Chris' '90 Toyota Celica
All-Trac Turbo  
(aka "The
Shuttle") 
Summer '03 Mod List - 
Electrical Wiring | 
    Updated:
    September 25, 2017 | 
  
  
Issue: Inconsistent voltage - Since relocating 
    the battery to the trunk, I've noticed inconsistent voltage at various times 
    and at various points on the car.   
Solution: Although I'm 98% certain the 
    variations I've noticed are due to poor grounding, I will go the extra 
    mile or so and thoroughly redesign the power distribution units under both 
    the dash and the hood, as well as upgrade the alternator output wire to a 
    larger gauge.  I'll also implement one of those 
"central earth" 
    grounding systems to ensure I have a consistent ground throughout the car.
Over the weekend 
of August 10th, I started digging into 
all the wiring that had been added to the car to accommodate the various gauges, 
controllers, alarm, and stereo gear, that have been added over time.  And, 
the more I dug, the more I didn't like what I was seeing.. a bunch of spaghetti.  
Now, I am pretty good at wiring, and have not had any shorts, blown fuses, or 
other problems (other than insufficient grounds) yet, I decided to redo 
everything.  So, I gutted all the non-factory wiring and am in the process 
of redoing everything.  So, with the front bumper cover off, the fender 
liners out, along with the seats (F & R), center console and center console of 
the dash... it's looking pretty barren.. I've also removed all the wiring for 
the fuse-box which I relo'd to the hatch with the battery; and, the fuse-box will make 
a return trip back to under the hood near its original location. Over the past 
few weeks, I've scoured JC Whitney, Home Depot, a couple stereo shops, and a 
couple electronic parts outlets here in Houston for all the components I need to 
rebuilt the power and ground systems the we they need to be done.
Outcome:
SUCCESS!!   I started the engine with the new wiring in place 
on Sunday, Sept 14, and found I had 14.5v pretty-much all the time with the 
engine running and the headlights on.
Key Accomplishments:
  - added two independent and individually 
  adjustable switches to the clutch pedal - one switch each for flat-shift and
launch control.
 
  - rewired the fuel pump with 12 ga. wire, adding 
  a relay in the rear hatch such that the Autronic SMC trips the relay which 
  then applies +12v power to the fuel pump directly from the battery
 
  - new 
  power distribution unit (PDU) - This has been fabricated and close to 
  permanent installation. 
 
  - mounted
  Greddy gauge controllers in center console.  
 
  - mounted the 
  Autometer ProComp warning lights 
  on the lower gauge pod on the A-pillar
 
  - fabricated mounts in the front left corner of 
  the engine compartment for a series of relays.  Although I'm planning 
  to use only four relays at present (two for fans, one each for nitrous and IC 
  spray), the mount will support up to eight relays.  And, for those who 
  wonder, the zip-ties are temporary; I'll permanently pop-rivet the relays to 
  the mount when I'm through fabricating and wiring them into their respective 
  circuits.
 
  - 
  fabricated a new mount 
  for the fuse-box so I can relocated it from the hatch to the front-left corner of 
  the engine compartment.
 
  - fabricated an
  intermediate harness which 
  connects the Autronic SMC to the new primary 
  control box.
 
  - relocated the factory
fuse-box 
  to the front-left corner of the engine compartment.
 
  - fabricated a 
  central ground 
  system for under the hood.. connected up the twin coil pack, both igniters, 
  throttle-body and both factory under-hood ground points. All are connected via 
  8 ga. stereo power cable to a 3" x 1" strip of copper that is mounted on a 
  steel brace just off the alternator mount.  This copper strip has a 2 ga 
  wire running to a second center ground point located under the rear seat, 
  which is a connect point for various 8 ga ground cables from the stereo amps 
  and a couple factory ground points under the dash.  This 2nd ground point is 
  then connected to the (-) side of the battery with another section of 2 ga. 
  cable.
 
  - fabricated a 
  nice bracket for a small 
  switch that will make contact at 95-100% throttle.  NOTE: I was going to 
  use this as part of the nitrous activation system but have since learned that 
  I can allow the Autronic SMC utilize throttle position in its control of 
  nitrous activation.  So, I no longer need to this switch...Fun 
  fun! 
 
  - 
  rewired alternator output with 
  2 ga. wire that runs across the front of the car, under the ac condenser, 
  to the 1 ga cable that connects to the starter.  This will ensure a good 
  path of current flow to the battery.
 
  - rewired alternator inputs
 
  - rewired a/c compressor circuit
 
  - rewired pre- and post-IC temp senders
 
  - fabricated
  a single harness to the stock 
  factory fan temp switch (located in the bottom tank), the n/b O2 sensor, and 
  the MR2T oil level switch
 
  - ran additional wires to an adjustable pressure 
  switch that will be used in conjunction with the Autronic SMC to control 
  nitrous activation.  This pressure sender will trigger nitrous below a 
  certain level of boost, at which point nitrous flow will terminate.
 
  - rewired existing oil pressure, oil temp, engine temp, 
  and trans temp gauges, and installed new wiring for oil pressure and 
  engine temp warnings
 
  - I've made several 
  modifications to both the
engine wiring harness and the 
Autronic SMC wiring pigtail.  Wires that are no longer needed were 
removed while other necessary wires were added.
 
  
        
        
          
    
    
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