My Winter Project

[Prof]

I have the electronic adjustable shocks on mine if you need pics etc.

That would be most appreciated - I have the diagrams from the PDF service manual - but piccies are so much better !   I did manage to find some quite small stepper motors - but the Koni Shocks are quite stiff, and I am not sure if they will have enough torque when used as direct drive - which would mean some sort of gearing required.  This part of the project has taken a back burner whilst I get the eManage plumbed in - ready for the MOT and emissions test

[Prof]

So it was bite the bullet time today - time to splice the old loom ready for the eManage to go in.
 
This was a job of 3 parts :
 
Part1) Modify the existing loom so that the injectors and ingition, airflow meter, pressure gauge and so on can be rerouted through to the eManage - this meant cutting each of these lines and then inserting a plug and socket between the cut ends - these are grouped by function (Igniton, Air Metering, Injectors) and there were also 7 other signals that the eManage will share with the existign ECU - these wires were not cut, but a socket connected by bearing the wire and looping it / soldering into a spade.
 
Part2) Modify the eManage loom so that it\'s connectors mate with those prepared in Part1).
 
Part3) Additonal wiring and circuits for Water Injection / Spray and electric Radiator.
 
Well Part1) is done, and the car was road tested afterwards to make sure I didn\'t screw up any of the wiring ! :driving :Giggle
 
Here is a piccy of the finished loom hack - the White Connector blocks (Farnell) are ideal for the job, as they make a good locking connection, are heat, chemical and weather resistant and use a spade type connector.  All joins are crimped then soldered.

[grinder]

so you already have a tuned ECU in there - and then gonna run the emanage ontop of that

could be interesting to tune as you will have 2 things changing the readings

to be honest , if i was you , i would be tempted to find a stock ECU ?? ( just a thought )

[Prof]

so you already have a tuned ECU in there - and then gonna run the emanage ontop of that
 
could be interesting to tune as you will have 2 things changing the readings
 
to be honest , if i was you , i would be tempted to find a stock ECU ?? ( just a thought )

I did wonder about that - but the good thing is, the eManage Ultimate comes preset to do nothing - just allows the signals to pass through unmolested.  So the first job once it\'s fitted will be to do some logging runs - watching things like injector duty versus RPM and boost, and A/F ratio\'s.  I can then see where the existing ECU is letting the side down (if it is), and map the upper portions of the tables that the \'stock\' ecu can\'t handle.  From the A/F reading\'s I have, the chipped ECU runs pretty rich and seems to be able to fuel upto 13-14 psi no problems, but the boost sensor doesn\'t go much beyond that, so I will use the eManage to produce an \'FCD\' for the orignal ECU, then do all the higher end mapping on a 3 BAR MAP sensor from GM - this area of the map will only be seen by the eManage - the stock ECU will assume the signals it\'s being fed relate to lower boost readings.
 
Also, the change of seconday injectors to 800 cc ones is just a couple of clicks for the eManage - it automatically trims fuel by the correct percentage for the larger injector.
 
I still have my old stock ECU if this one presents a problem, but I am fairly convinced that the eManage will effectively \'contain\' the parameters for the existing ECU within the areas that would still be stock.

[grinder]

yeah makes sense

i like the idea that you can run the emanage to do nothing - its a nice set up that way - and just watch the logging to see what the chipped ECU is doing - then just fine tune what it cant ( as you say the higher end of the boost / rev range )

will be a serious toy once you have finished

[Prof]

yeah makes sense
 
i like the idea that you can run the emanage to do nothing - its a nice set up that way - and just watch the logging to see what the chipped ECU is doing - then just fine tune what it cant ( as you say the higher end of the boost / rev range )
 
will be a serious toy once you have finished

It\'s already not slow with that bigger turbo and the street porting - first time I let it go round the clock on the rev gauge I nearly needed new undies - the car has never been slow, but it was a little like having a second turbo.  It really belts along now, and I find myself rarely planting the right foot all the way down anymore - just no need
 
I really do need to get a dyno trip done before I tune the eManage or put the larger injectors / intercooler on.  Also the WI must go on before the hotter summer days come to raise intake temps.  At least with the eManage I can see what these actually are now.
 
I expect to get about 270-290 with the car as it is now, and 340-360 once all the mods are made.
 
Also going to order another set of 800cc injectors to go in the primaries once I am happy that all is working as it should be, and that cooling is able to cope - that should see the figure closer to 380-400 - it will be time to stop then I think - except for perhaps fitting a charge cooler in place of the TMIC. :yes
 
One interesting thing I noted whilst wiring the new connectors in, a previous owner has definitely had some performance mods done in the past - all 4 injector wires were spliced, the Intake and Boost wires, the O2 and knock sensors and the old boost solenoid. :rolleyes: :3Confused

[grinder]

hummm i wonder what the car was running then

sounds like some serious figures though

i know single turbo FD\'s running a touch over 400 - so you will be hot on their heels

[Prof]

hummm i wonder what the car was running then
 
sounds like some serious figures though
 
i know single turbo FD\'s running a touch over 400 - so you will be hot on their heels

I think both me and the car will need to diet though - LOL :rollin

[grinder]

ha ha ha - not sure what you can strip out of the cab to make it lighter

as the added lots of strenghening to keep it rigid

[Prof]

Spent a lot of today getting the harness for the eManage wired up - basically it will mate with the harness on the old ECU, which I have already wired the connectors to/into.
 
Here are some pics - first one shows the harness in the raw state - I stripped about 2 foot of the black sleeving off it, as it\'s miles too long.
 
Second pic shows the connectors that will mate with those on the old loom.
 
For those interested in what signals are used:
 
Injectors in/out (4 Way)- allows the eManage to cut fuel as well as add
 
Ignition in/out (2 Way) - Leading/Trailing
 
Airflow in/out and MAP in/out - (2 Way) - allows mapping out the airflow meter, and creating an FCD for the stock pressure sensor - a GM 3 bar sensor will provide the new boost readings
 
Vehicle Speed (1 Way) for the launch control, Clutch (1 Way) for flat changing
 
TPS, Engine Air Temp, Water Temp, (4 Way)
 
Crank (G, NE) and BAC Duty (4 Way)  These signals will be used to control autotune, ignition timing, electric rad, water injection and the BAC duty is to adjust emissions on low idle and adjust the idle itself
 
There are other outputs that will feed Intake temp warning, Water Pump and Water Pump Duty cycle, Water spray for the intercooler, and electric Rad - these are brought out on a 6 Way connector

[Brett]

Looks like you\'re going to be doing some serious playing in the near future.. :yes

[Prof]

Yep - just need to be brave enough to plumb it in and stick the laptop on it - you\'re never quite sure what happens first time you turn it on :Giggle :Hammer

[Brett]

lol! Know what you mean!

Whats the software side of things like?  Can you have a play around with the software without it being connected to the ECU?
Does the unit come with a base setting thats deemed \'safe\'?

[Prof]

I think that is a yes to both of those questions - the default mapping is for it to do nothing - it can monitor the signals, but does not alter them in any way - inputs map directly to outputs.
 
I will most likey wire 12 volts up to it and see if I can\'t set most of the settings up before I wire it into the car - at least this way I will only have to setup the TPS and then I can get cracking. :yes

[Brett]

Sounds like a plan