Budget EFI

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Category: Fuel Injection

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Revision as of 06:54, 19 August 2016 ddgonzal (Talk | contribs) (->Manifold and Injector) <- Previous diff		Current revision ddgonzal (Talk | contribs)
Line 1:		Line 1:
-	Buy [[MegaSquirt]] II fully assembled about $400 USD or [http://www.ebay.com.au/sch/i.html?_odkw=Megasquirt+2&_nkw=Microsquirt+2&_sacat=0 $500 AUD off eBay].	+	Convert your A engine to EFI. Big HP (120hp) at a small price ($635 AUD w/o tuning).
		+
		+	= Youtube =
		+	{{YouTube|SDuVPEk6zbI|Datsun A12 EFI}}
	= Manifold and Injector =		= Manifold and Injector =
Line 11:		Line 14:
	* [[#Fuel Pressure Regulator|#Fuel pressure regulator]] from a circa 1997 Misubishi Lancer		* [[#Fuel Pressure Regulator|#Fuel pressure regulator]] from a circa 1997 Misubishi Lancer
	* 3-5mm thick alloy plate for the adapter		* 3-5mm thick alloy plate for the adapter
-	* 1 [[Injector|Fuel Injector]] (500cc)	+	* Fuel Injector ([[Injectors#16600-5L700|365cc]] for stock A12)
-	[http://datsun1200.com/modules/newbb/viewtopic.php?post_id=465339#forumpost465339 Mounting the injector, fuel rail and fuel pressure regulator]	+	{{UploadPost|6746_5507ae76319f2.jpg|464761}}
-	<br>{{UploadPost|6746_551625dbea3e4.jpg|465339}}	+
-	Pressure Regulator	+	Injector/Regulator assembly
-	<br>[http://datsun1200.com/modules/newbb/viewtopic.php?post_id=465352#forumpost465352 http://i297.photobucket.com/albums/mm219/ddgonzal/Datsun%201200/wiki/6746_5514ddb743e94.jpg]	+	<br>{{UploadPost|6746_5514bb8b3741f.jpg|465339}}
		+
		+	* Buy a brass Tee 1/4"
		+	* Drill each end to 14mm opening for the push-in type injector and the push-in type regulator
		+	* leave center T threaded, and screw in a barbed line fitting (for fuel supply hose)
		+	* Drill the manifold PCV opening with 14mm drill bit (for push-in type injector)
		+
		+	Assembled
		+	<br>{{UploadPost|6746_5514bc43661f9.jpg|465339}}
		+
		+	The injector assembly can be secured to the manifold with simple copper wire tie, or positively bolted on using custom brackets (see [http://datsun1200.com/modules/newbb/viewtopic.php?post_id=465340#forumpost465340 injector mounting]).
		+	<br>{{PhotoPost|6746_5514ddb743e94.jpg|465352}}
		+
		+	Pressure Regulator/Injector assembly installed
		+	<br>{{UploadPost|6746_551625dbea3e4.jpg|465339}}
	[http://datsun1200.com/modules/newbb/viewtopic.php?post_id=465859#forumpost465859 TB vacuum taps]		[http://datsun1200.com/modules/newbb/viewtopic.php?post_id=465859#forumpost465859 TB vacuum taps]
-	Accelerator Cable	+	You can use the stock 1200 air cleaner
-	<br>{{UploadPost|6746_55431eaa185a8.jpg|467154}}	+	<br>{{Photo|012-01a.png|Datsun%201200/USA}}
		+
		+	A seal between the throttle body and air cleaner can be fabricated, maybe using rubber hose cemented to the air cleaner bottom
		+	<br>{{UploadPost|6746_5514bd9947552.jpg|465340}}
	= Throttle Body =		= Throttle Body =
-	The X3 Excel Throttle Body is dime-a-dozen and easy to adapt. The 1995-1999 Hyundai Excel X3 (Accent in USA) SOHC engine is the source. Don't forget to get the wiring harness connectors and a couple of inches of wiring for the Throttle Body.	+	The X3 Excel Throttle Body is dime-a-dozen and easy to adapt. The 1995-1999 Hyundai Excel X3 (Accent in USA) SOHC engine is the source. Don't forget to get the wiring harness connectors and a couple of inches of wiring for the attached TPS.
-	{{UploadPost|6746_5507ae76319f2.jpg|464761}}	+	{{Upload|6746_5507acd79d5d3.jpg|464761}}
		+
		+	From the wreckers, get the throttle body with TPS attached.
		+
		+	{{Photo|Airtex_5S5179.jpg|width=SM}}
		+
		+	New TPS is as inexpensive as [http://www.rockauto.com/en/catalog/hyundai,1997,accent,1.5l+l4+sohc,1170773,fuel/air,throttle+position+sensor+(tps),5136 $22 rockauto.com]. New Throttle Body (mixing body) is [http://www.hyundaipartsdeal.com/parts-list/1995-hyundai-accent/throttle-body-injector.html?Diagram=31351A11 $183 from Hyundai], so buy a used one for $30 or so at the wreckers.
		+
		+	Hyundai X3 (Accent/Excel/Verna)
		+	<br>{{WikiCommons|Hyundai_Accent#First_generation_.28X3.3B_1994.E2.80.932000.29|1/15|%2796_Hyundai_Accent_Hatch.JPG}}
		+
		+	Fabricate the adapter out of aluminum sheet, using a stock gasket as a pattern
		+	<br>{{Upload|6746_5507ad73e7dee.jpg|464761}}
		+
		+	{{Upload|6746_5507ae40672e5.jpg|464761}}
		+
		+	Smooth Throttle Bore to better match the manifold. Use a round file or a rotary grinder
		+	<br>{{Upload|6746_5521ed75b1fcb.jpg|465873}}
		+
		+	Drill new holes in the Throttle Body flange and bolt it on
		+	<br>{{Upload|6746_5507ae76319f2.jpg|464761}}
		+
		+	Remove throttle bracket from Datsun carburetor
		+	<br>{{Upload|6746_5507e700d8441.jpg|464764}}
		+
		+	After cutting, bolt to the Throttle Body
		+	<br>{{Upload|6746_5507e72b2f844.jpg|464764}}
		+
		+	Fabricate throttle cable bracket from a short length of tubing and a strip of sheet metal
		+	<br>{{UploadPost|6746_55431eaa185a8.jpg|467154}}
	= Fuel Pressure Regulator =		= Fuel Pressure Regulator =
Line 41:		Line 89:
	Mitsubishi Lancer/Colt/Mirage 1997-2001		Mitsubishi Lancer/Colt/Mirage 1997-2001
-	<br>https://upload.wikimedia.org/wikipedia/commons/thumb/f/f9/1997_Mitsubishi_Lancer_%28CE%29_GLi_sedan_%282015-07-14%29_02.jpg/400px-1997_Mitsubishi_Lancer_%28CE%29_GLi_sedan_%282015-07-14%29_02.jpg	+	<br>{{WikiCommons|Mitsubishi_Lancer|f/f9|1997_Mitsubishi_Lancer_%28CE%29_GLi_sedan_%282015-07-14%29_02.jpg}}
	= Sensors =		= Sensors =
	With MegaSquirt you won't need the Datsun airflow meter. Instead, Megasquirt will calculate the air mass using a MAP sensor and and IAT sensor.		With MegaSquirt you won't need the Datsun airflow meter. Instead, Megasquirt will calculate the air mass using a MAP sensor and and IAT sensor.
	* MAP sensor is built into Megasquirt. Connect vacuum hose to manifold		* MAP sensor is built into Megasquirt. Connect vacuum hose to manifold
-	* Obtain GM IAT sensor from a Chevrolet or Holden. Drill hole in your air cleaner-to-throttle body pipe, and hot-glue the IAT in place. Or use JB-weld. Threaded bungs are available if you want to get really fancy.	+	* Obtain GM IAT sensor from a Chevrolet or Holden. Drill hole in your air cleaner and hot-glue the IAT in place. Or use JB-weld. Threaded bungs are available if you want to get really fancy. You can also place the sensor in a air-cleaner-to-throttle body pipe/hose. Alternatively you can drill the throttle body and tap it (3/8 NPT) to accept the sensor (see [http://datsun1200.com/modules/newbb/viewtopic.php?post_id=465873#forumpost465873 post])
	* [http://www.megamanual.com/v22manual/mwire.htm MegaManual]		* [http://www.megamanual.com/v22manual/mwire.htm MegaManual]
	* GM IAT Sensor 12146312 [http://www.rockauto.com/catalog/x,carcode,1038079,parttype,4748 $10 RockAuto.com]		* GM IAT Sensor 12146312 [http://www.rockauto.com/catalog/x,carcode,1038079,parttype,4748 $10 RockAuto.com]
-	http://i297.photobucket.com/albums/mm219/ddgonzal/Datsun%201200/wiki/th_TS10075A.jpg	+	{{PhotoTh|TS10075A.jpg}}
	* GM sensor connector 12162193 [http://www.rockauto.com/catalog/x,carcode,1038079,parttype,2564 $5 RockAuto.com]		* GM sensor connector 12162193 [http://www.rockauto.com/catalog/x,carcode,1038079,parttype,2564 $5 RockAuto.com]
-	http://i297.photobucket.com/albums/mm219/ddgonzal/Datsun%201200/wiki/th_HP3840.jpg	+	{{PhotoTh|HP3840.jpg}}
	= Fuel System =		= Fuel System =
-	Use a 280ZX fuel pump, connected to the stock fuel line coming from the tank.	+	Use a external EFI fuel pump, connected to the stock fuel line coming from the tank. We have selected a 51-psi system, so need a pump capable of high-pressure.
-	* 280ZX Fuel Pump [http://www.rockauto.com/catalog/x,carcode,1209338,parttype,6256 $45 RockAuto.com]	+	* Carter P74015 [http://www.rockauto.com/en/parts/carter,P74015,fuel+pump,6256 $70 rockauto.com]
		+	* Airtex E8228 Universal [http://www.amazon.com/Airtex-E8228-Electronic-Replacement-Applications/dp/B000DN7VM4 $79 Amazon.com]
-	Run a regular fuel line back to the the tank, and Tee it in to the filler hose. If you keep the tank above 1/4 full no baffles or surge tank are needed.	+	Pump can be placed in engine compartment or back by the tank. If you put it up front, you can use the stock hard line from the tank.
		+	<br>{{Photo2|P74015_P04_KIT.jpg}}
-	From the fuel pump output to the fuel rail, use EFI-rated fuel hose and EFI hose clamps. Use a 280ZX-style fuel filter.	+	Run a regular low-pressure fuel line from the regular back to the the tank, and Tee it in to the filler hose. If you keep the tank above 1/4 full no extra baffles or surge tank are needed. If you want, add a $50 [[Surge Tank]]. Have a shop braze a 5/16" line to a length of muffler pipe the right diameter for your tank filler hose.
-	Nissan EFI fuel pump with damper can be mounted in rear of car or in engine compartment	+	[http://www.autozone.com/fittings-and-hose-line-connectors/heater-hose-quick-connector/kat-s-heaters-2-in-lower-radiator-hose-connector/48249_0_0/?checkfit=true KATS plastic 2" hose adapter $3] (will it resist gasoline?)
-	<br>{{Album|21845}}	+
-	280ZX EFI fuel filter [http://www.rockauto.com/catalog/x,carcode,1209338,parttype,6200 $3 RockAuto.com]	+	Stainless marine filler hose adapter $30-$60
-	<br>http://i297.photobucket.com/albums/mm219/ddgonzal/Datsun%201200/wiki/th_BA0430165.jpg	+	<br>{{Photo2|HDT-2212_INLINE_FUEL_RETURN_TEE.jpg|width=SM}}
		+
		+	From the fuel pump output to the fuel rail, use EFI-rated fuel hose and EFI hose clamps. Best price is often at your local auto parts store in bulk (sold by the foot, $2-$3 USD/foot). Clamps can be had for less than [http://google.com/search?q=efi+fuel+hose+clamps&tbm=shop $2 each]. Best to use a hard line for the majority of the run.
		+
		+	Use a 280ZX-style fuel filter. 280ZX EFI fuel filter [http://www.rockauto.com/catalog/x,carcode,1209338,parttype,6200 $3 RockAuto.com]
		+	<br>{{PhotoTh|BA0430165.jpg}}
		+
		+	The fuel pump is wired up with a relay -- you don't want the high current to go through your ignition switch. As cheap as $10 for a used Nissan relay.
		+
		+	See: [[Electric_Fuel_Pump#Wiring]]
		+	<br>{{Album!|22115}}
		+
		+	= Ignition and Distributor =
		+	The ECU can take the RPM signal direct from your existing points-based distributor. It's also compatible with electronic ignition distributors.
	= Wiring =		= Wiring =
Line 76:		Line 138:
	* injectors		* injectors
	* IAT signal & ground/earth		* IAT signal & ground/earth
-	* Air Regulator
-	* EFI Water Temp
	* Tach signal (coil negative terminal)		* Tach signal (coil negative terminal)
	For full details, see http://www.megamanual.com/mtabcon.htm#wire		For full details, see http://www.megamanual.com/mtabcon.htm#wire
		+
		+	= ECU =
		+	Buy [[MegaSquirt]] II fully assembled about $400 USD or [http://www.ebay.com.au/sch/i.html?_odkw=Megasquirt+2&_nkw=Microsquirt+2&_sacat=0 $500 AUD off eBay].
	= ECU Configuration =		= ECU Configuration =
Line 93:		Line 156:
	* SuperTunix open source		* SuperTunix open source
-	In the software configure	+	In the software [http://www.megamanual.com/ms2/configure.htm configure]:
-		+
-	Fast Idle Valve (FIdle): Solenoid	+
-	Fast Idle Threshold: 120F	+
-		+
-	Nissan temp sensor	+
-	-40F 30-33000 ohms	+
-	80F 2000-2500ohms	+
-	160F 360 ohms	+
	CONSTANTS		CONSTANTS
	Required Fuel		Required Fuel
-	* displacement 1397cc (A14) or 1488cc (A15)	+	* displacement 1171cc (A12)
	* # of cyl 4		* # of cyl 4
-	* injector flow rate 188	+	* injector flow rate 365
	* desired AFR 13		* desired AFR 13
	Injector open time 1.0ms		Injector open time 1.0ms
Line 115:		Line 170:
	Fast Idle Threshold		Fast Idle Threshold
	Barometric Correction: Off		Barometric Correction: Off
-	Control Algorithm: Speed Density [non-TPS]	+	Control Algorithm: Alpha-N (TPS)
-	Injections per Engine Cycle: 1 squirt	+	Injections per Engine Cycle: 2 squirts
	Injector Staging: simultaneous		Injector Staging: simultaneous
-	Injector Port Type: multi-port	+	Injector Port Type: throttle body
	Engine Type: even fire		Engine Type: even fire
Line 150:		Line 205:
	The paid version of TunerStudio has a software auto-tuner which is supposed to be great, but it still requires some work (it's not totally automatic).		The paid version of TunerStudio has a software auto-tuner which is supposed to be great, but it still requires some work (it's not totally automatic).
-	[[Category:Fuel_Injection]]	+	= Cost =
		+	* $400 ECU with wiring
		+	* $ 0 Stock A12 intake manifold
		+	* $ 30 Throttle Body
		+	* $ 15 Fuel pressure regulator
		+	* $ 5 3mm thick alloy plate
		+	* $ 7 Fuel Injector
		+	* $ 20 new IAT Sensor & connector
		+	* $ 79 new 60psi fuel pump
		+	* $ 15 fuel hose & clamps (for front-mount pump)
		+	* $ 3 high-pressure fuel filter
		+	* $ 10 Nissan relay
		+	* $ 5 fuel pump wires
		+	* $ 3 fuse
		+	* $ 20 oil pressure safety switch
		+	* $ 6 1/8 BSPT-to-1/8 NPT adapter
		+	* $ 6 fuel filler hose Tee
		+	* $ 10 generic air hose
		+	------
		+	$ 632 TOTAL not including tax & shipping
		+
		+	Tuning:
		+	* $181 new A/F gauge, wideband controller & sensor
		+	or
		+	* $? engineer & dyno time
		+
		+	[[Category:Fuel_Injection]]{{End}}

---

Current revision

Convert your A engine to EFI. Big HP (120hp) at a small price ($635 AUD w/o tuning).

Contents 1 Youtube 2 Manifold and Injector 3 Throttle Body 4 Fuel Pressure Regulator 5 Sensors 6 Fuel System 7 Ignition and Distributor 8 Wiring 9 ECU 10 ECU Configuration 11 Software Tuning 12 Cost

Youtube

 V I D E O  Datsun A12 EFI (click to view)

Manifold and Injector

Rather than fabricate a custom manifold, use the stock one that's already on your A12! The photo here show the intake unbolted from the exhaust, but you can do it while it's still together.

Build instructions

Parts needed:

• Stock A12 intake manifold
• #Throttle Body (40mm) from a Hyundai Excel/Accent X3 SOHC
• #Fuel pressure regulator from a circa 1997 Misubishi Lancer
• 3-5mm thick alloy plate for the adapter
• Fuel Injector (365cc for stock A12)

Post 464761

Injector/Regulator assembly
Post 465339

• Buy a brass Tee 1/4"
• Drill each end to 14mm opening for the push-in type injector and the push-in type regulator
• leave center T threaded, and screw in a barbed line fitting (for fuel supply hose)
• Drill the manifold PCV opening with 14mm drill bit (for push-in type injector)

Assembled
Post 465339

The injector assembly can be secured to the manifold with simple copper wire tie, or positively bolted on using custom brackets (see injector mounting).
Post click for topic

Pressure Regulator/Injector assembly installed
Post 465339

TB vacuum taps

You can use the stock 1200 air cleaner

A seal between the throttle body and air cleaner can be fabricated, maybe using rubber hose cemented to the air cleaner bottom
Post 465340

Throttle Body

The X3 Excel Throttle Body is dime-a-dozen and easy to adapt. The 1995-1999 Hyundai Excel X3 (Accent in USA) SOHC engine is the source. Don't forget to get the wiring harness connectors and a couple of inches of wiring for the attached TPS.

Upload click to view

From the wreckers, get the throttle body with TPS attached.

New TPS is as inexpensive as $22 rockauto.com. New Throttle Body (mixing body) is $183 from Hyundai, so buy a used one for $30 or so at the wreckers.

Hyundai X3 (Accent/Excel/Verna)
WIKI go to Wikipedia

Fabricate the adapter out of aluminum sheet, using a stock gasket as a pattern
Upload click to view

Upload click to view

Smooth Throttle Bore to better match the manifold. Use a round file or a rotary grinder
Upload click to view

Drill new holes in the Throttle Body flange and bolt it on
Upload click to view

Remove throttle bracket from Datsun carburetor
Upload click to view

After cutting, bolt to the Throttle Body
Upload click to view

Fabricate throttle cable bracket from a short length of tubing and a strip of sheet metal
Post 467154

Fuel Pressure Regulator

Fuel Pressure regulator from a 1997-2001 Misubishi Lancer 1.5 engine, $15 used

Search
$35 RockAuto.com 51 psi
BECK/ARNLEY 1580463 {#MD311979)
STANDARD MOTOR PRODUCTS PR247
AIRTEX / WELLS 5G1265
Denso MD 311979

Mitsubishi Lancer/Colt/Mirage 1997-2001
WIKI go to Wikipedia

Sensors

With MegaSquirt you won't need the Datsun airflow meter. Instead, Megasquirt will calculate the air mass using a MAP sensor and and IAT sensor.

• MAP sensor is built into Megasquirt. Connect vacuum hose to manifold
• Obtain GM IAT sensor from a Chevrolet or Holden. Drill hole in your air cleaner and hot-glue the IAT in place. Or use JB-weld. Threaded bungs are available if you want to get really fancy. You can also place the sensor in a air-cleaner-to-throttle body pipe/hose. Alternatively you can drill the throttle body and tap it (3/8 NPT) to accept the sensor (see post)

* MegaManual
* GM IAT Sensor 12146312 $10 RockAuto.com

* GM sensor connector 12162193 $5 RockAuto.com 

Fuel System

Use a external EFI fuel pump, connected to the stock fuel line coming from the tank. We have selected a 51-psi system, so need a pump capable of high-pressure.

* Carter P74015 $70 rockauto.com
* Airtex E8228 Universal $79 Amazon.com

Pump can be placed in engine compartment or back by the tank. If you put it up front, you can use the stock hard line from the tank.

Run a regular low-pressure fuel line from the regular back to the the tank, and Tee it in to the filler hose. If you keep the tank above 1/4 full no extra baffles or surge tank are needed. If you want, add a $50 Surge Tank. Have a shop braze a 5/16" line to a length of muffler pipe the right diameter for your tank filler hose.

KATS plastic 2" hose adapter $3 (will it resist gasoline?)

Stainless marine filler hose adapter $30-$60

From the fuel pump output to the fuel rail, use EFI-rated fuel hose and EFI hose clamps. Best price is often at your local auto parts store in bulk (sold by the foot, $2-$3 USD/foot). Clamps can be had for less than $2 each. Best to use a hard line for the majority of the run.

Use a 280ZX-style fuel filter. 280ZX EFI fuel filter $3 RockAuto.com

The fuel pump is wired up with a relay -- you don't want the high current to go through your ignition switch. As cheap as $10 for a used Nissan relay.

See: Electric_Fuel_Pump#Wiring

Ignition and Distributor

The ECU can take the RPM signal direct from your existing points-based distributor. It's also compatible with electronic ignition distributors.

Wiring

Wire up the MegaSquirt harness

• 12V
• earth/ground
• fuel pump relay
• injectors
• IAT signal & ground/earth
• Tach signal (coil negative terminal)

For full details, see http://www.megamanual.com/mtabcon.htm#wire

ECU

Buy MegaSquirt II fully assembled about $400 USD or $500 AUD off eBay.

ECU Configuration

Download at http://www.diyautotune.com/softwarelinks.htm

• Mac
• Windows
• Linux

You have a choice:

• TunerStudio free version (most popular software for MegaSquirt)

  Free version supports all MegaSquirt features

• SuperTunix open source

In the software configure:

CONSTANTS
Required Fuel
* displacement 1171cc (A12)
* # of cyl 4
* injector flow rate 365
* desired AFR 13
Injector open time 1.0ms
batt V correction .20
PWM current limit 1000%
PWM time threshold  25.4
Fast Idle Threshold
Barometric Correction: Off
Control Algorithm: Alpha-N (TPS)
Injections per Engine Cycle: 2 squirts
Injector Staging: simultaneous
Injector Port Type: throttle body
Engine Type: even fire

VE TABLE

Generate a new table based on your peak horsepower and torque figures ('Settings/VE Table/Tools/VE Specific/Generate VETable').

ENRICHMENTS
EGO Step (%): 0
Warmup enrichment
-40F 180%
-20F 150%
 0F 140%
 20F 135%
 40F 130%
 60F 125%
 80F 118%
100F 110%
130F 103%
160F 100%

Afterstart Enrichment: between 25-45%for 100 to 250 cycles,

Software Tuning

Start your engine and let idle. Go to http://www.megamanual.com/v22manual/mtune.htm

And start tuning.

A big help in turning is to fit an Air Fuel Ratio Gauge. MegaSquirt 2 can directly read the wideband output of the wideband controller, but more importantly you can see the A/F Ratio on the gauge.

 See Main Article: Oxygen_Sensor#Air_Fuel_Ratio_Gauge

The paid version of TunerStudio has a software auto-tuner which is supposed to be great, but it still requires some work (it's not totally automatic).

Cost

* $400 ECU with wiring
* $  0 Stock A12 intake manifold 
* $ 30 Throttle Body
* $ 15 Fuel pressure regulator
* $  5 3mm thick alloy plate
* $  7 Fuel Injector
* $ 20 new IAT Sensor & connector
* $ 79 new 60psi fuel pump
* $ 15 fuel hose & clamps (for front-mount pump)
* $  3 high-pressure fuel filter
* $ 10 Nissan relay
* $  5 fuel pump wires
* $  3 fuse
* $ 20 oil pressure safety switch
* $  6 1/8 BSPT-to-1/8 NPT adapter
* $  6 fuel filler hose Tee
* $ 10 generic air hose
------
$  632 TOTAL not including tax & shipping

Tuning:
* $181 new A/F gauge, wideband controller & sensor
or
* $?   engineer & dyno time 

---

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