kpr's ae85

[kpr]

Finally brought an ecu.  wanted to try one of the new g5 links.  but couldn't justify the price, and no real need for it.    So  got a g4x xtreme, as is  lowest model that can run e throttle without and external box
Speaking of external boxes.  not a fan of any extra gauges, dashes,  keypads  etc.    and for the most part they just tell you when your engine is already blown up.  
So made some brackets that tuck the ecu and fuse box out of sight. 

 

yo dawg i heard you like brackets, so i put a bracket on your bracket 

paired up with the $40 dollar aliexpress fuse/relay box.  which is actually pretty choice, unless it catches fire. 

It come with a lid but doesnt fit behind kick panel.  so can stay open 

 

 

 

 

[kpr]

wires,  fun times.   Waiting for some more china stuff to finish it. but  got a good part of it done
running split loom for the main part, since 99% chance will change things at later date.  so needs to be serviceable 
most of it will be hidden, rather than a showpiece  

 

 

Trigger bracket on 
Made adapter to put oil pressure/temp sensor,  in oil pump bung. ideally would be post filter, to be most accurate of what engine is seeing.   
I did think about  making a block instead of the vvti banjo, with a port for the sensor, but wasnt that motivated.  Is only really there for a tuning aid anyway.

running aliexpress denso style plugs, on things that need plugs,  they seem decent and cheap 
plus if get keen, can make a bracket for them to clip onto.   yeah i deburred that hole 

 

 

[kpr]

Loom basically done.  changed some of the split loom after this picture. as the ali special stuff is super thin, crushes and looks horrible.   Coil / hot side stuff is heat sleeved.  the xlr connector down bottom by ecu plugs is for dyno wideband connection 

Getting pretty close to first start up.  shimless buckets showed up, so top end is all together properly now.   e throttles and stuff all work. engine turns over and has oil pressure.    Just waiting on a few more bits,  then rest can go together 

 

 

made this dipstick tube that doubles as the oil return for the vvti   

Have room on this setup, since no fuel rail in the way. so the lines do a sneaky sneaky  around the back 

 

Had a bit of a shitfight buying injectors, not naming any names   NZAIRFITER  / DSR TURBO   

massive sharn what happened.     But bosch group the flow rates of their 980cc injectors with a little dot on the side ,   red, yellow, blue.   I asked for them to be checked before sending them out. 

Yeah nar sends 2 red,  2 yellow.  red ones can flow up to 7-8% more than the blue and yellow somewhere in between.  I wont bore you with the details of the bad customer service, but was basically stuck with them. please dont buy anything of this guy 

 

The link can do pretty cool injector test. so ordered some measuring  tubes off aliexpress and rigged up this abortion with one of the bike rails. conveniently they have clips to hold the injectors in the rail and i can run deadhead setup on my fuel system.  This is all attached to the fuel system and ecu in the car 

Test run on the bike injectors.  they flowed nice and even. pretty good for some 10 year old injectors that have been kicking around the floor of my shed.   but they are a touch small to run as single set of 4. the bike runs 8 injectors 

 

with the 980's in the rail  wide open test  (100% duty) for 30 sec.   (double the time about 900cc/min)   red, red, yellow yellow    

 

Just as bosch states    the 2 red ones on left flow more than the yellow on right.    about 4.5%  difference.     real world (roughly) if you tuned the engine at 12.5:1 afr.  you would have the far left running at about 12.3afr and the far right running at 12.7afr.   not great, not end of the world. unless you got unlucky pair that far right injector up with a cylinder that wants to run leaner than the rest. 

 

 Next with  little math i simulated the engine running at about 8500rpm  for 1 minute  at about 40%  duty.   since this engine will never see anywhere near 100% duty. though may get lucky and they
would flow closer to each other  at lower dutys

Still about 4%   different down at that duty.        Yes the math doesn't math, as they should be flowing around the 360cc (360ml) mark,  going by the wide open test.   
The next day after the petrol fumes wore off i realized i didn't account for the the inejector deadtime.  so real world with the right deadtime numbers, that would be at about 28%  duty.    
Done another test at 80% duty  also, with similar results,  about 4% difference

Will order a pair of yellow dot injector off someone who is less retarded,  as thats whats in the starlet.   flow all 8 and match up 2 sets for both cars.   so not all is bad, the starlet might get a set of better matched injectors out of it as well 

 

 

 

 

[kpr]

/ Update. 

Yea i did nothing but bolt the on headers  and sat the intake on, to see what it would look like finished with loom 

 

 

 

[kpr]

So turns out after talking to another injector supplier,  bosch dont group the injectors by colour anymore.  If that means they make them more even now,  or they just cut costs and dont bother at all, i dont know.  so old mate was selling old stock.     annd my plan to buy more yellow ones was a fail.    So was either  buy a flow matched set and waste 400 bucks worth of injectors.  or test everything i had and hope for the best.    which i done the latter.   

ended up with; 
4x lower flowing set, with 1.5% difference   -  now in trueno
4x higher flowing set   with  2.6%   difference  - now in starlet.   the old grouping in the starlet was basically the same % 

Not terrible, the 2  red still the highest flowing  but they come together fairly close at low duty.    At 100duty they are all over the shop. so just flowed them where they will be used 

Back 1 million years ago i put a wideband in each cylinder in the starlet.  the front cylinder  was leanest and  4 was richest.   I have no idea if it was even running these injectors back then, or if cyl1 just gets more air.   but i'm now running the injectors in order, most flow number 1 least 4.     

 

Anyway, trueno.  It runs now.    gearbox seems to be leaking out the front  which is super annoying.  as its a complete dick to get in and out of the car and i hate mechanicing.    I didn't notice it  until drove it about 10m  to the dyno.   Will run it up to see if everything else works before pulling it apart  /  hope it self heals 

Exhaust is quiet and runs like a nana  for having 300deg cams.   so thats a win  

 

 

 

 

 

 

[kpr]

So  done a few runs on dyno today.  still lots of tweaks and testing to go.  but its doing pretty good on initial setup,  with ballpark tune and same deal with vvti settings 

141kw so far,    4th gear runs, will show more in 1:1  gear, close to 150.    Is using about  36%  injector duty vs the starlet at about 40% duty.  so the math is mathing.  

Kinda looks like it needs some intake length tuning the way it flat lines in the top end.  so might be a bit more there, along with bunch of other stuff  need to try  

 

 

put the "dyno wheels"  off starlet   on it  to try do a 1:1 gear run  (j160 5th)   then procced to get it beached on the rollers,   twice   

 

 

[kpr]

some perspective,  i dyno'd a basically stock ae86  the other day.