Test car Ford Fiesta XR 2i 1990

[Mad Max]

So today I begin to assembly my own version of Rusefi.
I need few of them because me and my friend we have 2 Fiesta Efi CVH, 1,6 110 HP in stock and 3-d one is rally car (CVH 1.4).
Also my brother planning to restore Ford Granada 1978 2,8 V6 in a future.
So I'm very interested in this project.

Ok, in stock EFI we have
- Inductive Crank sensor
- MAP
- TPS
- Coolant temp
- Air temp
- Speed sensor
- Passive Dual coil (2x2Cyl)
- 4 Injectors (2x2)
- Fuel Pump relay
- Absorber
- Idle valve
- Lambda

Lambda, absorber and speed sensor already deleted from system- I don't need them.
MAP is standard one with voltage out (0,2-4,8V)
TPS is just precise potentiometer(0,2-4,8V)
Coolant and engine temp- 2 thermistors
Coil is usual dual coil which works on 2 sparks at once. So I need 2 Darlington to drive it.

Here is schematic:

EFI.JPG (102.66 KiB) Viewed 24500 times

[AndreyB]

What is the position sensor(s) setup on this car? VR or Hall? Any idea what kind of pattern this is?

I suggest when you get a discovery board, get the board grounded & position sensor signal hooked up to PC6 pin on the board and get the dev console running so that you can see something like

[AndreyB]

I have just finished an instruction how to setup the board with pre-compiled binaries.

[Mad Max]

Nice post! Just what I'll need soon.

[kb1gtt]

Do you know a source for the OEM ECU PCB side of the connector? I think that's the same as what I made for @.

How would you replace the ECU? Are you chopping the harness up, removing and wiring direct, or using an ECU connector broken off a junk yard ECU or something like that.

When you say MAP, do you mean OEM hot wire, pressure sensor like MPX4100, or other?

[Mad Max]

I have stock connector and case from bricked ECU.
I don't will change any wiring harness.
Also I'll have possibility to install any ECU - stock of Rusefi.
So car will drivable at any time.

MAP- I mean stock OEM MAP-sensor (I don't have "hot wire MAF" or like that)

Maybe I'll change TPS to some other because my stock is very old and it can give me errors.
New one is very expensive (about 80-90 USD).

So I bought today 90% of electronics components to assembly RUSEFI MM Ver.
When it'll be ready you'll see complete schematic.

Here is my test-PCB:
Of course CPU-board and other components will be placed on component layer




Final version will be same - CPU board attached to peripheral board.

[AndreyB]

@, what is your plan of attach - I mean do you plan to solder the whole thing right away, or do you plan to solder maybe just the CKP sensor input & try to crank it to confirm signal input?

My own over-conservative approach a T-shaped harness extension so I can plug both stock ECU and rusEfi at the same time, with some wires plugged off the stock ECU.

[AndreyB]

Do you know a source for the OEM ECU PCB side of the connector? I think that's the same as what I made for @

Right. @, can you post a pic of your ECU harness connector?

[Mad Max]

I have same connector and I'll use it.
My connector is in garage now so I'll see it tomorrow.
In my case impossible connect 2 ECU at ones(also I don't want to do it). Because harness come from engine bay and ECU placed under instrument panel.
So access to harness is difficult. But ECU unit replace is simple.

[Mad Max]

Russian, on pic upper you can see connectors for Discovery.
I'll plan to use them in future.
So when we will make additional input-output or other ver It'll be necessary to replace peripheral board only.

By the way- my ver will be 6 cyl but with 3 coil driver and 3 injector drivers. (common schematic for 80-90' cars BMW,Opel, Honda,Mazda, Subaru etc)
I don't think that we need individual drivers now.

[AndreyB]

Are you going to run some wires between the discovery connector and the MOSFETs? I mean how permanent would this be - would there be a chance to re-wire this if needed?

As a start pinout you should refer to https://svn.code.sf.net/p/rusefi/code/trunk/firmware/config/boards/arro_board.h

[Mad Max]

As you I can see this is universal modelling PCB.
It will be total temporary board. Until we will make final schematic there is no reason to make normal PCB.
So I want make a first HW edition. Then we will see how it's work and if necessary change schematic- other solutions, other devices, additional schematics.

We need something to begin whole process.

[frig]

So I want make a first HW edition. Then we will see how it's work and if necessary change schematic- other solutions, other devices, additional schematics.

Its good idea.

[Mad Max]

My conception of schematics some changed.
I want to make non protected ECU (direct input, direct output without additional OP and other isolating chip's.

[kb1gtt]

OEM's can use far less protected IO as they have very strict control over the build process. This is why they don't need the protection over 5V and such, as they can guarantee that it will not exceed 5V by the MFG process. In the DIY world, it really sucks when you have one small brain fart and blow hundreds to thousands on equipment. I'd suggest using the protection, it's cheap and will very likely save you large piles of $.

[Mad Max]

I mean it'll be temporary solution- just for testing.
If non-protected ECU will work well into final version will be added protection.

[AndreyB]

By the way, I really like your prototyping board.

But it it is really made in Ukraine I guess I am out of luck.

[Mad Max]

Russian thank's
By the way I spend about 30 sec in electronics shop to choose this modelling board.
It doesn't matter which board to use.
I've just buy components in SOIC packages (to use them in future) because I found this PCB.
Otherwise I bought same components in DIP and use any PCB.

My assembly process of RusEfi ver. MM is going well. After few days I'll begin testing input and output for for ECU ports and sensors compatibility (Low-high voltage stability, input range for drivers, pulse shapes etc.)
After that (next week I hope) I'll install Discovery on PCB...

[AndreyB]

My assembly process of RusEfi ver. MM is going well. After few days I'll begin testing input and output for for ECU ports and sensors compatibility (Low-high voltage stability, input range for drivers, pulse shapes etc.)
After that (next week I hope) I'll install Discovery on PCB...

@ is taking the lead on the 2nd engine to run rusEfi but @ is following closely!

Please poke me when you will be closer to firing everything up, I have hints how to test everything step by step

[Mad Max]

Competition is good way to choose best schematic.

[AndreyB]

- Inductive Crank sensor

Want more details here. Is it 60-2? is it 30-1? What is it?

[Mad Max]

I have 36-1
All EFI/ CFI Fiesta, Escort, Orion with CVH engine from 1983 to 1997 have the same.

[AndreyB]

I have 36-1

Gotcha.
I will get the position sensor decoder code ready. Poke me if you would like to test basic sensor input before actually trying to start the car

[Mad Max]

It will be nice to have decoder code.
I'm busy this days and mostly mind about schematics (how to do).
And maybe I'll make testing stand with small 36-1 trigger. Now don't know.
Also I'll need code for ignition twin coil (spark at TDC into 1-st coil, at BDC at 2-d).

[AndreyB]

It will be nice to have decoder code.
I'm busy this days and mostly mind about schematics (how to do).
And maybe I'll make testing stand with small 36-1 trigger. Now don't know.
Also I'll need code for ignition twin coil (spark at TDC into 1-st coil, at BDC at 2-d).

Do you know where your TDC is relatively to the missed tooth?

I mean realistically we need to test something before attempting the whole thing. Do you want to put an op-amp (for isolation) & VR circuit on a running car? This case you should at least see a functional tachometer. If you do not want to isolate from stock ECU we should still test, like wire up just the position sensor and crank the engine.

[Mad Max]

Here I found all info about my EEC-4 system.
http://www.megamanual.com/ms2/EDIS.htm
It's look like I have missed tooth 50 deg before TDC.

I have EDIS system so I don't need VR board.
But I'll change schematic to check my VR module and other ignition components.

No. I don't will make any parallel connections.
I have free case from stock ECU so I'll use it.
I can check tacho without car.

[AndreyB]

I can check tacho without car.

Let me get you the code & let's plan this.

[AndreyB]

I can check tacho without car.

https://svn.code.sf.net/p/rusefi/code/trunk/firmware_binary/rusefi.fiesta.hex
this binary should print your current RPM into plain text console on the micro usb socket, it is compiled for 36-1 wheel

[Mad Max]

WOW! What the speed!?
I'll try to check it 2 days later.

Russian, thanks a lot!

[AndreyB]

rusefi.fiesta.hex now has position sensor simulator and coil is programmed (probably at the wrong angles, but this is easy to fix in your engine file)