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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
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Homemade PCB ready to be drilled. |
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Start of assembly according to the comprehensive instruction
manual. |
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Finished the input section according to the manual |
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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
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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... |
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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... |
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Final assembly |
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Final assembly |
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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.
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PCB and wiring
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PCB for Lucas
4CU (Paint Shop Pro 7.04)
Plug wiring for Rover SD1 V8 and Range Rover V8 3.5l no lambda
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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
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PCB for Volvo 760 (Paint Shop Pro 7.04)
Plug wiring for Volvo
760 V6 1987 (no lambda)
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25 pin Bosch PCB for connecting MS to Bosch plug. |
Extra 4 outputs PCB (Paint
Shop Pro 7.04)
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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. |
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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
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Software
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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
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.
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Software downloads
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version RV8A1-2.8
ASM (firmware) source files
for Volvo 760 and Rover SD1
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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.
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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.
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version RV8A1-2.8
MegaTune RV8A1 for the above cars
Sources files.
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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.
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version 1.1.2.13
Download MSToolsII
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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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