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Installing Megasquirt fuel injection

Winter 2002-2003

Installing a home made fuel injection system instead of the Lucas 4CU was decided because the extra fuelling could not be accomplished properly with the old Lucas system. The Megasquirt open source system was chosen because it was an open source system and it was cheap and you can build it yourself.

You can see more on:

Megasquirt home page
http://www.megasquirt.info/index.html
http://www.megasquirt.info/manual/mtabcon.htm
http://home.earthlink.net/%7Ejcgebhart/msindex.html



The Yahoo Megasquirt site is very active and everybody is very helpful if you have any problems. The Megasquirt system has a "simple" setup (compared to all other systems that I know) so you should stand a good chance of getting a car up running rather quickly. What's the benefit of a zillion adjustments if you only need a few adjustments to get the car running good. The point here is that you do not have to be an expert to tune this system and you do not loose the overview of the system because of it's size.




Finally thanks to Bruce Bowling, Al Grippo, Eric Fahlgren and all other people that joined in making this system available this way. And not to forget the comprehensive FAQ of Lance Gardiner at Megasquirt FAQ.



Here are some pictures of the assembly

Homemade PCB ready to be drilled.
Start of assembly according to the comprehensive instruction manual.
Finished the input section according to the manual
Megasquirt plug wired up to the interface PCB that should hold the plug for the Lucas 4CU connector.

This PCB will fit the following cars..
Rover SD1 V8 with Lucas 4CU
Range Rover 3.5 with Lucas 4CU
Jaguar with Lucas 6CU and 16CU
Opel Kadett C with Bosch L-jetronic
Other cars with Bosch L-jetronic and 35 pin 2 row plug
Lucas 4CU box with Megasquirt computer. (actually this is a Jaguar 6CU box, but same frame as the 4CU for the Rover)

Mockup assembly of what to come...
Lucas 4CU box with Megasquirt computer. (actually this is a Jaguar 6CU box, but same frame as the 4CU for the Rover)

Mockup assembly of what to come...
Final assembly
Final assembly


17-02-2003:Just fired up the Rover with MS.
MSToolsII is a utility for MegaSquirt to setup your coolant temperature sensor data and air temperature sensor data. The data can be saved to a database so you can have several configurations for different sensors from a lot of cars. MSToolsII can generate the INC files with temperature data that you need when assembling new firmware (S19 file). New firmware can be uploaded to MegaSquirt.

A window displays all the actual temperatures from your MegaSquirt computer, real time together with the actual ohm value of the sensors. This is good for checking that your temperature sensors is dead on.

 

1 April 2003:
Volvo 760 V6 is now running with MS. However the fuel economy is bad. I may need to connect a engine load signal from MS to the EZK ignition.


9 April 2003:
Fuel economy. The Volvo MS can now just nearly match that of the Bosch unit,  but still the engine has vastly more low rpm torque than with the Bosch unit. The EZK ignition now receives a load signal from the MS, so ignition is adjusted by the Volvo EZK unit in regards to engine load. This helped on the economy.

 

24 April 2003:
Fuel economy on the Rover looks to be improved by some 10% at small journeys of less than 20 km. The engine responds are better, but on boost the engine performs much better than before, mainly because fuel can be controlled correctly according to boost. No more black smoke when flooring the throttle.......

Still having idling problems when starting the Rover after some 15 minutes standstill on a hot day. It gets to lean mixture because of the air temperature after the compressor is above 65 degrees centigrade. Otherwise it runs just fine.

The IAC idle control is really a big improvement for the Rover.

 

15 May 2003:
Fuel economy on the Volvo is nearly matching the Bosch unit. I am still fighting hard to match that of the Bosch unit. The MS on the Rover is running good, without any problems. The Rover hot starting problem is solved with corrections in the MS firmware.

 

August 2003:

The Rover performs much better than it ever have before. The MS system is superior to the old Lucas 4CU an any respect. The Volvo760 has more torque and power than before, but I cannot match the fuel economy of the Bosch unit, but it come close. This is related to the way the Bosch fuel computer has control over the ignition, I think.


Below you can download the work I have done with our two cars. The software for both cars supports IAC idle control via the standard MS fast idle. The IAC unit is a Bosch type from Volvo 760 but also found in several other European cars.

Water injection is supported in both cars software if you make an extension board, but else you can leave it out.

PCB and wiring
PCB for Lucas 4CU (Paint Shop Pro 7.04)

Plug wiring for Rover SD1 V8 and Range Rover V8 3.5l no lambda

This PCB will fit the following cars..
Rover SD1 V8 with Lucas 4CU
Range Rover 3.5 with Lucas 4CU
Jaguar with Lucas 6CU and 16CU
Opel Kadett C with Bosch L-jetronic
Other cars with Bosch L-jetronic and 35 pin 2 row plug

35 pin Bosch/Lucas PCB for connecting MS to Bosch plug


PCB for Volvo 760 (Paint Shop Pro 7.04)

Plug wiring for Volvo 760 V6 1987 (no lambda)
25 pin Bosch PCB for connecting MS to Bosch plug.


Extra 4 outputs PCB (Paint Shop Pro 7.04)

Small PCB with 4 outputs to connect to the MS board. I use one of these for engine load signal to the EZK ignition on the Volvo and one for water injection on the Rover.

Wiring of Bosch IAC (Volvo type) for use with MegaSquirt's FIdle output. It must be wired this way so it does not overload the FIdle output.
This type has no spring loaded return.
Type 0 280 140 501


 

Software

I have extended the MegaSquirt firmware and MegaTune to suit my two cars, a Rover SD1 V8 3.5l with supercharger and ERL water injection, and a Volvo 760 V6 2.8l. However anybody can use my software on any car using the standard MS 2.0 hardware. I have not changed my MS hardware, but I have build an extra output board to support 4 outputs. So what do you get by using my versions on your car ? Well you get total incompatibility with Eric's versions of MegaTune, and B&G's firmware............

If you can live with that, you get the following from my RV8A1-2.8 firmware:
Support for IAC control via the standard MS fast idle output and Bosch stepper motor.
Engine sensor diagnostic
Monitor CPU scan time
Monitor high resolution rpm
Water injection control
RPM limiter by fuel cutoff
Automatic switch on of driving lights some seconds after starting
Around 100 bytes of extra RAM that is flashed on each burn command
Based on Eric Falgren's turbo code
Most of B&G ver 2.982 implemented (tach re-enabling)
Support for dynamic display of selected TPS acceleration bin
Support for dynamic display of selected warm-up bin
Prime pulse interpolation in relation to coolant temp
Reducing cranking pulse width 50% after a few seconds of cranking



MegaTune RV8A1-2.8 supports the following
Auto tune via MS EGO control. Megatune corrects your VE table entries while you drive. You decide how aggressive and how fast (and other options) MegaTune should adjust your VE entries before enabling auto tune. Auto tune only the one VE point you select.

IAC setup with 2x11 open/close speed table entries. When idling, the current speed table entry is marked red, so you can see from which table entry the MS firmware is regulating. You can edit any entry anytime, online, for easy and quick IAC speed reaction adjustments.
Disable IAC online, for when you are adjusting the mechanical basis idle speed

Warm-up table in the enrichments dialog displays, online, in red what entry is currently active
Display of engine diagnostic errors (in text) such as "Coolant sensor is broken" etc..ect..
Rotate of fuel map in 4 directions in the Tune screen and hotkeys
More main screen hotkeys
Logging of Idle DC, battery
Limitation on logging to a rpm range (log only when rpm is between 1000..3000)
Setup of driving lights control
Rev limiter by fuel cutoff
Setup of water injection
Display of detected firmware version on the main screen
Online display of active TPS acceleration bin in different colors in real time and enrichment window
256 bytes table editor
Compatible with standard B&G 2.0 firmware (I have tested it only on a stim with success)
Load your favorite settings file at startup 
Prime pulse interpolation setup in relation to coolant temp
Reducing cranking pulse width after a few seconds of cranking


After a power switch, MegaSquirt memory constants is compared with Megatune's constants. Result is displayed in the main screen. If a power switch happens in a tune or real time window and the constants differ, a dialog box offers choices of what to do.

Cold acceleration multiplier (also in MegaTune 2.15)
Warning issue if a setting is not supported (mainly when using B&G v2.0 code)
No display of BURN dialog box if working offline
All settings can be edited offline
MS constants is ONLY read into MegaTune settings at user command


Screen shoots of my MegaTuneRV8A1



If the above does not frighten you, please go ahead downloading.

To use the ASM firmware below, you must use my version of MegaTune RV8A1-x.x.

WARNING !!!
Please DO NOT use my version of MegaSquirt firmware with the original MegaTune.

If any one finds any bugs or ways to optimize my code or improvements on the existing code I would be happy to receive a note from you guys out there........:-))

I will try and keep the sources updated.


Software downloads

version RV8A1-2.8

ASM (firmware) source files for Volvo 760 and Rover SD1

Rover SD1 3.5L 1986 supercharged with water injection

Who can use it: Basic every Rover and Range Rover with the Lucas 4CU can use it. To use the IAC controller you must download my version of MegaTune. Even through my car is supercharged you still can use my ASM firmware and my Megatune on a standard Rover V8 or any other car for that matter.

What to do in engine bay:
Install EGO sensor.
Else do nothing... Can it be more simple ??? If you want to put the old Lucas box into action (but who does ??) just switch box and you are running.

If you want to use the IAC control, use a Bosch stepper motor from the Volvo below.
For connecting the Bosch IAC stepper motor look at the plug wiring diagram.

Software support via extension board for water injection that is triggered via boost and MAT temperature.

If you want to use the standard MAT sensor in the Lucas flow meter you must include the Lucas air temp INC file in the ASM source and recompile the ASM code.

You can use this software without the IAC and/or water injection wired up. So you can use this code for a standard Range Rover, Jaguar or any other car you have. We have tried for fun to plug my own box into an standard Range Rover 3.5 and it ran without any problems, however the VE map was not quite right.

This version writes 2x 128 bytes setup table to the firmware (normal is 128 bytes) with the "v" command.

Volvo 760 V6 1987

Who can use it: Basic every one can use it. The car can drive without the load signal to the EZK ignition, but fuel economy will be bad. To use the IAC controller you must download my ASM firmware and my version of MegaTune.

What to do in engine bay:
Install EGO sensor.
Install a throttle pot as an extension to the standard Volvo switch type. I use one from a 900 or 850 series. You must interconnect these two pots to the same shaft somehow and build them on top of each other. Then take a new wire from the new pot up to your MS controller. Both pots must stay as the EZK ignition uses the throttle switch.
Disconnect the MAF plug and borrow 2 wires from the plug for the air temp sensor.  That's all..........
Now if you want to put in the old Bosch ECU again, just remove the air sensor wires from the MAF plug and reconnect the MAF plug and you are going with the Bosch ECU.

For connecting the Bosch IAC stepper motor look at the plug wiring diagram.

Software support via extension board for engine load control to the EZK ignition. Look in the ASM source for documentation.

The Volvo ASM source modifies the 0.1 msec clock by dividing it by 4, for a good resolution of the load signal transmitted to the EZK ignition.

This version writes 2x 128 bytes setup table to the firmware (normal is 128 bytes) with the "v" command.

version RV8A1-2.8

MegaTune RV8A1 for the above cars

Sources files.

My MegaTune, supports setup of IAC idle controller, KPA and MAT trigger levels for the water injection.
On the Runtime page the engine status bits is colored so they are more easy to see (specially TPS accel/deaccel)

This version writes 2x 128 bytes setup table to the firmware. (normal is 128 bytes).

The table viewer supports display and editing of the extra 128 bytes ram variables. These will be burned when issuing the "burn" command from MegaTune.

Some MegaTune settings for the Rover and the Volvo is included.

You must copy the correct INC files to MegaTune depending on the car you uses.

THERMFACTORROVER.INC == rename to ==> THERMFACTOR.INC
MATFACTORROVER.INC ==== rename to ==> MATFACTOR.INC
AIRDENFACTORROVER.INC == rename to ==> AIRDENFACTOR.INC


And generate a throttle INC file from MegaTune Tools menu.

Will also run on standard B&G MegaSquirt firmware. 


version 1.1.2.13

Download MSToolsII

MSToolsII let's you configure your temp sensors from a database that you can extend. Display of online temperatures, ohms, voltage etc..etc

A download function for upgrading your MS firmware. This function releases the COM port after downloading so you do not need to shut it down before running MegaTune.

MSToolsII will run on standard B&G MegaSquirt firmware and my RV8A1 firmware



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