[Success Story] 86 Toyota MR2 AW11 + 4A-GE small port [Frankenso]

Your chance to introduce yourself and your vehicle
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

86 Toyota MR2 AW11 + 4A-GE small port [Frankenso]

Post by pk386 »

Evening from Mississippi!

My 86 MR2 Has been an on going project for the past 8 or so years.
It's now time to get rid of the 1980s ECU and step up to something more modern :D

Goals for this project are:
1) Learn
2) Update the ECM / Wiring harness
3) Make the car / Engine electrical more manageable and easier to service
4) Upgrade to coil-on-plug Ignition
5) Upgrade the injectors to a more modern variant.
6) Delete the 'flappy door' MAF.

About the engine
- 4A-GE 7 rib block,
- Rebuilt stock bottom end with / 5-10K miles
- ARP head studs
- Supertech MLS Head Gasket
- Piston rings gapped at widest factory tolerance (For boost)
- Small Port head
- Mild port on the intake
- Stock Cams
- Compression ratio ~9:1

Long term goals are 150-200 HP at the crank.
Going to stay NA for a while but plan on running a Small Turbo one day.

Once I get some experience under my belt I hope to contribute more to the project as time allows.


Board booting:
Annotation 2019-03-10 212829.jpg
Annotation 2019-03-10 212829.jpg (149.71 KiB) Viewed 28306 times
Car:
car  2019-03-10 213916.jpg
car 2019-03-10 213916.jpg (97.07 KiB) Viewed 28306 times
Engine:
Engine.jpg
Engine.jpg (243.86 KiB) Viewed 28306 times
Crank trigger setup.
crank 2019-03-10 214604.jpg
crank 2019-03-10 214604.jpg (188.36 KiB) Viewed 28306 times
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

Welcome!

Things are too clean and too assembled :) Trigger looks like 36/2 or 36/3 or something similar? Is there a cam sensor anywhere?

Do you have JP04 and JP05 between MAx9926 and stm32?

When do you plan to crank the engine with this ECU? :)
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
User avatar
kb1gtt
contributor
contributor
Posts: 3758
Joined: Tue Sep 10, 2013 1:42 am
Location: ME of USA

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by kb1gtt »

Welcome along. Looks like some nice progress.
Welcome to the friendlier side of internet crazy :)
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

russian wrote:
Mon Mar 11, 2019 3:04 am
Things are too clean and too assembled :) Trigger looks like 36/2 or 36/3 or something similar? Is there a cam sensor anywhere?

Do you have JP04 and JP05 between MAx9926 and stm32?

When do you plan to crank the engine with this ECU? :)
Yes Nissan instills 5S in the work place some of it carries over to personal life :)
https://en.wikipedia.org/wiki/5S_(methodology)

Not Yet But I will install them. I assume that is a common mistake People Make?

Probably Looking at sometime in July. Lots of little things to do between now and then

Got an ECU Case on Sunday but it was from a '92 Camry... (and NO the Frankenso Does not fit the 92 case, PN: 89661-06061, Mounting holes for the PCB don't line up)

So I went back after work today and got a case from a 95' Camry [PN: 89661-06270]
Had to cut out one corner but it fits now.

The arrow shows where I had to cut.
trim2.png
trim2.png (703.4 KiB) Viewed 28284 times
Close up of the cut:
trim.jpg
trim.jpg (81.66 KiB) Viewed 28284 times

The 3.5mm Head Phone Jack will have to be removed and a hole cut for the LCD.
Z-height.png
Z-height.png (777.45 KiB) Viewed 28284 times
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

Got some better Photos of the trigger wheel.

The trigger wheel is from a 7A/4A-FE Engine from a '96 Corolla
tw2.jpg
tw2.jpg (39.66 KiB) Viewed 28283 times
tw1.jpg
tw1.jpg (23.82 KiB) Viewed 28283 times
I haven't welded the Trigger wheel to the Timing gear so If any one has advice on how to Clock them it would be appreciated.

What I have in the pictures is it clocked the same relationship that it had with the original timing gear.
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

That corner of the LCD I just usually cut and most of my LCDs are mounted with only three stand offs.

The 3.5mm jack I usually yank out since it does not clear vertically anyway.
pk386 wrote:
Tue Mar 12, 2019 2:24 am
I haven't welded the Trigger wheel to the Timing gear so If any one has advice on how to Clock them it would be appreciated.
Why weld anything not OEM? Why not use OEM trigger and OEM sensor?
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
theflyingdutchp
Posts: 109
Joined: Wed May 18, 2016 11:03 pm

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by theflyingdutchp »

If this has the Toyota VAST ignition (with the two wheels in the distributor) it might work with that. I've been meaning to see if I can get synchronization but life is getting in the way.

Otherwise, the RusEFI wiki supports a "Global Trigger Angle Offset" mentioned here: https://rusefi.com/wiki/index.php?title=Manual:First_engine_start#Confirm_TDC_position
If @ can confirm that its currently working, then I don't see why the clocking of your position sensor will matter too much.
88 Camry Alltrac - 3SFE w/ CT26.
Ran ok, but rings are fried, moved on...
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

theflyingdutchp wrote:
Sat Mar 16, 2019 1:15 am
If this has the Toyota VAST ignition (with the two wheels in the distributor) it might work with that. I've been meaning to see if I can get synchronization but life is getting in the way.

Otherwise, the RusEFI wiki supports a "Global Trigger Angle Offset" mentioned here: https://rusefi.com/wiki/index.php?title=Manual:First_engine_start#Confirm_TDC_position
If @ can confirm that its currently working, then I don't see why the clocking of your position sensor will matter too much.

That's good to know.

Yes it does have the VAST ignition, (Which to be honest is a brilliant design with the limited technology available at the time.)
I plan on converting to coil on plug for better control of ign timing.

For now I plan on putting the stock distributor back in for using the single trigger as a sync pulse. I'd like to use something more compact in the future to clean up the engine bay.
trigger.jpg
trigger.jpg (89.39 KiB) Viewed 28227 times
(Picture borrowed from this Link:
https://www.toymods.org.au/forums/threads/25735-DIY-4AGE-Distributor-Rebuild)
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

Global trigger offset works for sure
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

Ok so I got some time to spend with the board.

I have two questions.

1) I tried the injector test with the console.... should the indicator LEDs light up or is there a 5V jumper I am missing?


2) How is the Joy stick mapped out?
I see this after moving the Joy stick in all 4 directions + center.

Code: Select all

2019-03-22 18_53: EngineState: confirmation_joystickinfo:12
2019-03-22 18_53: EngineState: total 7 center=4@PC8
2019-03-22 18_53: EngineState: a=2@PD10
2019-03-22 18_53: EngineState: b=0@NONE
2019-03-22 18_53: EngineState: c=0@NONE
2019-03-22 18_53: EngineState: d=1@PD11
I'm not sure If something is wrong with the Joy stick but it seems like
(Directions relative to the text of the LCD)
(Right) = Next (or down the list)
(Left) = Enter
(center) = Go back to main screen
(Down) = No function.
(UP) = No function


Thanks in advance, Just trying to get a feel for how things work before I start laying out the harness and the I/O
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

2) yes, Joy stick is wired weirdly. Looks like everything on your board, what I see is expected. Ignore Joy stick for now

1) no jumpers on primary low side drivers and LEDs. Something is not right here. Pictures of both sides of the board maybe? Do you have a beeping multimeter? It would beep since it would ground outputs.
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

2)... DOH, I forgot I didn't put the LED's on the low side, LOL :roll:

I also realised that In "Injector #1" in the console is NOT INJ-01_2 on the Frankenso board. :?

(I noticed the console Triggering PB9 in the console window and started tracing the schematics to INJ-09 on the Schematics)

Now I get 3 Ticks from my Multimeter when I hit test "Injector#1" :D
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

Small Update:

more painted bits on the engine:
1.jpg
1.jpg (292.88 KiB) Viewed 28087 times
engine harness deconstruction and labeling:
2.jpg
2.jpg (212.58 KiB) Viewed 28087 times
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

Long time No update....

been working on the wiring for this project
Annotation 2020-02-17 175839.png
Annotation 2020-02-17 175839.png (1 MiB) Viewed 27394 times
Annotation 2020-02-17 1758444.png
Annotation 2020-02-17 1758444.png (1.21 MiB) Viewed 27394 times
Annotation 2020-02-17 175859.png
Annotation 2020-02-17 175859.png (1014.22 KiB) Viewed 27394 times
Annotation 2020-02-17 175822.png
Annotation 2020-02-17 175822.png (937.81 KiB) Viewed 27394 times
Annotation 2020-02-17 1758fff4.png
Annotation 2020-02-17 1758fff4.png (1.89 MiB) Viewed 27394 times
Getting close to putting it back in the Car and start working on Powering it UP!
theflyingdutchp
Posts: 109
Joined: Wed May 18, 2016 11:03 pm

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by theflyingdutchp »

Looking great! Is that a TVIS manifold? I thought the small port didn't have it?
88 Camry Alltrac - 3SFE w/ CT26.
Ran ok, but rings are fried, moved on...
User avatar
kb1gtt
contributor
contributor
Posts: 3758
Joined: Tue Sep 10, 2013 1:42 am
Location: ME of USA

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by kb1gtt »

I like the colored shrink wrap on the fuel injector wiring.
Welcome to the friendlier side of internet crazy :)
mck1117
running engine in first post
running engine in first post
Posts: 1493
Joined: Mon Jan 30, 2017 2:05 am
Location: Seattle-ish

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by mck1117 »

kb1gtt wrote:
Tue Feb 18, 2020 9:56 am
I like the colored shrink wrap on the fuel injector wiring.
Me too - that's a great idea. Maybe that would satisfy my need that would otherwise be fulfilled by buying a machine that can print on shrink wrap...
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

Oh I plan on getting a label maker as well some day...

This was I had no other option at the time due to budget constraints. :lol:
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

theflyingdutchp wrote:
Tue Feb 18, 2020 2:32 am
Looking great! Is that a TVIS manifold? I thought the small port didn't have it?
I should update the title it's actually a large port with TVIS. I got my terminology mixed up.
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

Ok so I am finally getting to the point to setting up the trigger.

I have a 36-2? Toyota Trigger wheel from a 96+ Toyota Corolla 7A-FE connected to PA5 (leading edge of the gap hits the sensor at ~126deg BTDC#1 (Image is shown with Crank at TDC #1.)
image.png
image.png (3.15 MiB) Viewed 20814 times
I have a CAM Sync pulse 0deg TDC#1 connected to PC6
image.png
image.png (1 MiB) Viewed 20814 times
I need help logging these triggers with the RUSEFI console to set up the program correctly.

I do not know how to get the console to LOG PA5 and PC6.

Also I don't know how to set this up in TunerStudio


thanks in advance.
Last edited by pk386 on Mon Sep 21, 2020 12:33 am, edited 1 time in total.
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

How do I get this to show PC6 AND PA5????
image.png
image.png (99.75 KiB) Viewed 20814 times
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

Please post your current tune to https://rusefi.com/online
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

AndreyB wrote:
Mon Sep 21, 2020 9:04 am
Please post your current tune to https://rusefi.com/online
Done.

Note I checked PIN PA5 (Crank) and PC6(CAM) at the ST discovery board and I am getting the correct pulses.


https://rusefi.com/online/index.php?engineCode=4a-GE+(custom+trigger+wheel)&sorts[uploadedMsq]=-1&sorts[uploadedLog]=-1
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

Trigger configuration is very confusing and you have a few issues with your settings.

You have 36/2 trigger wheel, which has ONE wire (not two), which is a "4 stroke without cam" (your 36/2 has nothing to do with cam)

you also have a cam/vvt sensor which should be configured via "cam/vvt" input, and you would choose some cam/vvt mode other than "inactive"

I've just made an improvement in TunerStudio project - 36/2 trigger would no longer allow "second channel" same as 36/1 and 60/2 already do not allow it. Thank you for reporting this issue :)
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

OK, I'm not sure this is correct.

1) It shows 4 ign cycles per revolution of the crank shaft?

2) I'm not seeing Pulses (events) on PC6 (Cam Trigger). (I see the D802 LED blink for the cam pulse)

3) Next steps????
2020-09-22_22_30_44_829rpm_0_maf_0.002.png
2020-09-22_22_30_44_829rpm_0_maf_0.002.png (42.92 KiB) Viewed 20730 times
Tune with new settings is here:
https://rusefi.com/online/?engineCode=4a-GE+(custom+trigger+wheel)&sorts[uploadedMsq]=-1&sorts[uploadedLog]=-1
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

AndreyB wrote:
Tue Sep 22, 2020 9:37 am
You have 36/2 trigger wheel, which has ONE wire (not two), which is a "4 stroke without cam" (your 36/2 has nothing to do with cam)
You have 36/2 trigger wheel,

which is a "4 stroke without cam"

your 36/2 has nothing to do with cam

those details matter. your current setting selection need to be changed for engine cycle to be crank driven not cam driven. setting name operation mode / speed

I would not bother with cam sensor until your engine is running
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
mck1117
running engine in first post
running engine in first post
Posts: 1493
Joined: Mon Jan 30, 2017 2:05 am
Location: Seattle-ish

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by mck1117 »

AndreyB wrote:
Wed Sep 23, 2020 7:47 am
which is a "4 stroke without cam"
This does, however, mean that you'll need to configure the ignition in "wasted spark" mode, and enable "two wire wasted" so that it will operate in wasted spark using all 4 outputs.
User avatar
AndreyB
Site Admin
Posts: 14292
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by AndreyB »

Please change "advanced trigger" -> "vvt mode" from inactive to "first half"

but that would probably not help, open question why signals are not appearing on engine sniffer
Very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions

Always looking for C/C++/Java/PHP developers! Please help us see https://rusefi.com/s/howtocontribute
pk386
Posts: 37
Joined: Fri Feb 08, 2019 11:12 pm
Location: Ridgeland, MS

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by pk386 »

Ok This makes more sense. I have one Ignition pulse per cylinder per 720deg revolution
2020-09-23_17_57_14_104rpm_0_maf_0.004.png
2020-09-23_17_57_14_104rpm_0_maf_0.004.png (40.41 KiB) Viewed 20685 times
I'll get a timing light on it soon.

MY Cam is set to pulse at 0deg TDC #1

but MY gap on my 36-2 is at ~126BTDC #1. does my Global off set need to be -126?

Still not seeing events on the cam pulse :-/

Tune is here:
https://rusefi.com/online/index.php?engineCode=4a-GE+(custom+trigger+wheel)&sorts[uploadedMsq]=-1&sorts[uploadedLog]=-1
mck1117
running engine in first post
running engine in first post
Posts: 1493
Joined: Mon Jan 30, 2017 2:05 am
Location: Seattle-ish

Re: 86 Toyota MR2 AW11 + 4A-GE small port

Post by mck1117 »

pk386 wrote:
Wed Sep 23, 2020 11:10 pm

but MY gap on my 36-2 is at ~126BTDC #1. does my Global off set need to be -126?
I don't remember off the top of my head if it's + or - 126, but it's easy enough to figure out with a timing light (or just trying to start it!).
pk386 wrote:
Wed Sep 23, 2020 11:10 pm
Still not seeing events on the cam pulse :-/
Don't worry about the cam sensor yet - get it running on crank-only to start with.
Post Reply