Haltech Elite 2500 User manual

E N G I N E M A N A G E M E N T S Y S T E M S
ELITE 2500
GM GEN IV LS2 & LS3 NON-DBW
Terminated Engine Harness
QUICK START GUIDE
HT-141365
Suits – OEM EV6 Injector Connectors

LIMITED WARRANTY
Lockin Pty Ltd trading as Haltech warrants the HaltechTM Programmable Fuel Injection System to be
free from defects in material or workmanship for a period of 12 months from the date of purchase.
Proof of purchase, in the form of a bill of sale or receipted invoice, which indicates that the product is
within the warranty period, must be presented to obtain warranty service. Lockin Pty Ltd trading as
Haltech suggests that the purchaser retain the dealer's dated bill of sale as evidence of the date of
retail purchase.
If the HaltechTM Programmable Fuel Injection System is found to be defective as mentioned above,
it will be replaced or repaired if returned prepaid along with proof of purchase. This shall constitute
the sole liability of Lockin Pty Ltd trading as Haltech.
To the extent permitted by law, the foregoing is exclusive and in lieu of all other warranties or
representations, either expressed or implied, including any implied warranty of merchantability or
fitness. In no event shall Lockin Pty Ltd trading as Haltech, be liable for special or consequential
damages.
DISCLAIMER
Haltech will not be held responsible for any damage caused by the incorrect installation or tuning of
this product. It is the installers responsibility to ensure the wiring connections and pinouts match
that of the vehicle the unit is being installed into.
Haltech has taken all care to make sure the connections match the specified vehicles listed, but
variations in wiring and connections on vehicles can occur and therefore this should be checked
BEFORE the unit is installed.
Haltech highly recommends installation and tuning of this product is to be carried out by a
professional, with an understanding on installing and tuning engine management systems. Misuse
of this product can destroy your engine.
WARNING
This ECU is designed and sold for Racing use only. Using this product for street / road use may be
prohibited by law. Please check with your local vehicle authority before using this product.
GENERAL INSTALLATION WARNING
Avoid open sparks, flames or operation of electrical devices near flammable substances.
Always disconnect the battery cables when doing electrical work on your vehicle.
Do not charge the battery with a 24 Volt truck charger or reverse the polarity of the battery or any
charging unit. Do not charge the battery with the engine running as this could expose the ECU to an
unregulated power supply that could destroy the ECU and other electrical equipment.
All fuel system components and wiring should be mounted away from heat sources, shielded if
necessary and well ventilated. Disconnect the Haltech ECU from the electrical system whenever
doing any arc welding on the vehicle by unplugging the wiring harness connector from the ECU.
After completing the installation, make sure that there are no fuel leaks, and no wiring left un-
insulated in case a spark or short-circuit occurs and causes a fire. Also make sure that you follow all
proper workshop safety procedures. If you're working underneath a jacked-up car, always use
safety stands!
Figure 10 - 26 Pin Harness Connector Pin Allocation
ECU CONNECTOR (26 PIN)
(Looking into ECU)
8 9
16 17
24 25 26
18 19
20 21 22 23
10 11 12 13
14 15
1234567

configuration.
123456789
10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34
ECU CONNECTOR (34 PIN)
(Looking into ECU)
Elite 2500
GM Gen IV LS2 & LS3 Non-DBW
Terminated Engine Harness
Quick Start Guide
Harness Pinout
Congratulations on purchasing a Haltech Engine Management Terminated Engine
arness. This Plug and Play product allows you to be up and running in a few hours.
The Harness when installed in conjunction with a Haltech Elite 2500 opens the door to
virtually limitless performance modification and tuning of your vehicle. Programmable
systems allow you to extract all the performance from your engine by delivering precisely
the required amount of fuel and ignition timing that your engine requires for maximum
output under all operating conditions.
This quick start guide will walk you through installation of the Haltech GM LS2 & LS3
Terminated Engine Harness into a vehicle. This guide is accompanied by the full service
manual located on the USB key provided with the ECU that you or your tuner will need to
refer to before completing your installation and
Supported Engine
The Haltech GM Gen IV LS2 & LS3 Non-DBW Terminated Engine Harness supports the
following engine configurations:
• General Motors – Generation IV LS2 & LS3 engines without Drive By Wire Throttle
Control
Supported ECU
• Haltech Elite 2500
Included in Haltech ECU Kit (HT-151365)
• Haltech Elite 2500 ECU
• GM LS2 / LS3 Terminated Engine Harness with OEM EV6 Injector connectors
• CAM Sensor Connector Pack
• Deutsch Connector Pack
Optional Accessories (Sold Separately)
• Dual Channel Wideband Controller (HT059980), 2x O2 Sensors (HT010714) and
weld on bungs (HT010702)
• DTM4 CAN Cable (please specify length when ordering)
Figure 9 - 34 Pin Harness Connector Pin Allocation

Harness Overview
The Haltech GM LS2 / LS3 DBW Terminated Engine Harness is a plug and play
solution for wiring a General Motors LS2 or LS3, Drive By Wire Engine.
Installation is simple and easy as the harness is designed for the engine, all lengths
are correct and all wires are clearly labeled.
Notes on Installation:
• Make sure your Engine is grounded directly to the chassis of the vehicle.A heavy
gauge ground strap should be used to ground your engine to the chassis of the
vehicle. The Haltech Terminated Engine harness does not ground your engine.
WARNING!
Damage can occur to your harness and / or ECU if you do not ground your
engine properly. Please ensure heavy gauge cable is used.
• Keep all wires away from the exhaust manifold and extreme sources of heat.
• The harness is designed to plug directly into the OEM ignition loom and therefore
no ignition loom is supplied.
Initilal Setup
When installation is complete it is now time to upload the basemap to your ECU.
Connect to the ECU using the Haltech Elite Software Programmer (ESP). When
connected navigate through the software to File>Upload Map>Base Maps and select
the basemap that suits your application. ESP will now upload the selected basemap to
your ECU. When upload is complete it is now time to check and setup any non OEM
performance parts and accessories (ie. injector size, boost control, etc.) that your
engine may require.
At this time it is important to calibrate your throttle position sensor. To do this
please go to the Throttle Position Sensor function in the setup page and follow the
prompts to calibrate the throttle. Once complete you are now able to start your engine
and proceed to check timing and tune.
Please refer to the help file located within the ESP software for more information on
setup and tuning.
Figure 8 - Throttle Position Sensor Calibration

Battery Connections
The following cables will connect directly to the battery on the vehicle:
RED / WHITE
TO BATTERY +12V
RED/GREEN
RED
TO BATTERY +12V
TO BATTERY +12V
BLACK
TO BATTERY -VE / GROUND
Figure 7 - Battery Wiring
Termination Descriptions
Analogue Voltage Inputs (TPS, MAP, Fuel-P, Oil-P)
The Analogue Voltage Inputs can accept variable voltage inputs from 0V to 5V. These
inputs can also accept switch inputs that change between two different voltage levels.
The on voltage and off voltage define what the thresholds are between the on and off
states. The voltage can be viewed as a channel within Haltech ESP Software to
determine thresholds for a switched input.
Fuel Pressure Sensor (Fuel-P, AVI 3)
The Fuel-P labeled connector connects directly to the fuel pressure sensor on the
engine. This will enable the user to know the current fuel pressure of the vehicle.
Oil Pressure Sensor (Oil-P, AVI 4)
The Oil-P labeled connector connects directly to the oil pressure sensor on the engine.
This will enable the user to know the current oil pressure of the vehicle.
Throttle Position Sensor (TPS, AVI 10)
The TPS labeled connector connects directly to the throttle sensor on the engine. This
will enable the user to know the current throttle position of the engine.
Spare Analog Voltage Input (AVI 5, In Engine Bay)
The AVI 5 labeled connector is a spare Analogue Voltage Input (AVI 5).
The 4 pin connector has the following terminations,
Please isolate all unused terminations.
Pin # 1 – Blk/Wht : Sensor Ground
Pin # 2 – Org : +5V Sensor Power
Pin # 3 – Org/Grn : Sensor Signal (AVI 5)
This input can be programmed within the ESP Software to read inputs such as:
• O2 Sensors
• Pressure Sensors
• Temperature Sensors
• Various Switches
• Trim Module
For a full list of input options and explanations please go to the help within the
ESP Software.

1 2 ADB C
HT400091 HT400090 Standard Harness Connector
Figure 1 - Available Alternator Connectors
Alternator (ALT)
The Alternator output connects directly to the OEM Alternator. The +12V signal and
alternator excite wires are pre-wired into the loom. Both two and four pin versions of
the alternator connector are available.
Camshaft Postition Sensor Input (CAM)
The camshaft position sensor is used in conjunction with the crank angle sensor to
determine crankshaft position and stoke of the engine.
Connector style and wiring of the CAM sensor varies between models therefore two
connectors have been supplied for the end user to terminate for their application.
Some applications connect to the CAM sensor directly whilst others use a small pigtail
harness.
Refer to the table below for correct wiring of your CAM Sensor. Insert pre-rminated
pins into the rear of the connector until they lock.
CAB C
A B
Looking into front of connector
Wiring to Pigtail Harness
Location
A
B
C
Wire Color
YELLOW
BLUE
RED
Wiring to Pigtail Harness
Location
A
B
C
Wire Color
YELLOW
BLUE
RED
Blue = GroundRed = 12V Yellow = Signal
Figure 2 - Alternate Cam Sensor Wiring
Cabin Wiring
The Cabin Wiring is made up multiple inputs and outputs. Correct connection of these
cables is essential for proper operation of the harness.
All wires have been labeled and required cables should be connected as outlined
bellow.
PINK
VIOLET/BLACK
GREY/BLACK (SHIELDED)
GREY/RED (SHIELDED)
WHITE
GREY
+12V IGNITION INPUT SIGNAL
SPARE DPO OUTPUT
SPARE SPI2 INPUT
SPARE SPI4 INPUT
SIGNAL OUTPUT FOR WBC DIGITAL GAUGE (CH1)
BLACK / WHITE
RED
SIGNAL GROUND FOR WBC DIGITAL GAUGE
+12V FOR WBC DIGITAL GAUGE
ORANGE/BLUE
ORANGE/GREY
+12V OUTPUT FOR FUEL PUMP FROM RELAY
+12V TO STARTER SOLENOID
SIGNAL OUTPUT FOR WBC DIGITAL GAUGE (CH2)
ORANGE/BLACK
SPARE AVI INPUT
Figure 5 - Cabin Harness Wiring

Engine Coolant Temperature Sensor (ECT)
The Engine Coolant Temperature Sensor input connects directly to the OEM engine
coolant temperature sensor located towards front of the head of the left bank.
The Engine Coolant Temperature Sensor provides the ECU with a signal that allows
the ECU to know the current engine temperature.
Intake Air Temperature Sensor (IAT)
The Intake Air Temperature Sensor input connects to a temperature sensor located in
the intake air stream.
The Intake Air Temperature Sensor provides the ECU with a signal that allows the
ECU to know the current intake air temperature.
Ground (GND)
The Ground cable connects directly to the engine block.
this in the earth cable for the engine, please ensure that you earth the
engine with an earth strap from the block of the engine to the chassis of the car.
Ensure that the chassis of the car is connected to the battery negative (-) terminal with
heavy gauge cable or earthing strap.
Damage to the ECU and or terminated harness may result if this is not done.
Wideband O2 Inputs (Wideband Controller, O2-1, O2-2)
Wideband O2 sensors accurately measure the Air/Fuel ratio of the engine which is
required for precise tuning and control of the engine.
The Terminated harness has been integrated with the Haltech WBC2 wiring harness
allowing a quick installation of a Haltech WBC2 and Wideband O2 Sensors.
Connect your optional Haltech wideband sensors (HT010714) directly to the supplied
connectors labeled O2 in the engine bay. Mount the sensors in the exhaust manifolds.
Connect the Haltech WBC2 to the allocated corresponding connector located near the
main ECU connectors labeled O2,
Connect the Haltech WBC2 to the Haltech Elite ECU directly via the supplied CAN
Cable.
Enable the Haltech WBC2 in your map using ECU manager software.
Your Haltech ECU will now have access to correct Air /Fuel Ratio readings allowing
precise tuning and control of your engine.
Warning NOT
Starter Signal (STS)
The Starter Signal connects directly to the starter motor solenoid. This will supply 12V
to the solenoid on receiving a start signal from the ignition switch when in the start
position.
Please ensure you supply a main power connection to the starter motor and a
main earth strap to the engine to ensure correct operation of the starter motor,
and to avoid damage to your terminated harness and ECU.
Spare Digital Pulsed Outputs (DPO 1, DPO 2 , DPO 4)
The Spare DPO's connector contains one Digital Pulsed Output and one +12V DC
Switched Power.
When the output is activated by the ECU the output will switch to ground. Solenoid
valves and shift lights etc can be run directly from the output, however high current
devices such as thermo fans and additional fuel pumps must be activated through a
relay. A Relay can be wired between the DPO and the supplied +12V DC on this
connector. This way the output is only switching the relay and not a high current draw
device.
The Digital Pulsed Outputs are limited to 800mA Max current draw.
These outputs can be programmed within the ESP Software to control auxiliaries such
as:
• Air Con Output
• Aux Fuel Pump
• Boost Control
• ECU Diagnostic Light
• Intercooler Fan
• Shift Light
• Thermo fans
• Reverse Lockout Solenoid Valve
For a full list of output options and explanations please go to the help within the ESP
Software.

Fuse Box
The Haltech fuse box is connected to the harness. Contained within the Haltech Fuse
box is 6 fuses and 6 relays, each fuse protects the corresponding relay output (ie. fuse
#1 protects relay output #1, fuse #2 protects relay output #2, etc.).
The Haltech fuse box can handle a maximum continuous current draw of 70AMP,
exceeding this value may cause damage to the fuse box therefore please ensure all
auxiliary devices, fans and fuel pumps connected do not exceed the supplied fuse
current limits.
The functions of each of the relays are outlined below:
R1 R2 R3 R4
R5 R6 F1 F2 F3 F4 F5 F6
10
20
15
20
10
Figure 3 - Haltech Fuse Box Relay Allocation Table
Figure 4 - Haltech Fuse Box Layout
Crank Angle Sensor (CRANK)
The Crank signal connects directly to the engine Crank Angle Sensor located in
the right rear of the engine block behind the starter motor.
The Haltech ECU uses this signal to accurately measure crankshaft position and
engine speed.
Ignition 1-8 (IGN1, IGN2, IGN3, IGN4, IGN5, IGN6, IGN7, IGN8)
The ignition outputs connect directly to the factory ignition harness. Ensure the correct
ignition output is connected to the corresponding coil bank on the engine.
Please refer to the label on the harness for correct cylinder bank allocation.
Injection 1-8 (INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8)
The injector outputs connect directly to the injectors. Please ensure the correct
injector output is connected to the corresponding injector in the engine.
Please refer to the label on the harness for correct injector allocation.
Knock Sensors (Knock 1 , Knock 2)
The knock sensor inputs connect directly to the OEM knock sensors. This signal is
used by the ECU Knock Control function to detect knock events within the engine.
Manifold Absolute Pressure Sensor (MAP)
The Manifold Absolute Pressure Sensor is located on the intake manifold.
Connect the MAP labeled connector directly to the sensor.
The MAP sensor measures changes in the intake manifold pressure which result from
engine load and RPM changes and converts these into a voltage output so the ECU
knows the manifold pressure.
Vehicle Speed Sensor Input (VSS-Input) (optional)
The Vehicle speed sensor provides information on vehicle speed to the Haltech ECU
which can be used to display vehicle speed, detect gears or controlling of switches etc.
Connections on the plug are as follows
Pin# 1: Blk/Wht – Sensor Ground
Pin# 2: Gry/Red - +12V Sensor Power
Pin# 3: Grey (Shielded) – Sensor Signal (SPI 1)
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