. I fixed them And the system works fine again.

Well that and the plastic housing for the FAV plug literally cracked and fell apart and caused a short from vibration.

All of which I found and repaired no thanks to your condescending replies.
KornShaDoW097 is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

All times are GMT -4. The time now is 06:34 PM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2024 Axivo Inc.
Copyright ©1999 - 2019, North American Subaru Impreza Owners Club, Inc.

As an Amazon Associate I earn from qualifying purchases.

When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission
Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.