V1 Blue Man's City Goblin - 05 Base Donor

[Ross]

The rest of the connectors on the harness? Well, the connectors all came from the same car...
Not sure what/why you are asking. Of course the connectors fit back on the car they came off of.
I didn't need to replace any connectors like you are doing with the fuel pump.

 

[RCK605]

Where did you buy the new fuel pump and connector? Would you mind sharing? I want to make sure I get a working part. Thanks!

I will look back through my stuff this evening on where I bought everything. I'm pretty sure it was from rockauto.

 

[Blue Man]

The rest of the connectors on the harness? Well, the connectors all came from the same car...
Not sure what/why you are asking. Of course the connectors fit back on the car they came off of.
I didn't need to replace any connectors like you are doing with the fuel pump.

Yeah, I wasn't very clear. I just meant the fuel hoses. I can check those on my current pump at the house and make sure they match. Sorry for the confusion.

 

[Blue Man]

I will look back through my stuff this evening on where I bought everything. I'm pretty sure it was from rockauto.

Thanks. I went and looked at Rock Auto and they had a number of pumps. There was one that had the connector with it, so I'll probably try that one.

 

[RCK605]

This is the pump and connector I went with. I don't know if this one is better or worse than the others listed on Rock Auto.

More Information for SKP SKEFP038 (rockauto.com)

More Information for WVE 1P2604 (rockauto.com)

Some additional information on the fuel pumps.

Fuel Pump Module Interchangibility | DF Kit Car Forum

 

[Blue Man]

Okay, so the frame, subframe and a few other parts are off to get powder coated. Excited for those to come back!

Got the new fuel pump with the different connector, so my son and I can get going on the wire harness again. That harness has been kicking our butts so far . . .

Also ordered new hubs and a few other items while we were at it. My garage is full of boxes of car parts right now. Not somewhere I ever thought I would be in life, but I have enjoyed the process so far.

We are excited to actually start building the car, but I feel like I crested a rise on a mountain, only to realize there is basically the whole mountain to go. However, I look forward to both the challenges and the eventual completion.

It's about the process, right? Otherwise I might as well buy a car, and I have plenty of those. I can't believe how much more I already know about cars than I knew a few months ago. And I have a bunch of cool new tools . . .

 

[Robinjo]

Don't look at the overall, just look at it as small items to tackle each day. Before you know it, there won't be anything left to do (and you'll be happy and sad).

 

[Blue Man]

Okay, so back to working on the wire harness and I am at the fuel pump... I have a few questions if anyone can help.

As recommended, I bought a 2006 fuel pump. The wiring does not match the wiring from my 2005 cobalt. I have tan, gray, purple and black (x2 twisted together). The new fuel pump has orange/black, purple, gray and black.

The documentation that came with it is worthless, listing a lot of possible combinations and colors for many different vehicles, none of which is the cobalt.

Has anyone done the 2005 to 2006 fuel pump wiring? could you give me a shout?

The wires from the harness are small gauge, while all the wires from the new pump are larger and then same size.

Thanks to anyone who can give me a hand. Kind of stuck on the harness right now. Worried about wiring it up and then the pump doesn't work and need to tear it all back down. Evap wires have already been cut out, BTW.

 

[Blue Man]

Here is a picture of the connector and the wires from my harness...

 

[Ross]

The wiring for the 2006 fuel pump is here. I don't have access to the wiring for a 2005 fuel pump.
Maybe you can analyze your stock 2005 pump and figure it out?
The fuel pump will have a 12V+ and a 12V-. (PK/BK and BK wires on the 2006)
The fuel level will have a output voltage (maybe 12V+ to 0V+) and a reference voltage (12V-). (YE/WH and PK/OG wires on the 2006)

 

[RCK605]

It has been a while since I did mine and it is taped up now. Also, my new connector had four white wires. I basically cross-referenced the images below to determine which wire goes where. You can also plug your connector into the fuel pump and move the level sensor and measure resistance across ground and level sensor signal to confirm it is the correct wire.

2006 Connector

2005 Connector

 

[Blue Man]

Okay, so looking at the new fuel pump I can see that the orange/black and grey wires go to power the pump and the purple and black wires are the fuel level sensors. This makes sense as the grey wire is thicker on my harness. So now the question is which wire is which for the fuel sensors.

So I wired orange/black to the wire harness ground (2 black wires) and the grey to the grey.

Pictures

below.

 

[TravMac]

They shouldn't matter because it's measuring a resistance across the wiper card on the sensor. If you put a multimeter on the leads and measure resistance you can watch it change as you sweep the sensor. If it doesn't do anything, you might have the wrong wires. Can check it right at the sender terminals too

 

[Blue Man]

Okay. So the cold and snow have slowed us down, but we are moving forward . . .

The car is back from powder coating and I think it looks good.



Today we are going to install the radiator hoses through the frame, put the floor on and flip it over. We are excited to actually start the building part of the process!

One we get it flipped over, I'm going to update my user icon to the actual car. A small thing, but satisfying . . .

 

[Blue Man]

We are also nearly done with the wire harness (finally!)

A few questions if anyone can help... (keeping in mind that this is a 2005 automatic cobalt)

1. The video has a red and white wire and a purple wire that are wrapped up and taped to the dash portion of the harness. What are those used for later? I have the red and white wire, but I do not have a purple wire. Am I missing something?

2. I have a connector that is labeled "Starter Enable Relay Contact Control" It was not cut in the videos and is on the list of soldered wires marked as "manual only" but I'll admit I am afraid to cut it. Do I need it? I have gone through the build videos and do not see where it would connect.

3. The new finished the dash harness video (i have watched all harness videos, old and new, several times) refers to a "Heat exchanger fan wire" that is in the group of last wires hanging off the table (including the radiator fan wire, head light wires, red fuse, etc.) I do not have this wire. Is this a supercharge/turbo wire or am I missing something?

4. I also have 3 connectors heading to the brake/clutch branch. The videos only show the automatic using two plugs, so I'm guessing I'll need to cut and cap one of these? I can't test them because we accidentally tossed the plastic brake sensors so new ones are on the way (fortunately only $10 for both and shipping).

I think that is it. I have watched the videos (build and wiring) many, many times and I have all the connectors accounted for except the ones listed above.

If anyone has any input or information on this, I would appreciate it. Thanks!

 

[Joebob]

I will try my best as it has been a while. I have a 2008 NA auto so we are pretty close. See responce in green.

We are also nearly done with the wire harness (finally!)

A few questions if anyone can help... (keeping in mind that this is a 2005 automatic cobalt)

1. The video has a red and white wire and a purple wire that are wrapped up and taped to the dash portion of the harness. What are those used for later? I have the red and white wire, but I do not have a purple wire. Am I missing something? The purple wire if I am not mistaken is to go to the switch panel to actuate the old foglight circuit. It now powers the ACC button on the button panel from DF. If you don't have it, everything should still work except the ACC button. I currently do not have mine used yet. The red and white wire is a key on hot wire if you want to do somethng else such as a USB port or underglow lights.

2. I have a connector that is labeled "Starter Enable Relay Contact Control" It was not cut in the videos and is on the list of soldered wires marked as "manual only" but I'll admit I am afraid to cut it. Do I need it? I have gone through the build videos and do not see where it would connect. With my auto, I don't remember this connector. If there is no plug to put it, you can tape it up out of the way. if everything works without it plugged in, after a while, you can cut it out.

3. The new finished the dash harness video (i have watched all harness videos, old and new, several times) refers to a "Heat exchanger fan wire" that is in the group of last wires hanging off the table (including the radiator fan wire, head light wires, red fuse, etc.) I do not have this wire. Is this a supercharge/turbo wire or am I missing something? This is a boosted thing that we don't have or have to worry about.

4. I also have 3 connectors heading to the brake/clutch branch. The videos only show the automatic using two plugs, so I'm guessing I'll need to cut and cap one of these? I can't test them because we accidentally tossed the plastic brake sensors so new ones are on the way (fortunately only $10 for both and shipping). Again, my memory failed me with number of plugs but I only recall one for the accelerator and one for the brake and no left overs. the power steering has a couple and there is one plug left unused on the steering motor top.

I think that is it. I have watched the videos (build and wiring) many, many times and I have all the connectors accounted for except the ones listed above. Make sure you extend the auto shift selector wires about 10-12" as mentioned in the old wiring but not the new wiring.

If anyone has any input or information on this, I would appreciate it. Thanks!

The below link is one of the most valuable things I found to help with the wiring. It is not exact to yours but is for a 2008 NA auto with what each wire goes to and is needd or cut. Look it over and see if it helps.

BAR-AIR's build up in Buffalo N.Y.

Yes those are 5 3/4” lenses. Just make sure they are the DOT lenses. Those were advertised as DOT lenses but when they showed up no DOT markings. Took about a month of back and forth with the manufacturer before they sent a set of DOT lenses. Nate’s car is using a set of 5 3/4” headlight shells...

dfkitcar.com

Joe

 

[Ross]

1. Red wires on a Cobalt are typically "battery positive voltage" wires, then once they go thru a fuse, are
Red wires with a White stripe. If they also go thru the run/start relay, then they are typically
Pink wires, that are switched by the key.
If I remember correctly, the purple wire was the fog lights wire, after the fog light dash switch.

2. I wonder if that wire is the safety switch that went to the clutch. A standard transmission car will only start if the clutch is pressed.

3. Yes, heat exchanger is only on a supercharged and turbo cars. You might need it when you add the supercharger to your car

4. I'm not sure. You can see the connectors on my donor if it helps. Or check out a wiring diagrams.

Corrected AllData wire colors for the Fuel Pump and Fuel Level Sender sensor.

 

[Gtstorey]

I will add the purple fog light wire isn’t very good as anything other than fog light. It will only work when the lights are on dim and will have to be re-engaged every time your ignition is cut off.

 

[Robinjo]

Okay. So the cold and snow have slowed us down, but we are moving forward . . .

The car is back from powder coating and I think it looks good.

View attachment 38698

Today we are going to install the radiator hoses through the frame, put the floor on and flip it over.

Warm up those hoses before pulling them. It’ll save you a lot of frustration and swearing.

 

[Blue Man]

I will try my best as it has been a while. I have a 2008 NA auto so we are pretty close. See responce in green.




The below link is one of the most valuable things I found to help with the wiring. It is not exact to yours but is for a 2008 NA auto with what each wire goes to and is needd or cut. Look it over and see if it helps.

BAR-AIR's build up in Buffalo N.Y.

Yes those are 5 3/4” lenses. Just make sure they are the DOT lenses. Those were advertised as DOT lenses but when they showed up no DOT markings. Took about a month of back and forth with the manufacturer before they sent a set of DOT lenses. Nate’s car is using a set of 5 3/4” headlight shells...

dfkitcar.com

Joe

Awesome, stuff. Thanks!