FUSE REQUIREMENTS FOR CONVERTED HARNESS:

Hello friends,
I will start this as a new string - I finally got around to measuring
the current flowing in the B+ and Ign On circuit on my test stand
engine.  As I suspected the KEP fuse sizes are away too large. Here is
what I measured:

1) Ign On - 93 EJ22 harness arangement:

     - around 0.2 amp with Ign On, fuel pump cycling but engine not running
     - idling at about 500 rpm it was 1 amp.
     - at 3000 rpm it was 2 amps.
You can see the affect of having the coil connected to this wire.

2) B+  :

     - Ign ON but engine not running - about 0.4 amps.
     - Engine running - 0.45 amps independent of rpm.

So as you can see the KEP instructions are not good from a wire and
circuit protection point of view. I strongly recommend that you change
your fuses to the following:
- B+ - should be the 15A fuse 
- Ign On - should be 10A fuse.
- Alt Light - NO fuses is needed in theis circuit

I have been getting quite a few e-mails from people who have melted
their wiring and damaged their ECUs dues to short circuits. I am not
saying the smaller fuses would have helped but they certainly would
have blown much earlier than 30 A fuses.

Tom Shiels,
Burlington Ontario
http://www.subaruvanagon.com/


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1) ECU pin C9 (Bl/Rd) is wired to the A/C clutch connector pin 1
(Yl/Gn) and also out to the VW Black box to pick-up the VW compressor
clutch wire. If you A/C compressor nas a three pin connector the other
two pins are not used.

2) ECU pin C10 (Bl/Rd) - you are correct this wire connects to the the
Vanagon START wire that will be in the Black box - Steve it is shown
on the diagram I sent you (Round WHITE connector).

3) ECU pin C16 (Bk/Bl) - is the tach signal from the ECU.
Unfortunately this signal will NOT drive your 91 tach without
modifications to the tach circuit - refer to files for modification
needed. The tach modification is far better than using the two diode fix.

4) ECU pin D19 (Rd/Yl) - goes to your Check Engine light - and your
description is correct - the ECU grounds D19 when it wants to turn the
light on - so power the light from the Ignition ON wire. Place the
light where it will be handy for checking the codes - it is a very
handy diagnostic tool.

5) Regarding the ground wires - Bk, Bk/Rd, Bk/Yl and Bk/Wh - keep them
all separated and they run through sparate pin in the 16 pin Gray
engine connector - then to a bolt on the right hand side of the intake
manifold. KEP's instructions can be a bit difficult to follow on this
item.