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InläggPostat: ons 08-06-18 22:35 
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Disclaimer :The description given herein is for technical understanding only. It is the sole responsabilty of any reader to have it implemented , without claiming to have the author's responsibility engaged in any respect whatsoever.

Summary

1. Building Flexitune II
2. Man Machine Interface
3. Installing Flexitune inside the vehicle (Volvo 480 2 liters)
4. Applicability to other Volvo 400 series (440, 460, 480)
5. Applicability to Peugeot 205 GTI & other L/LE/LE2/LU2-Jetronic, possibly Motronic 1.3 ?
6. Where to install Flexitune : in the engine bay or in the passenger compartment ?
7. Overall
8. Adaptability to 1995 Rover 214 MK2 1L4 16V



1. Building Flexitune II
Well … you made your mind and decided to order Flexitune. A few days later the postman rings the doorbell with just an envelope
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Inside : just a few components :
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Well you'd better buy separately 1 LED, 1 switch to select the fuel type (SP, E85, mixed) and a pushbutton for the choke…personally, I added a IC support for the µP
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The board is rather small … when compared with a 2 Eurocents
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First thing to do is to properly classify the various components
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Then you may have the soldering iron warming up, a multimeter by hand … and one hour later, you get
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Easy
Just put the power on … the LED starts blinking: great

2. Man Machine Interface
You had better deeply think where you want the switch and pushbutton installed… experience shows that you may spend quite a long time when building such a Man Machine interface.
Volvo 480 carries side by side with the long beam switch 2 small switches for heated seats … but my car has no heated seats option fitted in. Those 2 small switches are then ready to be hacked.
Well you have to drill those dummy switches, to adjust, to adjust again and again … so you'll spend quite 2 hours for only:
Bild

3. Installing inside the vehicle (Volvo 480)
Of course, you have several possible choices and you have to study the pros and cons :
a/ install Flexitune in the engine bay … which implies that you'll have to find the holes in the wall in order to connect the man machine interface. In addition, the box may suffer from dirt and heat.
Well of course, if you decide to have neither the choke pushbutton nor the LED … installation is easier and becomes trivial if the fuel selection switch remains in the engine bay.
b/ or in the passenger compartment where you'll have to find a +12V and a sound ground
c/ connect Flexitune directly to the +12V car battery
d/ or on a +12V after ignition which is far better; on the one hand, it will not be pumping any power when the car is at standstill; on the other hand an additional choke system is available is this case.

So decision is :
- Flexitune to be installed in the passenger compartment
- Flexitune connected to a +12V after ignition, in fact on the wire powering the ECU on.

In Volvo 480, ECU is located at the feet of passenger seat and can be easily accessed just after removing a few screws.

Haynes manual indicate that ECU set injectors to ground --- injectors are referred as B3 on the drawing --- via ECU output port number 21
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You have then to find port 21 and have it rerouted to Flexitune.
ECU connector looks like:
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No indication whatsoever on the outside .. you have then to have it opened (one screw and one strap to be removed) and then you'll see :
Bild
Port 21 gives access to a light green wire, the 3rd on the 2nd row. Well before cutting this wire, you had better crosscheck if it is that very wire you are looking for. Just install a plug on the light green wire and verify any electric continuity between port 21 and the plug.
Bild
Then it is time to have the light green wire cut and to install on each part a male and a female connector respectively ... then reconnect both light green wire male and female connectors.
Bild
Have the ECU connector reinstalled and now you are ready to crosscheck if the car still runs as before … which is the case indeed.
Open then the light green wire and reroute each part towards Flexitune. This rerouting is performed with 2 (blue in the picture) wires which carries exactly the same male/female connectors as the 2 parts of the light green wire:
Bild

Of course the original wire from ECU to Injectors is now cut into 2 parts but as shown above, it is quite easy to return to the initial situation just by reconnecting the male and the female plugs.

Before going on, you had better to perform some additional crosschecks. In the engine bay, the injectors connector looks like:
Bild.
As this connector is used on different cars with various injection systems (simultaneous injection on B20F but semi sequential one on B18E), it authorizes the connection of 2 sets of 2 injectors as described hereafter :
Bild
So you can crosscheck that there is electric continuity between the light green wire and each injectors sets:
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Bild
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And that is really the case.


To get +12V, decision is to use the relay which gives power to the ECU. Such a relay is located just behind the glove box :
Bild

When so doing, the global power going thru the appropriate fuse will be more or less the same. In the original car, the ECU was driving the injectors while now it is Flexitune which is in charge of … but the overall power going thru the fuse is of the same order of magnitude.
Ground is available either on ECU port 1-2 or on the body shell.
Bild

Then you just have to connect all Flexitune wires … and finally they are 11 of them :
- 2 small ones for the LED
- 2 small ones for the Choke pushbutton
- 3 small ones for the fuel selection switch (E85, SP, mixed)
- 1 larger one (1,5 mm2) for Power
- 1 (1,5 mm2) for Ground
- 1 (1,5 mm2) to the ECU
- 1 (1,5 mm2) to Injectors

During the trial phase, Flexitune is just resting in the central console:
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After trial positive results, Flexitune is then moved and screwed behind the glove box … where it remains invisible from the outside.

Now having Flexitune easily accessed, you can measure the injectors opening level just with a multimeter between +12V and INJ signal
1000 rpm :
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1000 rpm with aircon on :
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2000 rpm :
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3000 rpm :
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In addition, you can perform many other measures between +12V and INJ depending on the fuel switch position. With an engine warmed up, you'll be able to read about 0.75V (it changes very often due to the lambda sensor) with the fuel switch set to 00, about 0.80V with the fuel switch set to 50 and about 0.85V with the fuel switch set to 100.
You can also observe how ECU or INJ signals vary depending on the rpm and the fuel switch position ... in short you can learn a lot about your injection system and observe if Flexitune runs well.


4. Applicability to others Volvo 400 series
According to Haynes handbook, various injection systems have been installed on Volvo 400 Series (440, 460 & 480) :
- B18E semi sequential injection: injectors being grouped 2 by 2 on ECU ports 20 & 21 … Flexitune II is not convenient in this case and Flexitune S with only 2 installed channels should be used in instead.
- B18F & B18FT: simultaneous system on ECU port 13
- B18 EP, B18FP, B16F, B18U, B20U et B20F: simultaneous system on ECU port 21


5. Applicability to Peugeot 205 GTI et other L/LE/LE2/LU2-Jetronic systems , Motronic 1.3 ?
Please refer to the excellent 205 GTI injection system description given by Dethomaso (sorry in French) in http://www.club205gti.fr/forum/viewtopic.php?t=13213 , paying special attention to Chapter 6. One may assume that any eighties-nineties injection system based on L-Jetronic, LE-Jetronic, LE2-Jetronic ou LU2-Jetronic use sibling components .. but please crosscheck with the concerned car handbook.

As far as Peugeot 205 GTI is concerned, some evolutions took place alongside with the production but in short, from 1988 onwards, the ECU and the main injection relay are located in the ceiling of the glove box.
The main relay carries +12V after ignition, +12V when engine running, Ground, etc… (photo site 205 GTI Club de France in
http://img338.imageshack.us/my.php?imag ... cv5sk6.jpg )
The ECU connector is sibling to the Volvo 480 one with ports 9 and 12 linked to injectors, +12V and Ground respectively (photo site 205 GTI Club de France in
http://img266.imageshack.us/my.php?imag ... anczi5.jpg )
You can then reroute the wire connected to port number 12 as shown for the Volvo480 to connect ECU and INJ signals.

At the end of the production, some Peugeot 205 with XU9JA/Z, XU9JA/L use Motronic 1.3 in instead of LE2/LU2-Jetronic. According to Haynes Handbook, in this case, the four injectors are established as 2 sets of 2 injectors, each set being set to ground via ECU ports 16 and 17 respectively. Flexitune II is not convenient in this case and Flexitune S with only 2 installed channels should be used in instead.


6. Where to have Flexitune installed: in the engine bay or in the passenger compartment ?
One may say that it mainly depends where the ECU is located

If ECU is located in the passenger compartment, all signals are then available there and it is probably simpler to have Flexitune also installed there.

On the opposite, if ECU is located in the engine bay :
- Having Flexitune installed in the engine bay should imply 7 small wires (2 for LED, 2 for choke, 3 for fuel selection switch) to go thru the wall between the engine bay and the passenger compartment … down to 4 if you decide to let the fuel selection switch in the engine bay … down to 2 if you do not install the choke button and down to zero without any LED in the passenger compartment.
- Having Flexitune in the passenger compartment will imply 2 larger wires to go thru the wall : ECU and INJ

So it is more or less the same

It should be noted that the LED is a rather useful man machine interface as it indicates:
- the choke level for cold start
- the injectors saturation level blinking slow at 80%, more rapidly at 90% and very rapidly at 100%

7. Overall
For an amateur, building Flexitune II can be performed in one hour while building the Man machine interface requires 2 hours. Installing Flexitune can be done in 1 hour if you know a lot about the car's ECU .. but much more if you have to chase for the various signals you need. Having the electric schematics and drawings is a must of course.

Without such a description of the ECU system, the only possibility left is to directly hack the wires leading to the injectors, having them either cut or rerouted with the appropriate male/female injector connectors which are for instance available for 7.5 USD a pair in http://www.change2e85.com/servlet/Page? ... Connectors

So as you can see, building Flexitune is not the most consuming time part .. and for the Man/Machine interface and the flex box installation, the problem is always more or less the same whichever is the concerned flex box.




8. Adaptability to 1995 Rover 214 MK2 1L4 16V
Note : at the time of writing, no realisation performed .. only a feasibility study

Rover 214 MK2 1L4 16V has 4 injectors :
Bild
Depending on the construction year, it is either a multipoint simultaneous or sequential (or even semi sequential) injection system which has been fitted. Similar cars with less powerful engines used also Monopoint injection system.
Unfortunately, Haynes manual only describes the latter.
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while ... good luck ... its French counterpart describes the Multipoint sequential one
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The 4 injectors are driven via a connector
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which is in direct relation with ECU


ECU sits in the engine compartment, near the fuse box with a 36 pins connector
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Wire number 1 is in fact that one on top, fusebox side
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According to :
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you should then have the corresponding relation wire-function :
01 Injector n°4
02 Stepper motor phase 2
03 Stepper Motor phase 1
...
22 Stepper Motor phase 3
23 Injector n° 2
24 Injector n° 1
25 Coil (-)
26 Injector n°3
27 Stepper motor phase 4
28 12V from main relay

To have this Rover 214 running on E85, you then need to get Flexitune S and reroute wires 1, 23, 24 et 26 from the ECU to Flexitune S

Bye


Senast redigerad av Ceyal35 sön 08-06-29 16:27, redigerad totalt 12 gånger.

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InläggPostat: ons 08-06-18 22:45 
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Blev medlem: ons 07-01-03 13:14
Inlägg: 669
Ort: Halden/Asker/Trondhe
Very nice write-up. It will probably be to a lot of help future FT converters :D

_________________
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"Six months in the lab will save you an afternoon in the library"


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