Glenn_

iTrader: (1)

Congrats on another mag feature. I hope your health will get better soon.

turbo m

iTrader: (2)

Ordered my copy...

gcfcos

Hope u get better soon mate

slammedorion

Booked in for a new ecu/ loom, cambelt, water pump for end of the month
It’s away for a week or so... will include a new map, and more boost



I’ve got a few jobs to sort before it goes so will add a few pics soon

bassboy

Howcome the change of ECU? Whats going in?

slammedorion

The wiring wants tidying on the fan side, and it’s gonna be controlled via ecu this time
It’s over due its final map since fitting the new exhaust manifold
Just makes sense to fit something more modern while we’re doing doing a few changes

New Ecu is a EcuMaster Classic

Technical details:

6 fuel injector outputs (5A),
6 AUX outputs (5A),
6 ignition outputs -passive or active coils software selectable (7A),
4 stepper motor outputs – bipolar/unipolar (1A),
2 EGT direct inputs,
2 knock sensor inputs,
Inbuilt wide band lambda controller LSU 4.2,
Inbuilt map sensor 400kPa,
Inbuilt baro sensor,
4 digital inputs VR/HALL – software selectable,
3 dedicated analogue inputs (TPS, CLT, IAT),
4 additional analogue inputs (0-5V),
Compliance with ISO 7637,
Support 1-12 cylinders,
Max rpm 16000,
Injection time resolution 16us,
Ignition advance resolution 0,5 deg,
Knock sensing 1-20 kHz,
Speed Density, Alpha-N algorithm,
Table VE 16×16, resolution 0,1% VE,
Ignition table 16×16, resolution 0,5 deg,
AFR Target table 16x16m, resolution 0,1 AFR,
Injector voltage compensation,
Coil dwell calibration,
User calibrated IAT, CLT
PID idle control strategy,
Boost control,
Nitro injection control,
Aux outputs for fuel pumps, rad fan,
Motorsport strategies launch control, gear dependent shift light, flat shift ( gear change cut),
Logging over 100 parameters,
Possibility of check engine lamp,
USB communication no additional interface needed,

At a later date I’d like to add traction control
For now...
Having the fan controlled by ecu will mean one less switch in a hose
Map sensor is built in so that can go from the engine bay
Battery , alternator, starter motor wiring is gonna be renewed and re routed
There was talk of a new hard pipe to the fmic
It’s due a cambelt
And finally we’ll see what Max’s our first, injectors of Turbo
It’ll be road mapped and top end tweaked on rolling road
Then I’ll get it back all done with a big bill

slammedorion

Before it goes for work
I’ve jobs to sort

First off, once again the 2nd new starter motor since 2011 is suffering from heat I sort of put it off hoping the Mtx75 would be in by now ( anyway, hopefully one day )
So... so I don’t p!ss my mapper off I decided to sort this so there’s no push starting needed
One new transit connect starter motor bought via eBay on Thursday afternoon, arrived Friday morning, fitted Sunday morning with some new heat protection
Shorter, cranks faster... hopefully won’t get as hot and copes better

Rsmat

iTrader: (2)

Looking good mate ..ive some stainless ties of you want them sending for that starter ..Ecu controlling the fans is the future its what mine will do I've also opted for the egg to trigger the fuel pump also if you want to look into that as your ecu will do it.

slammedorion

Next up... since I decided to fit the first tubular manifold, then sell that and go custom thanks to Crazycage
I still seem to struggle with bonnet release cables, I’m not melting them anymore, but when it’s hot the release is stiff, once cooled down it’s fine
Even though there’s heat wrap, protection everywhere I’m still not happy
So currently in progress I’m having a beefier bonnet release cable made up, with a shorter outer casing
The casing is roughly 30cm shorter
So I’ve bought a spare bonnet release mech to cut the cable location/ tension bracket off
That bits getting welded onto a small plate
That’ll be riveted to the front panel over towards the OS headlight keeping the outer casing away from the manifold hopefully curing all bonnet cable issues
The bare cable is having a length of coiled spring slipped over it to stop catching/ fraying
I’ll add pics as it happens

slammedorion

Cheers
I’ve got stainless ties here thanks , I never considered fitting them...

Rsmat

iTrader: (2)

I do stuff like that all the time

Long as your sorted mate .

Cracking things going off great to see your at it again .

slammedorion

Taxed the Orion today

Ready for it’s road trip...

slammedorion

A few miles put on it today as the sun was out

slammedorion

A few more pics

slammedorion

That’s it for today’s pics

Rsmat

iTrader: (2)

Looks well mate ..been a lovely day for it.

slammedorion

Was nice to get out in it... The new starter motor works a treat
There was plenty of classic/ retro stuff out and about today

slammedorion

Can’t get a EcuMaster Classic for 4 weeks, so I’ve had to upgrade to the EcuMaster Black, cost abit more but should future proof the Orion

https://rover.ebay.com/rover/0/0/0?m...2F112689644955

The EMU Black is a class-leading, stand-alone engine management system, designed to operate the most advanced and complex engines presently available. It is a successor of our proven system, EMU. During the EMU lifetime we collected lots of data that allows us to substantially improve the device hardware and software.

EMU Black targets race cars, road cars, motorcycles, boats, and stationary engine applications.

The EMU Black controls fuelling, ignition and auxiliary systems on 1-12 cylinder engines including those with drive-by-wire throttles and VVT.

It can drive up to 6 passive or 12 smart coils directly and does not require external amplifier/power modules to achieve this. Sophisticated drive-by-wire strategies provide a wide range of throttle control along with advanced plausibility (fault/error) checking for safety.

The system capabilities increase over the time due to easily-upgradable, free of charge firmware (eg. new strategies, trigger patterns, CAN data streams).

The EMU features more built-in value than any other aftermarket ECU. It easily matches the functionality of other stand-alone management systems with multiple inputs and outputs. Unlike many other ECU systems, EMU has built-in wideband lambda input (Bosch LSU 4.2, and LSU 4.9 sensors wire directly in), MAP control connector (4 bar MAP sensor on board), 2 EGT probe inputs and an input to directly connect a Flex Fuel ethanol content sensor. All of this provides greater flexibility, reduces costs and negates the requirement for external osupplemental signal conditioning control systems and the associated wiring that other management systems require.

TECHNOLOGY

EMU Black is assembled according to IPC-S-815A standards to ensure high reliability of the product. The device is manufactured on an automated assembly line with optical inspection, automatically tested including burn-in. The PCB board quality and design, special surface coating and IP65 enclosure keeps the device operational in the harshest environments. The components used allows continued operation in a very wide temperature range (AECQ-100 GRADE 2 (-40 to +105˚C).

SPECIFICATION

GENERAL

Temperature range AECQ100 GRADE2 (-40 to +105˚C)
Reverse battery protection Yes, internal
Operating voltage 6-22V, immunity to transients according to ISO 7637
Enclosure IP 65, custom CNC machined aluminum
Size (mm) and weight(g) 150x72x31, 390
Connectors 1 x 24, 1 x 39 FCI Automotive connector
PC communication USB (with PC client software), serial, CAN
OUTPUTS

Injector outputs 6 protected outputs 5A, low side
Ignition outputs 6 outputs 15A (passive and active coils supported)
Aux outputs 6 protected outputs 5A, low side
Other outputs Full bridge up to 7A, can be used as separate outputs or 2 H-Bridges
WBO heater Protected low side up to 5A
Communication Serial, CAN BUS 2.0B
INPUTS

Analog inputs 9 inputs, resolution 10Bits, 0-5V (protected)
EGT inputs 2 for K-Type thermocouple
Knock sensor 2 inputs
Oxygen sensor LSU 4.2, LSU 4.9 or Narrow band
Trigger inputs 3 (primary, 2 cams) Hall/ VR software selectable
VSS 1 (Hall / VR)
Flex Fuel Sensor Yes
Switch inputs 3 inputs, switched to ground
SENSORS

Temperature sensors IAT, CLT, Oil temperature, AC evap temperature
Pressure sensor MAP, Oil pressure, Fuel pressure (user defined characteristic), AC pressure sensor, Back pressure
Oxygen sensor LSU 4.2 or 4.9 (built in controller), Narrow band, external WBO controllers
Speed Vehicle speed sensor (VR/HALL), Gear sensor (sensor, calculated)
FUELING

Injectors Up to 8 HiZ injectors (sequential)
Injection angle control 0-720 deg, start or end of injections
Battery compensation User defined, wizard for popular injectors
Fueling strategies VE based speed density, Alpha N
Air charge temp. Based on IAT and CLT
VE table 2 tables 16×20 (Load x RPM), resolution of 0.1%
Individual cylinder trim Yes
Staged injection Yes
Additional correction Oxygen sensor corrections, EGT correction (per cylinder), BARO, TPS vs MAP, TPS vs RPM, Warmup, Nitrous, LC, ALS, ASE, Fuel pressure, Knock sensor
Lambda based real time correction Using Lambda target table
Acc. / Deceleration enrichment Yes
IGNITION

Ignition outputs 6 for passive and active coils (software selectable)
Supported triggers N-1, N-2, N-3, N+1, Multitooth, Subaru triggers, Nissan trigger, Lotus Elise, Audi trigger, Renault Clio Wiliams / Alpine, Colt 1.5CZ, Wrangler
Ignition angle table 2 tables 16×20 (Load x RPM), resolution of 0.5 Deg
Per cylinder trim Yes
Dwell time battery compensation Used defined, wizard for popular coils
Odd fire compatibility Application dependent
Additional correction CLT, IAT, TPS vs MAP, Nitrous, Idle, Knock sensor, LC, Pit limiter, ALS, Flat shift, Timers, Acc. enrichment
KNOCK SENSING

Channels 2
Resonant frequency range 1-20kHz, 3rd order AAF
Sampling Ignition event driven, knock window
Actions Ignition retard, fuel enrichment, dashboard indication
IDLE CONTROL

Control type PWM solenoids (2,3 wires), drive by wire, stepper motors (bi and unipolar), ignition cut, fuel cut
Control strategy Open / Close loop , ignition angle control
VE correction Yes, for Alpha-N
Corrections AC clutch, coolant fan, analog input
BOOST CONTROL

Boost ref and target tables 2 sets 10×10 (TPS vs RPM)
Control strategies Open / Closed loop (PID based)
Corrections Gear, VSS, IAT, EGT
DRIVE BY WIRE

Control strategy Advanced 3D PID + static friction compensation
Supported throttles All with DC motor and current requirement lower than 6.5A
Wizard for 28 popular electronic throttles
PPS to throttle position characteristic 3D table
BLIP support Yes
ALS support Yes
TRACTION CONTROL

TC strategy Delta RPM, gear compensation
Torque reduction Spark cut using 3D table (16×20)
Sensitivity control 10 position rotary switch
VARIABLE VALVE TIMING

Supported systems VVTi, MiVec, VANOS, Double Vanos
Number of camshafts 2
Control strategy PID based closed loop, CAM angle target tables 12×12
FLEX FUEL

Ethanol content measurement Yes
Fuel temperature measurement Yes
Tables blending VE, IGN, Lambda/AFR, Boost, Cranking fuel, ASE, Warmup
Fuel temperature PW correction Yes
SPORT

ALS 2 independent ALS setting, DBW support
Shift light Per gear shift light
Launch control Yes
Gear cut Yes (Open loop), DBW blip supported
Source: Switch, load cell, CAN
Pit limiter Yes
Rolling anti lag Yes
ENGINE PROTECTION

Fail safe values for critical sensors Yes
Dashboard indication of failures Yes, user defined
Over temperature engine protection Yes (oil and coolant), user defined, RPM limit
Low oil pressure protection Yes, user defined, shut off
Fuel pressure protection Yes, fuel dose compensation, RPM limit, engine shut off
High exhaust temperature Alarm, per cylinder fuel trim, boost limit
CAN BUS

CAN standard 2.0B 125, 250, 500, 1000 kbps
Supported CAN Dashes ECUMASTER, Motec M800 Set 1, Haltech E8 E11v2, Pectel SQ 6, AEM
Supported OEM CAN streams BMW E46, Citroen C2, Mazda RX8, Ford ST, Polaris RZR, Mini Cooper R53, Fiat 500, Renault Clio, Lotus, Ford Fiesta, Ford ST, EVO X (AYC support)
OTHER

Unused injection outputs can be used as AUX output Yes
Output functions Fuel pump, coolant fan, parametric outputs, nitrous control, PWM 3D table output, AC clutch, main relay, speedometer, tachometer
Password protection Yes, 2 levels
Timers Fuel, Ignition, Boost, timers controlled by virtual outputs
Serial dashboard support AIM, RaceTechnology
Autotune Yes
Built in trigger scope Yes
Logging Real time logging to PC computer, logging on external loggers (serial / CAN)

slammedorion

Orion made its final run on the Adaptronics yesterday without fault...
Hopefully get it back in a couple of weeks
Just in time for Classic Ford

Rsmat

iTrader: (2)

Good to hear mate .

slammedorion

A brief update
It’s now running on it’s new ecu
Still jobs to do, including mapping, Mot
I’m hoping to pop up on Wednesday to fit modified bonnet cable
Fingers crossed I’d hope to be driving it home next weekend
I didn’t manage to make Classic Ford but hope to make Really Retro Show at Stafford in a couple of weeks time
It’s booked in @ Efi Parts early July for a final tweak...

studabear

Rome wasn't built in a day, don't worry about it, You will get there.

slammedorion

Alittle prep/ painting done on modified bonnet release cable bracket ( this’ll be mounted towards the n/s headlight )
Black rivets found
Modified bonnet cable

Off up to fit it on Wednesday
Hopefully all goes well...

Rsmat

iTrader: (2)

Might be an option for me if mine breaks ..looking forward to seeing if it works .

slammedorion

It’ll work fine I think...

boost monster

Your progress is great. and car is superb. I’ve had my ecu, inlet and the other bits and bobs in the boot for 5 years!

slammedorion

Popped up to the Orion late this morning...
Armed with the new modified bonnet cable courtesy of Ford RS Spence Spares
Old one removed, new one fitted
Custom bracket put in its place... holes marked, drilled, bracket riveted on...
Alittle heat protection put on just to stop any catching but all looks good
Works perfect, should be just the job...
So much happier now the bonnet cable issues should be put to rest forever
Had so much grief since fitting the first tubular exhaust manifold
It’s just been kick after kick in the
Looks really good fitted, very oem imo

Rsmat

iTrader: (2)

Looks proper mate.

slammedorion

Orion passed its mot today
Fingers crossed mapping tomorrow...
Nearly there now

slammedorion

Collected from Andy @ Overboost

slammedorion

A few pics of the wiring upgrades

slammedorion

Quickly cleaned up for The Really Retro Show today @ Stafford

slammedorion

A few pics from The Really Retro Show

slammedorion

And a few more

slammedorion

Rolling road tweaks happen Saturday afternoon

slammedorion

Started off this afternoon with 262bhp @ 12psi

Finished up maxing the turbo out at 313.5bhp @ 17psi



I’ll add pics/ videos tomorrow

boost monster

������ That is epic. Bet it takes a bit of holding onto now.

slammedorion

It’s lively
Absolutely useless power But I love it
Can’t thank Andy @ Overboost enough for his continued work on the car...

The boost is set lower in 1st, 2nd ( 12psi ), 3rd ( 15psi ), 4th, 5th ( 17psi )
New Ecu has made it a lot nicer to drive
Traction control will happen at a later date.
As it is now I’m happy

Next power upgrade will be hybrid turbo, upgraded injectors, that can’t happen until the Mtx75 goes in
Unless there’s a better option of gearbox upgrade

slammedorion

A few pics for now...

slammedorion