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Dash Light Mods (Fuel, Oil and Temp Warning Lights)

Come and see what our Jon is up to, with his electric gizmos that his mind and hands mould into magic little boxes of tricks, he gets bored very easily, so if you have an idea that you can throw at him, all the better for him to play with ;0)
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binarypunk
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Dash Light Mods (Fuel, Oil and Temp Warning Lights)

Postby binarypunk » Wed Jul 17, 2013 9:44 pm

These kits have been around a while now and I have just finished a major revision to the range. I thought I would give everyone the low-down on them, the new features, how they work, how to fit them and use them and so on.

Scroll down for the fitting and usage guides.

Two kits are available, both compatible with mk1-mk2.5 cars. Both are fully CE/RoHS compliant and now feature improved protection against mis-wiring and reverse polarity, a new, much smaller 45mmx25mmx15mm control box with recessed button to prevent accidental activation, and they come with a 1-year warranty. Both are stocked exclusively by our friends at Autolink.

Fuel Light Kit
Adds a fuel light to the dash - not something you'd really expect to need to add to a post-war car, but I guess Mazda figured you'd want to be checking your gauge all the time, or running out of fuel a lot - well no more! Yes, there are DIY circuits out on the internet that can give you a fuel light, but frankly they're a bit of a hassle, and quite rubbish in my book. This fuel light kit is much better in many ways, not least because I've done the soldering for you!

- The fuel light has 2 warning levels (low and very-low) and the levels for each can be adjusted independently at the push of a button
- The light is a 3mm amber/red bicolour LED with a white opaque lens - giving a high-quality, good-looking finish
- You have 5 different light styles/colours to choose from. The default is amber for low and red for very low, but you can choose a red or amber light that begins flashing at the 'very low' level, or an old-school on/off red or amber like boring old factory fuel lights.
- The fuel level is sampled and averaged over the course of 30 seconds to ensure smooth, flicker-free operation, yet is quick to react to a fill-up
- All settings are saved and are stored even if the battery is disconnected, but without any additional dark current

3-Way Warning Light Kit
Features the fuel light as above, plus warning lights for low oil pressure and high engine (coolant) temperature. The oil and temperature levels are sampled very accurately, many times a second, to warn you quickly of either low oil pressure or high engine temperature, and the high-brightness red LEDs draw your eye to the gauges more effectively than a moving needle. The temperature warning light is preset to illuminate when the temperature exceeds the cooling fan switch-on temperature. The oil light when fitted to early mk1s with the 'real' pressure gauge (the one that waggles around as you drive) will illuminate when the pressure drops to around 22-24psi. On later cars with the on/off style gauge, the light will illuminate as soon as the pressure switch closes. You can choose to either use individual lights for oil and temperature warnings, or set it to use a single shared warning light for both gauges.

Needless to say, overheating or oil pressure loss are both extremely serious and if it happens it is imperative that you pull over and switch off the engine without delay to help avoid damage - thanks to faster reactions and better visibility, the warning light will give you much more time to do this than a gauge alone, and could well save your engine. If you race or do track days in an mx5 this kit is, in my opinion, an essential mod.
Jon - UK Mk1 1.6 1993 Classic Red

Check out my MX5 mods and tools:
http://www.binarypunk.co.uk
Need spares? Go to Autolink!
http://www.autolinkuk.co.uk/
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Re: Dash Light Mods (Fuel, Oil and Temp Warning Lights)

Postby binarypunk » Thu Jul 18, 2013 6:55 pm

Fitting Guide

You will need a cross-head screwdriver, and a 3mm drill bit.
Optionally you might like some small ring or fork connectors and a suitable crimping tool for attaching the wires to the instrument panel connectors. If you prefer, you might like to use bezels or surrounds for the LEDs to give a different look to the finished job - if so look for holders suitable for 3mm T1 LEDs.

You will also need to have a think about where you want the LED(s) to be - most commonly on the dash panel next to the relevant gauge.

First you need to remove the instrument panel from the car:

1) Disconnect the battery earth. (I'm not nagging, it's just cheaper and MUCH less annoying than having to replace the fuse)
1a) Disconnect the battery earth. (I am nagging now because I know you ignored me the first time)

2) Remove the drivers side dash lower panel by removing the 2 screws and pulling the bottom outwards

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3) Remove the steering column cowl by removing the screws (if present) and pulling apart.

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4) Remove the instrument cluster cowl by removing the two screws and pulling towards you

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5) Disconnect the 2 or 3 electrical connectors at the back of the instrument panel
6) Remove the 4 screws holding the instrument cluster in place and pull it out towards you

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Now take some time to study the panel and decide where to fit your warning light(s)

7) Take apart the cluster by pressing in the tabs/clips and pulling apart - take care of the exposed dials - then gently remove the perspex front, taking your time and working your way around slowly with a flay screw driver to crack the seal, there is no points for rushing this...

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8) Drill a 3mm hole for each LED where required (or follow the manufacturer's guidance if using a bezel. Make sure there is adequate clearance for the LED, bezel and wiring once the panel is reassembled.

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9) Thread the warning light LED(s) through the panel from behind so they pop out the front near where you want them - take care not to bend or twist the LED connectors - and insert them into the prepared holes with a small dab of black silicone to hold it in place and improve the finish.

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10) Carefully route the wiring and push the panel back together, taking care not to crush or bend the LED connections or wiring

11) Refer to the wiring guide in your instructions and connect the sensor and power wires to the relevant connectors on the back of the panel
(each connector has a brass screw and washer that you can trap the wire under - or for a professional finish, use small ring or fork connectors)

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Now you can return the panel to the car. Before reassembling, loosely fit the panel and reconnect the electrical connectors and battery, then test the fitment by ensuring that when the ignition is switched on, the warning lights come on, then go out one by one. If so, the lights are wired up correctly. If you wish to change any of the default settings, now is a good time.

13) Reassembly is the reverse of disassembly. Fit the control box in place behind the panel before reattaching the panel cowl.

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Jon - UK Mk1 1.6 1993 Classic Red

Check out my MX5 mods and tools:
http://www.binarypunk.co.uk
Need spares? Go to Autolink!
http://www.autolinkuk.co.uk/
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Re: Dash Light Mods (Fuel, Oil and Temp Warning Lights)

Postby binarypunk » Thu Jul 18, 2013 7:04 pm

Setting Up:

All settings are adjusted using the button, which is recessed into the end of the control box. The button has many functions and setup may seem complex, but if you're happy with the default settings, there is nothing to do but go drive. Otherwise, it's something you only need to do once as, once set up, all settings are saved even when the battery is disconnected.

Fuel Light Mode
One short press on the button enters 'set mode' and the fuel light displays the current mode. Further short presses on the button will change the mode.
The default is 2-colour (amber for 'low' and red for 'very low'), the other options will be shown in this order:
Red (off/on)
Red (off/on/flash)
Amber (off/on)
Amber (off/on/flash)
2-colour (off/amber/red)
Release the button for approx 5 seconds to exit set mode and save the setting.

Fuel Warning Levels
By default the 'low' warning light will illuminate at approximately 1/8 tank remaining. The 'very low' light will illuminate with approximately 1/2 gallon remaining.
To change either warning level you first need to wait until the tank is at the desired level. For a very accurate setup, you can drain the tank and refill with a measured quantity first. Then ensure that the car is stationary and on a level surface for at least 60 seconds, with the engine running, to ensure all sloshing has stopped and the level is correctly measured.
- To set the current level as the 'Low' level, press and hold the button for 5 seconds. When the fuel light flashes, release the button.
- To set the current level as the 'Very Low' level, press and hold the button for 10 seconds. Ignore the first flash, then release the button after the second.
If you adjust the 'low' level to be lower than the 'very low' level, or vice versa, the other level will be automatically adjusted to suit.

Warning Light Type (3-way kit only)
By default, individual LEDs are used for oil and temperature warning lights on the 3-light kit. This can be changed so that the oil warning light becomes a shared warning light for both parameters.
A short press on the button enters the 'set mode'. Now press and hold the button for 5 seconds. The shared warning light will flash twice to confirm. Release the button to exit and save the new mode.

Carry out the same procedure to change back to individual lights - in this case both lights will flash once to confirm.

Reset Factory Defaults:
If you want to go back to the default settings, press and hold the button while switching on the ignition, then release.
Jon - UK Mk1 1.6 1993 Classic Red

Check out my MX5 mods and tools:
http://www.binarypunk.co.uk
Need spares? Go to Autolink!
http://www.autolinkuk.co.uk/
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binarypunk
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Re: Dash Light Mods (Fuel, Oil and Temp Warning Lights)

Postby binarypunk » Tue May 27, 2014 5:48 pm

3-Light Kit 2014 Revisions:

In response to feedback and feature requests, there have been a few small revisions to the 3-light kit.

It is now possible to adjust the oil pressure and engine temperature warning thresholds. This is to suit track cars, or those that have hotter/cooler thermostats for whatever reason, or thicker/thinner oil, or just to taste. It also allows for cars with other gauge mods (like the linear mod) or slightly out-of-spec wiring or senders. In addition to this, the LED wires are now colour-coded for easier fitting, and the circuit board is fully sealed for long life.

The new version is available now from Autolink.
Jon - UK Mk1 1.6 1993 Classic Red

Check out my MX5 mods and tools:
http://www.binarypunk.co.uk
Need spares? Go to Autolink!
http://www.autolinkuk.co.uk/
User avatar
binarypunk
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Re: Dash Light Mods (Fuel, Oil and Temp Warning Lights)

Postby binarypunk » Wed May 28, 2014 12:41 am

New Version - Setting Up

Setting up the fuel light display mode is the same as the previous version - a short press to enter the display setup mode, then further short presses to select the mode and then release for 5s to save. In display setup mode, a long press changes the kit type to shared-warning-light mode or back to individual oil and temp lights. The oil light becomes the shared fault light.

The fuel, oil pressure and engine temperature thresholds are all set in the same way. The kit is able to sample the current gauge level, and use that to set the thresholds. With the fuel thresholds, the level is set at exactly the point the gauge is - the light will come on straight away. However, with oil and temp thresholds, a small margin is added for reasons that will become clear further down.

To set a level, first do a long press on the button and release when the lights flash once - the fuel light will flash amber (for setting low fuel) - now do short presses on the button to select the threshold you want to set (low fuel > v.low fuel > oil > temp) and keep pressing until you have chosen the threshold you want to set. If you do nothing for 5 seconds, it will exit without changing anything. When you are ready to set the selected level, do a long press on the button and release - the gauge level is sampled at the point you release the button, so if you want to wait for the perfect moment, you can sit with the button held down and release at the right point. The new threshold will be saved and the kit will then reset itself.

Fuel Thresholds:
By default the low fuel warning lights up at around 1/8 tank, and the v.low warning with about 15-20 miles to go - but there are variations between cars and components and there is no way to be precise about where it will come on. To change the levels, first you need your fuel gauge at the desired level, so wait until the right moment, get the car stopped on level ground, and then set the threshold as described. If you're the sort that likes to be extremely accurate and you feel confident doing so safely, you can drain the tank and then refill measured quantities first - but you would do so at your own risk. If you try to set the levels so they overlap (eg the low fuel below the v.low fuel) then the other level will be changed as well (in this case the v.low threshold will be set to just below the new low fuel threshold).

Temperature Threshold:
Most people will want the temperature light to come on if the coolant temperature exceeds the fan temperature by a margin. The kit is pre-set to a reasonable level for most cars - not so hot that damage is being done, but hot enough to definitely signify a fault. If you need (or want) to, you can reset the threshold by running the car up to temperature and then setting the threshold as soon as the fan comes on. The kit will add a small margin to ensure the light won't come on in normal use, and then set the threshold there. If you like, you can set the threshold higher by removing the fan fuse and waiting for the gauge to reach the desired level before setting it, however this is not recommended unless you're confident you know what you're doing and you do so at your own risk.

Oil Pressure Threshold:
If you have a later mk1, or a mk2, with the on/off pressure gauge, don't bother setting the threshold. If you have an aftermarket mechanical gauge, don't bother using the oil light at all. If you have an aftermarket gauge that works on a variable voltage signal, it might work once set as below, but I can't guarantee it).
If you have a stock 'proper' waggly pressure gauge, you might like to change the threshold for whatever reason. By default is is pre-set to around about 22-24psi or equivalent, but again variations mean that yours might be different. This is below a healthy-minimum idle pressure (28psi or equivalent) and probably signifies a fault if pressure drops below this. Or you've stalled...or are just about to :-)

To set the threshold, you will first need the engine fully hot and at idle, to give you your lowest pressure level. You set the threshold as above, and again a small margin is used to set the threshold a little lower than the current gauge level. If you like you can reduce the level further by dragging the clutch slightly to drop the revs (and therefore the pressure) further, before releasing the button.

Factory Reset:
As with the older version, hold the button down while you turn on the ignition to reset everything back to defaults if you mess it all up.
Jon - UK Mk1 1.6 1993 Classic Red

Check out my MX5 mods and tools:
http://www.binarypunk.co.uk
Need spares? Go to Autolink!
http://www.autolinkuk.co.uk/

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