Got all the wiring in today, including the fuel level kit.
Started & ran it on the jacks, made quite a racket since there is no muffler attached yet & the brakes squeak like crazy with 3 weeks surface rust.
No way to know yet if the AWD is functional, but I did find that the circuit I used for the Haldex is not good - (C:41) - it's live all the time. I only found out because I was under the back of the car test fitting the muffler adaptor & could hear the Haldex pump running, which meant it was running for a good 4 hours with the car off. Hope that's OK. I unplugged the pump until I can figure out what leg to use that has switched power. C:35 & C:38 are open, no idea whether they are constant or switched.
Pin C:41 is where I added the Haldex feed
EDIT - pin 38 is the correct feed
Green/Red wire, right of center, front row
Fuel gauge works, so the circuit is kosher, but the reading is off. Recoding I presume.
I made a bridge for just the main sender signal & the 5v supply and bypassed the Arduino. Gauge reads pretty much what I added to the tank this evening
Arduino location:
Interior out, wiring being run to match AWD harness layout.
Routing harness along existing. I'm anal enough to route it neatly along original path , but not so much as too open the existing harness & add the AWD wiring for a real factory look
wires added to 64/51 connector (Molex 30700-1147, female) by fuel module (DS under back seat)
Harness spliced into F:16, F:14. My CEM has different terminals /connectors than the '05, so no way to use the harness as is.
And at 64/112 SWM connector
DEM harness (12 Pole Male #1452303-1, YESC 1.5 & 2.8mm series terminals) going through floor, with existing ABS added into it
Connectors under pas side forward wheel arch
Carpet back in
Added the new console trim kit while I had it out
Still have to do the door handles.
After that, I spent way to many fing hours welding this. It really kicked my butt. Had to make little pie cuts to fill voids on either side & had endless trouble with maintaining a puddle and/or issues with helmet (either too dark, too much flare, etc.) Flange distorted from the heat. I couldn't leave the band clamp on & still get under the lip to weld it at either end. Heated the crap out of it with Oxo-Acetylene & beat the V band clamp over the flanges. Tightened it down & then heated it cherry red from the inside, then beat on it some more. Seems to be flat again now.
Hopefully tomorrow I get the power supply sorted & the rear muffler welded, or I won't be driving to Ithaca in it on Friday.