Captain Awesome's 4y EFI Conversion

[SideKick]

The problem is the Hilux is my main form of trasportation including to work and back. I can't go without if for a couple of days to install the EFI

I took leave for that Wednesday, Thursday and Monday to have that 7 days off so will have to make a plan to do it then . . .

[LouisZ]

Kry eers al die parte, maak skoon en doen van die goed waar mens net hoef af te bout en en weer op. Soos Willie se, daar gaan 'n dinge wees wat jy teen 9 uur die aand. Ook wees reg vir bolts&nuts wat val waar jy dit nie kry of wat strip.

Dan bedrading, doen dit vroeg oggend, een fout is te veel.

[fredster]

Hi Stephan,

Die plek met die dissy's is SA Autoparts (pers gebou), en vir die ander manne wat dalk een daar gaan soek - presies waaar stephan gese het - moenie eens met die ander probeer praat nie - Vra vir die voorman met die grys baard - Hy ken sy storie - het sommer die ICV ook daar gekry vir R350, so die inkopie lys raak korter :)

[fredster]

Terwyl ek nou Stephan se thread hier hi-jack - Met daai dual pickup dissy - het ek nogsteeds die TP100 module nodig vir my dicktator setup of nie?

[SideKick]

Terwyl ek nou Stephan se thread hier hi-jack - Met daai dual pickup dissy - het ek nogsteeds die TP100 module nodig vir my dicktator setup of nie?

Daai ignitor en coil was ook volgende op my vrae lys . . .

Kom ons kyk maar wat sê die slim mense vir ons.

[Mr_B]

If you going with the Dicktator setup... yes you need an external ignitor(TP100). I believe the ignitor is built into the GoTech and Spitronics. The drawback with "built-in" is that if it gives hassles you got to send the whole EMU in for repairs. If it's external to the EMU, then you can just replace the faulty ignitor.

Dicktator make their own ignitor, but I don't think there's any really difference to the other(cheaper) options on the market.

Dicktators one just looks cool:

[SideKick]

If you going with the Dicktator setup... yes you need an external ignitor(TP100). I believe the ignitor is built into the GoTech and Spitronics. The drawback with "built-in" is that if it gives hassles you got to send the whole EMU in for repairs. If it's external to the EMU, then you can just replace the faulty ignitor.

Dicktator make their own ignitor, but I don't think there's any really difference to the other(cheaper) options on the market.

Dicktators one just looks cool:

That TP100 is the ignitor, isn't it?

What about the coil?

[Mr_B]

The coil is inside the distributor if you are using a Toyota 3YE dissi! The ignitor(TP100) fires/triggers the coil!

[fredster]

Ok,

So I have the following already:
3YE EFI intake manifold semi complete,
3YE Dual pickup statc dissy,
2.3 Kombi ICV,
Velociti fuel pump
Metal Fuel Filter unit

I believe I still need the following:
2nd Water Temp sensor,
Air Temp Sensor (picking this up tomorrow)
Dicktator unit + TP100 module,
Heat Shield to go between intake and Exhaust manifold,
Intake manifold gasket

Also I'm looking for a SFA Hilux 3y/4y Sump to replace the current fong kong 4y one (which already has a fat dent from the diff :) ), so if anybody can point me to one it will be extremely helpful.

Have I covered everything that I'll need to do the install on my chinese 4y? Or am I still missing some parts?

[The Legend]

Ok,

So I have the following already:
3YE EFI intake manifold semi complete,
3YE Dual pickup statc dissy,
2.3 Kombi ICV,
Velociti fuel pump
Metal Fuel Filter unit

I believe I still need the following:
2nd Water Temp sensor,
Air Temp Sensor (picking this up tomorrow)
Dicktator unit + TP100 module,
Heat Shield to go between intake and Exhaust manifold,
Intake manifold gasket

Also I'm looking for a SFA Hilux 3y/4y Sump to replace the current fong kong 4y one (which already has a fat dent from the diff :) ), so if anybody can point me to one it will be extremely helpful.

Have I covered everything that I'll need to do the install on my chinese 4y? Or am I still missing some parts?

Contact Louis at 4x4 megaworld Menlyn.May be he can help you with one.

[fredster]

Mr B? Comments on my list - Have I covered all or have I missed something, or is there something that I need to watch out for?

Thanks
Freddy

[LouisZ]

Dizzy setup is very important

[Mr_B]

Fredster, have you looked through the list on the thread: viewtopic.php?f=3&t=16112" onclick="window.open(this.href);return false;

I think everything is there... when you say the intake mani is semi complete... what exactly is missing?

[fredster]

It's missing the rubbers between the fuel rail and the lower portion of the intake, as well as a few bolts. Have managed to find other spacers from a scrappy that I can mod to the required length.

I eventually found your article, and compared my kit list with yours and save for a few pipes and relays it looked complete. Then Louis helped me out by pointing out a few other possibly obvious components that I have overlooked.

So at the moment my kit list has been updated with the mag adaptor and a new throttle cable (std carb cable does not quite make the distance). I have also purchased the additional piping for the new fueler setup.

What I need to come up with is a solution around the fact that the velociti pump intake is about 18mm and the pipe into the tank will only be 8mm. So some form of reducer is required.

Other than that it is just the uncertainty of the entire job :)

[SideKick]

Hi Guy

So my EFI project is back in motion.

Anyone know where I can source a 3Y intake (with the needed bits)? I can't find anywhere

[SideKick]

Hey all

Like I said. Project EFI is back in motion.

What I got earlier this week:

Standard Dictator ECU
TP100 Ignitor
MAG Adaptor

I hope these are all correct!!!!

[SideKick]

Hey guys

What I also got all the way from JHB thanks to Dawie's help!

What I would like to know. Is there anything I can/should do to prepare this intake for installation?

The distributor I got is so full of oil/grease/dirt, I'm gonna wash it properly with soap.

But what do I do with the intake? I obviously want to get rid of that yellow paint . . .

[Mud Dog]

Cool Stefan! Grease and oils should be washed off with an engine cleaner before anything. Then you'll obviously have to strip it down ... the alu parts will brighten up with some elbow grease together with a stainless / brass wire brush, followed by a polishing wheel fitted to a variable speed drill. All the steel brackets and clips can be done the same way if the galvanising is still good, otherwise you can clean them up, treat any rust spots and spray-paint them or have them re-galvanised.

Good luck!

[The Legend]

Thats how it looks like when Louis Zanoli (4x4 megaworld) tackle it with his tools.

[fredster]

Hi Stefan,

I have a slightly cleaner plenum and bottom half with all the other bits and pieces. I bought a 2nd unit just to make sure I had all of what I needed (nothing succeeds like excess). Let me know if you are interested. I have just finished putting all the EFI bits on Skorro, so the rest is spares ...

Freddy

[zepplin]

And if you still need an ICV I have a rotary type unit from a VW that was on my 22R EFI before the 5VZ conversion - yours for R200.

[SideKick]

Hi Guys

I got all those parts already . . . .Thanks.

[SideKick]

So I FINALLY started the get this EFI installed.

Here are the first couple of pics:

BEFORE:

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Before

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Before

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Before

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First things first. I gave the engine its first wash ever:

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Washed

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Then I started stripping.

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Stripped

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Stripped

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Stripped

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[Stef]

Sitting here in the office and have got meetings comming out my my ears!

Also don't have tools, or the needed two point plug thingy, to connect it up to the batt now to test anyway . . .

You'll be hard pressed to find that plug, unless the harness is still there then just ut it out wit enough slack.

Got my ICV off a Golf II (not sure if 1800 or 2L), unfortunately no harness. I used those ferrules with the blue plastic coating that you buy at any hardware/midas store and reshaped one end with the crimper to fit sungly on the pins of the ICV.

I think MR B is correct, the 1800 ICV should also work, VW probably fitted the bigger one on the smaller engine as well. Mine has a 19mm ID & believe me, in the Dictator settings the home postion is towards the lower end of the range.

[SideKick]

Powerflow modified my branch a bit to allow for the new intake.

They did it free of charge Thanks a lot guys!!!!

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[SideKick]

My new 3YE intake.

Before:

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Before

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Stripped:

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Stripped

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Cleaned:

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Cleaned

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Cleaned

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Cleaned

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Cleaned

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Cleaned

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Cleaned

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OK. I know it's not as clean as it can be, but it's clean enough!

Took me hours of scrubbing to get them this clean

5H!T35t job EVER!!!

[SideKick]

Next up is the heat insulation for the branch and the gaskets for the throttle body.

When I picked up my Hilux from Powerflow, I spoke to Roddy quickly and he told me to go to masterparts regarding the gaskets.

Went there looking for the gasket material and the heat insulation. They couldn't help me with either, but told me to try Nesco engineering, or Midas. Said I should ask for Flexoid or Vellumoid for the gasket material.

Went to Midas and asked for Vellumoid, but they came back with a sheet of Flexoid. Somewhere along the line I was told to avoid Flexoid because it is made for oil resistance. That the paper does the opposite with petrol and soaks it up. (Later reading here http://www.vellumoid.com/sheet.html seems to prove other wise. It will work, but is an inferior product to Vellumoid. Also more reading on that site indicates that you actually want a specific type of Vellumoid. Velcar B-10. Not just any type of Vellumoid) Anyway, Midas, Autozone, all those places when I asked for Vellumoid, they try and give me Flexoid. When I got to Nesco Engineering, they told me I should use Perminite and that it will work better. But they only sell it in 1m x 1m sheets. Told me to try Goldco for smaller sheets.

They also told me to not use those heat insulation sheets, but rather the stuff they use for turbos that you wrap around the pipes. Told me to get it at SA Autoparts (Moags).

Goldco didn't have stock of the gasket material.

Went to Moags and got a 10m roll of Foil-Backed Fiberglass Heat Insulation that is normally used for turbos. Thats the smallest quantity the sell Cost me R300. I used just above 4m.

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Foil-Backed Fiberglass Heat Insulation

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Branch wrapped with Foil-Backed Fiberglass Heat Insulation and tied down with galvanised wire

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I wrapped the branch with the roll, foil on the inside, and tied the ends down with thin galvanised wire. Was told once the insulation is heated up properly the first time then it will stay in place.

Back to the drawing boards with the gasket material at that point. Started calling around looking for a place that can supply me. After many referrals I end up at a place called Gasket & Shim Industries in Montaque Gardens. Spoke to the sales lady there (Can't remember her name ) I told her what I need and she told me they could help me out. I took the throttle body with to tell her what I need and to show her what I need it for. Because of the small quantity I need and the big quantities they work with, she organised me two pieces of cut-offs for free Tesnit JMP 6000. This stuff is waaayyyyy overkill for what I actually need. Comparing it to Flexoid. Flexoid can handle pressure up to 40 bar and JPM 6000 can go up to 120 bar. Flexoid can handle temperatures up to 120 degrees and the JPM 6000 can handle up to 440 degrees. Like I said, overkill, but it was free

0.8mm thick, but the stuff is quite hard compared to Flexoid. Use a VERY sharp carpet knife to cut out the gaskets.

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JMP 6000

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My new gaskets

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Didn't even use a half of the one sheet I got for the gaskets.

I have 6m of heat insutating left. R150 for the next guys that want to install EFI. And he can get the gasket material for free

[Willied]

I had similar wrapping on my brospeed branch when running the carb to protect it from percolation.. I found that the wrap tends to draw moisture from the air like and exhaust would.. Had scales of rust on the branch within 6 months of use..

Something to look out for maybe as a cautionary note.

[dustbuster]

Stephan what happened with you EFI?