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How to instal EFI - my version - lots of pics! + More pics!!
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Thu Jul 17, 2008 6:55 pm    Post subject: How to instal EFI - my version - lots of pics! + More pics!! Reply with quote

As requested my write up of EFI for the 924, pics below:

You will need:


Ford Mondeo fuel rail (Probably a 1.6 Duratec engine, new if possible, you will be welding to it)
4x injectors (I have cream top 21 lb/hr, standard Mondeo ones are a bit small)
Adjustable fuel pressure regulator(Min 3 bar)
944 expansion tank
Cone filter and 76mm pipe work(Air box is going in the bin)
Megasquirt (I have a MS1)
Mega Stim (Makes checking your Megasquirt much easier!)
Lambda sensor and boss (I have a wideband Innovate, but narrow band will do at a push!)
Air intake temp sensor
Coolant temperature sensor
Ali and steel for brackets
Nuts, bolts & washers
Lots of cable
Lots of pipe
Lots of solder
Lots of heatshrink
Lots and lots of time

Options:
Locked dizzy (Pull it apart and replace the little advance springs with locking wire and secure the vacuum advance solidly)
Or
36-1 Trigger wheel
Ford EDIS
Ford coil pack
Ford HT leads
Dizzy blanking plate

Stripping out the CIS


Disconnect the battery!! (Stick it on charge, you will be a while!)

Remove:
Airbox
Air meter
Fuel injectors and bungs (Will be stuck)
Fuel pipe work from the filter to return hard line
The TIU, TTS, WUR & CSV can all go too(Back of the head, by the dizzy)
Expansion tank
Coolant temp switch for the air meter replace with copper pipe
Rubber intake boot for air meter(Leave the hard pipe and the throttle body boot)

Optional removals:
Coil (If going wasted spark/EDIS)
Dizzy(If going wasted spark/EDIS)
Wiring to removed items(I tied it all back to begin with and stripped it out later on)


Mechanical fit:


Fit the coolant sender in the place of the TTS (I needed an M14 adapter for mine)

Fit the intake air temp sender in the hard intake pipe (There is a flat spot on the back which I drilled)

Fit dizzy blank or locked dizzy (Depending on spark option)

Fit 36-1 trigger wheel (EDIS only!)

Fit wheel sensor (EDIS only! Bit rubbish on mine)

Fit coil pack somewhere within reach of your coil leads (O/S inner wind on mine)

Fit 944 expansion tank to N/S wing.

Remove the blanking plate by the throttle cable adjust(To clear injectors)

Replace blanking plate with thinner plate and bolts

Cut mounting legs off the fuel rail (If the rail is second hand flush with solvents and leave overnight)

Trial fit injectors and rail to mark up brackets (I used ¾” wide steel bar and picked up cam cover studs)

Silver solder brackets to fuel rail (Weld if you can!)

Refit and adjust to get a good fit. (My mounts have a bolted on part that can be adjusted)


The injectors must be clamped squarely between the rail and the head! 3 Bar fuel goes a long way!

Get this stage right as you cannot easily re-weld the rail if it has been filled with fuel.


Mount fuel pressure regulator (I used the coil mount but anywhere intake side will do)

Make up a vacuum take off that fits in the CSV hole (I used brass plate and soldered a brass tube to it)

Make up intake pipe work; don’t forget a take off for the brake servo (I used washing machine fittings!)

Fit cone filter and brackets to support it. (Remember to ensue that there is some flex)

Plumb in the fuel pipe work (Use injection pipe and good quality clips!)

Filter to fuel rail

Fuel rail to pressure regulator (Get the “in” and “out” the right way round!)

Pressure regulator to return line (Pressurise the system with the fuel pump to 3 bar, fix any leaks, be careful!)

Your car is now fuel proof again

Plumb in the vacuum line from the CSV take off to the Megasquirt

“T” in a take off for the fuel pressure regulator. (This compensates for manifold pressure, a plastic T is fine)

Plumb in the 944 tank, just needs 2 longer pipes

Fit the lambda probe somewhere in the exhaust pipe work. It needs to go in the collector pipe so it sees gas from all 4 cylinders (Mine is fitted in pipe in front of the centre box as the centre box is cheap to replace if it went wrong!).

Electrical fit:

This is very much dependant on what you have chosen to do. Its pretty much a case of wiring each sensor and injector in accordance with the Megasquirt diagrams, be careful you have the right diagram for your Megasquirt beware that you have the right soft ware loaded too. I use the latest Megasquirt Extra code; this gives all the spark control options and loads of other stuff too.

Things to watch:

1. Existing wiring is old and rubbish, earths are generally poor and need work.

2. If you don’t need to disturb something, leave it alone! The AAV is a good example of this, if it works, leave it, you have enough problems already!

3. Make sure each joint is good, sleeve it in heatshrink and secure the wiring as often as you can, it will make fault finding easier if you don’t have to check for broken joints!

4. Use proper plugs if you can. The make better contact and make changing things easier! Injectors are a prime example. The sockets are hard to find but not that expensive when you do (Junior timer female sockets)

5. Avoid snap lock /scotch locks. Do it properly. Enough said.

6. Fuse things. I know the battery is nearby, but if it goes wrong, fuses are cheap, ECUs are expensive!

7. Chock-blocks / Screw terminals are useful for prototyping and test, once it’s all proven, solder and sleeve it! Stop being lazy!

I brought all the wiring in through 4 x 15mm holes next to the cabin air intake, above the passenger foot well and sealed it all with silicone. The wires first come through holes in the firewall then down into the cabin, this is to minimise the exposure of the cabin holes to the engine bay fumes.

I took power from the fuel pump relay socket, it can provide significant power (16A) and also has the permanent live, the ignition switched live and the fuel pump feed too. I just used spade connectors to plug into it.

I mounted the ECU and EDIS units under the glove box on an ali plate secured to the LHD pedal box mount. Also bolted to this is the relays and the fuse box (Well is should be, haven’t quite finished that yet!) The tacho can be wired to the EDIS unit, but mine has gremlins are the moment and does not always work!

The wiring is extensive and complex, there is a lot of it all coming into one place and its confusing, use different coloured wire where you can and if you have to use the same colour then mark it at both ends! (I didn’t and fault finding was a nightmare)

Take your time to get all the sensors working properly, use Easy Therm to calibrate them. It will make things easier if they are 100% (Mine are about 80% accurate and a pain!)

And finally

After you have wired everything up then check and double check the Megasquirt gets power on the right pins and the earths are good (No resistance to the negative terminal of the battery) unplug the fuel pump feed, plug in the laptop and switch on the ignition. It should show up on the laptop with all the correct temperatures and pressures. If it does, well done! More likely it doesn’t then its time to start fault finding! Sadly you are pretty much on your own… I was!

It is now time to gather your fire extinguisher, take your brave pills and plug in the fuel pump…

It won’t start, but it should turn over…

Once things start to move in the right direction then it’s just a matter of tuning. The Megasquirt website and forums are your friends. There is so much variation from car to car and install to install there is little or no point in sharing tables, but if you need help or have any questions drop me a line and I’ll do what I can!

Regards and good luck!

Rich
richard(dot)humble(at)gmail(dot)com
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec


Last edited by Rich H on Sat Jul 19, 2008 6:50 am; edited 2 times in total
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Thu Jul 17, 2008 7:12 pm    Post subject: Reply with quote

Megasquirt, power wiring and tail


Installed:



Fuel rail:




Fuel Rail in place:


Another View (FPR has now moved to the coil bracket)


Engine Bay before:


The engine bay with first install:


I need to take a pic of the current as there are a few more bits fitted and the wiring is much improved!
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Thu Jul 17, 2008 7:21 pm    Post subject: Reply with quote

Bits missing from the last pictures:
Vernier pulley (currently for show)
Coil pack (By the timing belt bolted to the inner wing
944 expansion tank
EDIS trigger wheel and sensor

I'll get some more pics later tonight if the rain lets up.
British summers eh?
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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Martijnus  



Joined: 29 Dec 2006
Posts: 2020
Location: Netherlands

PostPosted: Fri Jul 18, 2008 3:29 am    Post subject: Reply with quote

nice work

what't that funny switch do on your MS unit?

as far as I can see I've got the same FPR.... does it have a (brand)name?
mine is euhhhh.... race tech R or something like that.
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"Rule: Turbo's make torque, and torque makes fun." (C. Bell)

924 "50-jahre", 1981.
MSII/extra, LPG, ITB's, 5lug.
To be turbo'ed in a while.
Killed her at the Nurburgring, Porscheless at the moment
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Fri Jul 18, 2008 8:24 am    Post subject: Reply with quote

Top tips for the MS, I have fitted 2 switches, one on the fornt one on the back, the fornt switch cuts the SAW to the EDIS so you can set the timing at 10 degrees (Limp mode) and the one on the back enables the boot jumper so you can flash the ECU without taking the case off. I have still not managed to get my sensors calibrated properly, they are still a bit out.

The FPR is a bit crap as it has a plastic diaphragm, not ideal, but it will do for now.
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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pocketscience  



Joined: 23 Apr 2006
Posts: 1650
Location: Sydney, Australia... mate!

PostPosted: Fri Jul 18, 2008 6:45 pm    Post subject: Reply with quote

Nice write-up! Did you swap out the TB for something bigger?

Would love to see some final pics when you get a chance!


Cheers,
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81 924 N/A, GTS lights, Saratoga, interior, headers, Integral cam, EFI (sold)
95 993
69 911
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Fri Jul 18, 2008 6:55 pm    Post subject: Reply with quote

TB is now an Audi Coupe (Audi 5000 in the US IIRC) and is massive.
I had to hog out the inlet manifold quite alot and make an adapter plate. You can see form the pics below how much bigger the TB is when the adapter is placed against the old TB.

I have motorbike throttles in the post...

I'll try and get some pics later, if my bits turn up I'll be swapping the backing plates for the drums this afternoon so the camera will be out!




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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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Peter_in_AU  



Joined: 29 Jul 2001
Posts: 2740
Location: Sydney, Australia

PostPosted: Fri Jul 18, 2008 7:57 pm    Post subject: Reply with quote

This is great stuff Rich. I'll move it to the How-To where it belongs.
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1979 924 (Gone to a better place)
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1982 924 (As featured on Wikipedia)

Learn to love your multimeter and may the search be with you
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morghen  



Joined: 21 Jan 2005
Posts: 7832
Location: Romania

PostPosted: Fri Jul 18, 2008 9:02 pm    Post subject: Reply with quote

great job and great writeup !!
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Sat Jul 19, 2008 6:49 am    Post subject: Reply with quote

More photos fresh from the rain. However the damn bonnet catch spring has broken now!
Overall pic:


Coil pack, its quite close to the cambelt and the manifold, but any further out and the leads are too short and the wing is too far away.


FPR mount:


The electrics:


Rich
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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Pieter  



Joined: 06 Mar 2008
Posts: 53
Location: South Africa

PostPosted: Sat Jul 19, 2008 10:32 pm    Post subject: Reply with quote

Awesome Rich,

Just a request or two:

1. can you post a pic of the EDIS trigger mount,
2. the 944 expansion tank?

Thanks.
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Tue Jun 09, 2009 10:31 pm    Post subject: Reply with quote

Just refound this thread after reading one of Dan's old threads, totally forgot about it! A couple of updated pics that might be of interest:

Overall:

The EDIS Mount:

The new filter:


It has recently completed 1200 miles round trip to france and back, 2 minor hitches, one waiting for the ferry when she kicked out a couple of wires and one 2 miles from getting home in the McD's drive thru queue where a wire had fallen off the fan switch!

Averaged over 60mph and 32mpg (Imperial gallons!) and a litre of oil as well...

Car is now waiting for me to gether the entusisam to strip the engine and replace the mains, BEs and rings assuming nothing else is to cock.

Rich
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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ideola  



Joined: 01 Oct 2004
Posts: 15499
Location: Woodstock IL

PostPosted: Wed Jun 10, 2009 12:02 am    Post subject: Reply with quote

Calling Pocketscience...hey Gavin, check out Rich's throttle cable...might be an idea for you. And btw, I still have that bracket for you if you need it. LMK.
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Rich H  



Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK

PostPosted: Wed Jun 10, 2009 2:29 am    Post subject: Reply with quote

Throttle cable is standard RHD
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec
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Martijnus  



Joined: 29 Dec 2006
Posts: 2020
Location: Netherlands

PostPosted: Wed Jun 10, 2009 4:26 am    Post subject: Reply with quote

Rich... I'd like some more info on the fuel rail.

I've got bosch injectors, 13.5mm on top. Is the ford fuel rail the right one for that? In other words...do your injectors have a diameter of 13.5mm too...?

Any specific info on the model Mondeo? Years it was produced or something like that? Maybe less effort for me to go to the scrapyard than building a new rail from water plumbing stuff.
_________________
"Rule: Turbo's make torque, and torque makes fun." (C. Bell)

924 "50-jahre", 1981.
MSII/extra, LPG, ITB's, 5lug.
To be turbo'ed in a while.
Killed her at the Nurburgring, Porscheless at the moment
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