What do I need to convert my MFi RS Turbo to run EFi? Updated 12/01/12!

[mentalasanything]

It has struck me that other than the Cossie brake upgrade, there is a question that keeps on getting asked day after day! "What do I need to convert my MFi RS Turbo to run EFi?" I propose a Sticky thread on a "Basic" conversion using OFAB or OFAC. I've done a lot of research into this as I plan to do this conversion myself. Before I start here's a quick list of my references: www.rsbible.co.uk - Very descriptive, good pictures and diagrams. www.extraefi.co.uk - A good EDIS diagrams www.passionford.com Our friendly Forum www.dainst.com lots of EDIS info Other sites I may have to add! Here's my 2p's worth feel free to add, remove or CONSTRUCTIVELY criticise: You will need: 1) CVH EFi Head (XR2i or Fiesta RS Turbo) or MFI>EFI sandwich plate. 2) Complete EFi inlet (Inlet manifold, throttle body, injectors, fuel rail, pressure regulator, Throttle position sensor, Idle speed control valve and injector wiring loom) 3) ECU and engine Loom (OFAB or OFAC, loom to suit) An XR3i EFi loom can be used with OFAC. 4) Electronic Distributorless Ignition System (EDIS-4 unit, Crank Position Sensor and Coilpack). 5) Suitable HT Leads. 6) Some form of Crank Position Sensor pickup, either: .....a) A drilled block and EFi flywheel. .....b) Sierra CVH crank and alternator pulleys with sierra CVH lower timing belt cover and ribbed aux belt. .....c) A N Other 36-1 tooth trigger wheel on the crank with Crank Position Sensor bracket (Oddkid creations have been mentioned). 7) MAP sensor (ECU Specific). 8) CO2 Potentiometer. 9) Vehicle Speed sensor. 10) Fuel hose from fuel filter to fuel rail. 11) Engine sensors for the ECU type chosen. 12) XR2i or XR3i EFI throttle pedal and throttle cable. 13) Fiesta RS Turbo rocker cover and charge carrier (ERST ones may be used but a bit fiddly). 14) OFAB will need a MAP sensor suppressor You won't need: 1) XR3i EFi Dash pod and rev counter. Contrary to popular belief you don't need an XR3i EFi Rev counter. If you intend to keep the wiring as it is, the standard output is from pin 10 of the EDIS which is one of the 2 coil drive outputs. This will obviously only give you half the reading of the current revs which the XR3i EFi rev counter can interperate correctly but the S2 one can't as it would need an input from both coil drive outputs. The way around this is to add an output to pin 11 of the EDIS which is its CTO (Clean Tacho Output). There is no pin there on the XR3i loom and I'm not sure about the FRST loom but one can be easily added. I just used a diferent bit on my soldering iron to melt a hole through the back section of the casing, stole a pin from a spare EDIS connector and pushed it through. This was then run as far as the RPM suppressor and plugged directly into the green cable running to the dash bypassing the suppressor and the output from pin 10. A few things to note: 1) If you want to run anything other than standard settings, the relevant chip and injectors are required (165/195chip, Bosch "beige" 701 injectors). 2) If you want to run more than 1 bar (14.5 psi) of boost, you will have to use an alternative MAP sensor. For OFAB you can use a Cosworth 3 bar MAP sensor which can measure up to 2 bar of boost (1 bar atmospheric pressure and 2 bar positive boost). For OFAC, you can use a Small Turbo Escort Cosworth MAP sensor. This sensor is a 2.5 bar item (1 bar atmospheric pressure and 1.5 bar positive boost). 3) If you want to use an XR3i EFi car & engine loom (1AfA) whith OFAC there are no pinout changes. If you want to use an XR3i EFi car & engine loom (1AfA) whith OFAB visit www.rsbible.co.uk for the pinout changes. 4) You may get a seemingly low reading from the rev counter. If so run a wire from pin 11 of the EDIS module as described above. 5) If you use the Sierra 1.8 CVH crank pulley you will need the Sierra 1.8 CVH alternator bracket. This bracket needs 5mm machined off the one side to align it with the crank pulley. You will also need a 5mm washer (As sold by Oddkidd creations) to fit between the crank pulley and the retaining bolt. How to with FRST loom: I wont make this a full step by step, that would be dificult as there are a few diferent scenarios and would take forever. If you have chosen the correct loom for the ECU then no pinout changes need to be made (Obviously). Thus making neither OFAB nor OFAC harder than eachother. 1) Disconnect the battery! 2) Fit all of your mechanical parts. 3) Fit all of your sensors. 4) Tape back the parts of the original loom not required. Once finished and tested you can cut out and remove any parts of the loom not required if you like. 5) Install the EFi engine loom. 6) Connect the engine loom to the car loom. You will need to do a bit of chopping and changing. This bit can be tricky, but I will re-post this diagram by passionford member Rab as I think it shows it quite well: 7) Run a wire from the rev counter input to pin 11 of the EDIS-4 unit. 8) Connect up the engine loom to the sensors, cooling Fan, ECU, coilpack, Idle speed control valve and EDIS (Some wires may need to be extended eg. Fan and ISCV). 9) Double check everything! 10) Cross your fingers and fire up the car! If you use the loom from an EFi XR3i it's even easier, just fit the loom to the car, plug in an OFAC ECU and MAP sensor and you're away. That's my plan: One almost complete loom, just needs a trial fit and taping up. I'm not claiming this is complete, but it should answer most of the repetitive questions! and a big thanks to everyone for the info I've gathered. Lee

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[Karlos G]

Good work mate thanks!
Sticky would be a good idea too!

[mentalasanything]

Originally Posted by Karlos G

Good work mate thanks!
Sticky would be a good idea too!

Have requested it!

It struck me that I was going to offer an answer to yet another EFi question this morning so thought why not, I was waiting for the missus to get ready so I had a a spare hour!

Cheers

[Karlos G]

I cant see why it would'nt be made a sticky, the Cossie brake conversion was and questions related to MFI-EFI conversion are asked probably just as much!

[Zetecfiesta]

deffo mate, good information!!

[Chris69]

nice writeup mate its about time somebody wrote one and got it made a sticky
As a side note its worth mentioning in order to get a working standard look rev counter a 90 spec Xr3i item will be needed and conection to the edis module using pin 11 for the feed to it

[mentalasanything]

Originally Posted by Chris69

nice writeup mate its about time somebody wrote one and got it made a sticky
As a side note its worth mentioning in order to get a working standard look rev counter a 90 spec Xr3i item will be needed and conection to the edis module using pin 11 for the feed to it

Added! I forgot about this, may have a workaround rather than replacement though......

I have read that you can use the coil of a relay to boost the tacho signal (See "Hi Voltage diagram" on page 2 here: http://www.extraefi.co.uk/Drawings/P...cho_Wiring.pdf) I know this is for a megasquirt and I haven't tried it. But it may work for the non EFi rev counters. Anyone have any oppinions to offer on this?

Lee

[rstel1]

nice one

sticky all day long

[notroubleclubber]

So what your saying is i can do the complete mfi to efi swap using a donor xr2i? My mfi head needs a rebuild so would use the efi head and use a sierra pulley system for the cps.Then i can use everything else from the xr2i and will use my mfi charge carrier as its nice and polished and make it fit somehow!!

Am i correct?

Once the efi is installed is it ok to turn up the boost to say 15psi and the fuel will automatically be adjusted?

[mentalasanything]

Originally Posted by notroubleclubber

So what your saying is i can do the complete mfi to efi swap using a donor xr2i? My mfi head needs a rebuild so would use the efi head and use a sierra pulley system for the cps.Then i can use everything else from the xr2i and will use my mfi charge carrier as its nice and polished and make it fit somehow!!

Am i correct?

Once the efi is installed is it ok to turn up the boost to say 15psi and the fuel will automatically be adjusted?

I dont know about the XR2i loom, but you can use the complete head and inlet without any problems, they are the same as the Fiesta RS Turbo items. You can use your charge carrier, the hose connecting it to the throttle body may be tight but use a silicone hose and a very light smearing of fairy liquid and it'll go on.

As for the boost, you should get the car set up by a tuner initially, if only to get the CO levels right. Once that is done, the ECU and EDIS module should work out the ignition and fueling based on how much boost the MAP sensor sees. You will need a 195 chip and Beige 701 injectors to run that much boost though.

Hope that helps

Lee

[nigel b]

you can use the escort cossie 2.5bar map sensor on ofac

[notroubleclubber]

Ive now heard i would need a fiesta turbo ecu and matching map sensor? Is this true or can i use everything from xr2i and just get the 701s and cossie map sensor?

[daveselwood]

does this work as im converting a series1 to efi using frst parts from my old frst

[Bryan_RST]

i thought the xr2i loom was the same as the the turbo loom the only thing the xr2i loom does not have is turbo contral

[Chris69]

Originally Posted by mentalasanything

Added! I forgot about this, may have a workaround rather than replacement though......

I have read that you can use the coil of a relay to boost the tacho signal (See "Hi Voltage diagram" on page 2 here: http://www.extraefi.co.uk/Drawings/P...cho_Wiring.pdf) I know this is for a megasquirt and I haven't tried it. But it may work for the non EFi rev counters. Anyone have any oppinions to offer on this?

Lee

I've heard about this but don't know of anybody that has made it work, I was gonna give it a go after reading about it but stumbled upon a Efi item in a scrappy so i know that works with a frst ofab setup for sure.

[mentalasanything]

Edited to update rev counter info.

[B1G_RST]

few bits of info needed for tapping into the exsiting loom/wiring,,

1.which relays which ? haha whats colour of the fuel pump relay and fuel injection relay?
2. pin 6 goes to the oil press sw, this the switch that the turbo braided hose goes into at back of block?
3. anyone no colour of ignition switch cable i need to conect into?
4. pin 3 go to the back of the rev counter aswell as a cable from pin 11 to the back of the cover?

cheers for any advice

[mentalasanything]

Originally Posted by B1G_RST

few bits of info needed for tapping into the exsiting loom/wiring,,

1.which relays which ? haha whats colour of the fuel pump relay and fuel injection relay?
2. pin 6 goes to the oil press sw, this the switch that the turbo braided hose goes into at back of block?
3. anyone no colour of ignition switch cable i need to conect into?
4. pin 3 go to the back of the rev counter aswell as a cable from pin 11 to the back of the cover?

cheers for any advice

Right, I'll have a go:

1. Fuel injection relay is a spst one
2. I can't completely remember where it comes out of but I'm sure you're correct.
3. Cant remember the colour off the top of my head, use an inline tester to look for the one that lights up the tester with the ignition lights on.
4. If you have a EFI dash then pin 3 goes to the rev counter. If you have a S2 dash then run a cable from pin 11 of the EDIS to the rev counter (You could cut the cable to pin 3 on the multi plug and replace it with a feed from pin 11 of the EDIS)

Lee

[Rab]

This is why I've been getting PM's recently

I did wonder why all of a sudden people were aking questions about EFi again

[mentalasanything]

Originally Posted by Rab

This is why I've been getting PM's recently

I did wonder why all of a sudden people were aking questions about EFi again

Sorry dude! Good work tho!

Lee

[Rab]

Originally Posted by mentalasanything

Sorry dude! Good work tho!

Lee

No worrie mate, happy to help! I reckon I'll do another one soon I'm THAT stupid

[MIKE_ERST]

is the xr2i loom the same as an rs turbo loom? if so is it ofab or ofac?

[darrenb16two]

If i got an xr2i could i use it as the donor car? Would i need to buy much else?

[clarke5700]

[steven botes]

i dont agree about the head

the carbed cvh can be modified to accept the efi inlet without an adaptor plate

my xr3i has a standard head modified by myself with a drill and dremel mini grinder - using a efi inlet gasket as a guide , remove material at the top of the port for the injectors - you do not need to remove the material as far up as the gasket , just enough to accept the injectors

[rst cabbie]

im a bit stuck with this ive just been told by jam sport that i cant run a cossie 3 bar map sensor with my ofab ecu is the case or can i

[mentalasanything]

Originally Posted by rsi cabbie

im a bit stuck with this ive just been told by jam sport that i cant run a cossie 3 bar map sensor with my ofab ecu is the case or can i

Yes you can but only on OFAC. A cossie 3 bar map sensor will read up to 2 bar of boost.

[mentalasanything]

Originally Posted by darrenb16two

If i got an xr2i could i use it as the donor car? Would i need to buy much else?

TBH the only things you need off an XR2i is the top end of the engine so unless it was dirt cheap it's probably uneconomical.

Originally Posted by MIKE_ERST

is the xr2i loom the same as an rs turbo loom? if so is it ofab or ofac?

I'm unsure mate, I bet it is the same as one of them! Anyone have any idea?

Originally Posted by steven botes

i dont agree about the head

the carbed cvh can be modified to accept the efi inlet without an adaptor plate

my xr3i has a standard head modified by myself with a drill and dremel mini grinder - using a efi inlet gasket as a guide , remove material at the top of the port for the injectors - you do not need to remove the material as far up as the gasket , just enough to accept the injectors

You have to be very carefull. I found a fantastic article the other day:
http://www.pumaracing.co.uk/CVH.htm

I think it was that one and it defined what heads can be modified for what. And I did read that some heads have water ways running through the parts of the head where you have removed metal.

Just something to note really, you can as you rightly say remove metal, but I personally wouldn't when a CVH EFi head is so easy to come by.

Lee

[mentalasanything]

Just an update on the loom:



I basically bought an XR3i EFi loom off e-bay and had an extra 1 thrown in for free. 1 of the looms seemed ok and the other one not so good. On closer inspection they were both not so good. One had a good car loom with all the extra's wired in but someone had cut off the ECU plug = No good. The other had been cut about, had a few melted wires in but the engine loom was perfect.

So basically I took the car loom from one and the engine loom from the other and made 1 good loom, turns out there are only a few common pickup points connecting the 2.

I then added an extra cable out of the EDIS to run my S2 rev counter. For this I ran a short wire from pin 11 as far as the original rev counter suppressor, cut the applicable plug from the other loom and plugged it straight into the rev counter wire, easy. I also moved the CPS plug to the other side of the engine bay to suit my 1.8 CVH crank pickup, again easy just using shielded cable bought from Maplin.

I've added some extra's in there too. I've added a time delayed interior light relay, the fading type like all modern cars have and also a "Lights on" warning.

Other than that I've just tidied any wiring faux pas that had been added, put heatshrink over any exposed wire and that's about it.

All that remains now is to trial fit it, once I'm happy I'll loom in the alarm and tape it all up.

Hope you like!
Lee

[MIKE_ERST]

what relay is the fuel injection relay? (NOT the fuel pump relay) from the diagram in the first post? is it from the escort loom or fiesta loom? what colour, maybe part number ect.. any help will be muchly appriciated

cheers, mike.

[mentalasanything]

Originally Posted by MIKE_ERST

what relay is the fuel injection relay? (NOT the fuel pump relay) from the diagram in the first post? is it from the escort loom or fiesta loom? what colour, maybe part number ect.. any help will be muchly appriciated

cheers, mike.

Basically they arent part of the engine loom, but they are identical standard 40a SPST relays (fuel pump and injection). FRST ones can be used if you want a factory look, otherwise just get some from your local motor factors, not expensive at all. Just make sure the terminal numbers on the underneath match.

The ones for my '3i loom are part numbers 85BG6911AA (Yellow - Fuel pump) and 81AG14N089CA (Red - Fuel injection). They are identical relays, just a diferent colour for ID purposes. The relay types are standard accross the board where EEC-IV is installed, just diferent colours for ID.

The fuel pump relay from MFi can't be used either, must be a spst item. The reason being that the EEC-IV controls the priming, whereas in MFi the fuel module provides a positive pulse to one pin to make the pump prime iirc.

Lee

[MIKE_ERST]

ok so basically im after 2 40amp, 4 pin relays with the 30 - 85 - 86 - 87 pins?

Edit: ive got 2 81AG14N089CA relays, theyre both yellow, 40amp and have the right pins. Theyll do nicely

cheers, mike.

[mentalasanything]

Originally Posted by MIKE_ERST

ok so basically im after 2 40amp, 4 pin relays with the 30 - 85 - 86 - 87 pins?

Edit: ive got 2 81AG14N089CA relays, theyre both yellow, 40amp and have the right pins. Theyll do nicely

cheers, mike.

Nice! Glad to be of assistance!

Lee

[MIKE_ERST]

yet another queery mate. Im using an ofab loom but i dont think i have a map sensor supressor. do you happen to have a picture or could you get one to show me what im looking for?

cheers, mike.

[churchy(ilikeitwide)]

very helpful write up as im planning to build a zetec turbo for my s2 rs and will need to convert to mfi ,, cheers

[motormel]

Originally Posted by mentalasanything

Basically they arent part of the engine loom, but they are identical standard 40a SPST relays (fuel pump and injection). FRST ones can be used if you want a factory look, otherwise just get some from your local motor factors, not expensive at all. Just make sure the terminal numbers on the underneath match.

The ones for my '3i loom are part numbers 85BG6911AA (Yellow - Fuel pump) and 81AG14N089CA (Red - Fuel injection). They are identical relays, just a diferent colour for ID purposes. The relay types are standard accross the board where EEC-IV is installed, just diferent colours for ID.

The fuel pump relay from MFi can't be used either, must be a spst item. The reason being that the EEC-IV controls the priming, whereas in MFi the fuel module provides a positive pulse to one pin to make the pump prime iirc.

Lee

what colour are the plugs that the relays connect to for the fuel pump and injection relay? i have a series 2 and trying to do this converstion, think i've wired into same relay (the big pink one), so i can change the relays to yellow ones (al long as they are correct numbers) but thats only the fuel pump relay, don't know which relay is the fuel injection one. Can someone please help??
many thanks
Mel

[mentalasanything]

Originally Posted by motormel

what colour are the plugs that the relays connect to for the fuel pump and injection relay? i have a series 2 and trying to do this converstion, think i've wired into same relay (the big pink one), so i can change the relays to yellow ones (al long as they are correct numbers) but thats only the fuel pump relay, don't know which relay is the fuel injection one. Can someone please help??
many thanks
Mel

On the original MFi loom the pink plug is for the fuel pump relay, there is no fuel injection relay. So you need to remove the pink plug and rewire the neccessary connections as per the diagram at the top, you then need to add a plug and relay for the fuel injection.

In my loom pic above the yellow holder is the fuel pump relay and the red holder is for the fuel injection.

Lee

[motormel]

Originally Posted by mentalasanything

On the original MFi loom the pink plug is for the fuel pump relay, there is no fuel injection relay. So you need to remove the pink plug and rewire the neccessary connections as per the diagram at the top, you then need to add a plug and relay for the fuel injection.

In my loom pic above the yellow holder is the fuel pump relay and the red holder is for the fuel injection.

Lee

cheers that helps loads, many many thanks. if i get stuck efi loom here i come lol
regards
mel

[rs milesy]

What does the speed sensor look like ?
What does the co potentiometer look like ? And were do they fit ?
Any chance of some photos please of them fitted
Cheers.

[Blunt.RS]

What is OFAB & OFAC
am currently getting bits to turbo my xr3i its running efi
but getting abit confused as to what i need
links are great but not understanding all of it