Installing Mp3.1

[pug_ham 244 3 Cars]

If you are planning on keeping the ecu in the engine bay the wiring is kinda easier but you still need the old loom taking out to seperate the wires you need out so there isn't much difference.

 

You can take the fuel pump wire from the tachy relay plug & run that out into the engine bay instead of over the dash (connects to wire from pin 1 on double relay) & the coil feed wire (has your car got inlet mounted coil or not? ) to reach the double injection relay (pin 14) / coilpack (pin 4) but iirc they are split in the ZX engine bay loom & not before the inner wing plug. (Both these wires might need extending).

 

The rev counter wire can also be taken from the original loom to the coil & joined to the one from the ecu plug (pin 21) & the K light (ecu plug pin 17) will need extending to the under dash plug / clocks if you choose to wire it in.

 

That should be it, just four connections til your up & running.

 

Graham.

[welshpug 1,657]

thanks graham, once I've got the old loom off and checked it all out and removed the unwanted wires and plugs it should be plain sailing when I've got the new components bolted on.

[welshpug 1,657]

XU9J4 flywheel and clutch fitted;

http://i47.photobucket.com/albums/f169/wel...Ti/PICT0363.jpg

 

pulled the ECU wiring out over the steering column, what a faff that was!;

http://i47.photobucket.com/albums/f169/wel...Ti/PICT0379.jpg

 

Original BE1 gearbox has TDC and diag sensor holes ;

http://i47.photobucket.com/albums/f169/wel...Ti/PICT0366.jpg

 

also fitted an XU10 starter wile I was at it (had a spare one);

 

http://i47.photobucket.com/albums/f169/wel...Ti/PICT0377.jpg

 

I have a separate electrical problem at the moment, since puttign the engine back in and connecting the wiring back up I have no signs of live whatsoever, so I cant close the window!

[welshpug 1,657]

pulled the 205 loom off the car, from the engine bay into the cabin seemed easier than trying to get teh ECU plug through the hole in the bulkhead as the rubber grommit has been sat on the cabin side of the bulkhead for months!

 

 

I wasnt sure where to start with the wiring but seeing as the ZX loom is self contained in the engine bay I thought **** it! chop!

I cut it just where it goes through the grommit

 

then I pulled the other side of the cut wires out of the loom, cut the ones that linked to the starter wire and I'm left with the sensor multiplug and a smallhandfull of other wires to be connected

(I pulled the 2 pins out of the tacky relay plug)

 

much slimmer!

 

nice and neat

 

I've clipped the loom up to the existing section that is just behind the brake lines, it goes right across to the other side behind the expansion tank.

ECU will sit here I think (will need to make a bracket I think)

 

getting there

 

[welshpug 1,657]

refit intake manifold, bolt down stat housing, replace injector wiring, extend 3 wires and join ZX loom to 205 loom and its done (all wires taped together for now so I dont lose any!)

 

[welshpug 1,657]

job jobbed!!

 

just got to work out the rev counter now.

 

pics of where I've routed the wires in the morning (its dark!!)

 

not sure what to do with the ECU yet, either make a bracket and bolt it to the inner wing, or find a battery box from a 306.

[pug_ham 244 3 Cars]

Nice one.

 

It really is an easy swap & makes such a difference to the way the car drives imo.

 

Graham.

[welshpug 1,657]

yeah, now i've completed it I have to say wirign is a lot easier when you break it down.

 

I've yet to drive it though! no coolant yet and I was sitting there soldering iron in one hand and Heineken in the other!

[welshpug 1,657]

I've driven it, bloody hell!

 

what's the rev limit with this ecu?

 

 

oh, and I havent got a K-Light facility on my dash

 

a few more tidy up pictures,

 

ECU temporarily bolted down, doesnt fit here when inside the metal box

 

 

Injection double relay has a secure position without drilling any holes

 

 

map sensor connected to bottom of throttle body

 

[pug_ham 244 3 Cars]

AFAIK the rev limit on the standard ZX ecu is about 6.6k, thats what was indicated approx on the4 rpm of the Volcane I drove with MP3.1 fitted anyway.

 

As I've said on the PSOOC topic, I don't think the vacuum capsule offtake is ideal to use for the map sensor as its a lot smaller in diameter inside the tb & located the wrong side of the throttle butterfly imo. The ZX map sensor pipe is about 2mm internal diameter & on the main part of the inlet just above where the TB is fitted.

 

Graham.

[welshpug 1,657]

I did wonder if it would be big enough but I havent checked the size of it, but it is after the T/B and bigger than the 2 you mention, I know they're tiny!

 

will check the size of the hole shortly,

 

heres a pic of the old unit, its identical to the ZX t/b bar the actual spindle where the tps sits, so if the 205 t/b spindle was shortened it would work.

 

 

also there is a damper in the pipe, courtesy of my ZX

 

I put it there as its the most convenient place, and near identical to where PSA mounted the MAP sensor on the XU10J4RS.

[pug_ham 244 3 Cars]

I've never seen an offtake like that on an 8v TB, what was fitted to it originally?

 

I didn't fit the damper on mine, I've got a couple somewhere downstairs. One from a 405 & one from a ZX.

 

Graham.

[welshpug 1,657]

Thats my original T/B, that port had a blanking rubber on it.

 

IIRC i saw in the service history that it has been replaced by a dealer many years ago, something about the jubilee clip being overtightened I think!

 

It looks identical to my ZX's T/B bar the cam for the throttle cable, and the length of the Butterfly's spindle.

 

I used the damper as it was still attached to the hose I used

[pug_ham 244 3 Cars]

Thats my original T/B, that port had a blanking rubber on it.

OK, wonder if that was one from an A?C car.

It looks identical to my ZX's T/B bar the cam for the throttle cable, and the length of the Butterfly's spindle.

Yeah, thats all the difference is, well that & a slightly different hole spacing for the TPS fitting.

 

Graham.

[welshpug 1,657]

OK, wonder if that was one from an A?C car.

 

Yeah, thats all the difference is, well that & a slightly different hole spacing for the TPS fitting.

 

Graham.

 

not in my case! I tried the ZX pot on my original unit and it would have done was it not for the longer spindle, so this must definitely be originally meant for a different car, but a dealer fitted it!

[welshpug 1,657]

checked the size of the hole in the bottom of the T/B, about 3mm

 

tried this as suggested in another thread

 

 

didnt work, so I persevered with an adapter, which works

 

 

its soldered inline here, with an additional wire going across to wire 112.

 

theres not much space left in here, I wish the XU used a rad with an inegral expansion tank so I could bolt the ECU down on the inner wing, its going to have a bracket and sit right here instead.

 

 

on a rally car with a relocated battery I'd just bolt it to the battery tray, not an option here unfortunately.

 

just a quick thought, I've heard of the use of a BX rad in a 205, do these have an integral expansion tank?