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Squirt your 02 using the E30 318i intake and Megasquirt.

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I've noticed a lot of EFI/Megasquirt questions lately, and thought I would spend a little bit of time doing some writing. What follows is from my experiences building my MS2 system in 2005, and now re-doing it using MS3 in 2011. I reccomend parts from various suppliers or whatever, this isn't anything more then an reccomendation based on my own experience, if I mention a vendor and a specific part, its because they make good stuff, and will probably save you time, not cause I'm on the take. That said, I hope the information is useful. To those looking for a "drop in" solution. There really isn't one.

I will attempt to provide correct BMW part numbers etc, as well as a few options in parts. (ie: m20 throttle body instead of M10)

Intake manifold: This comes from a 1984-1985 318i. BMW part number: 11611709585

Fuel Rail: Comes from the same. BMW Part number: 13531707731

Fuel Pressure Regulator: 1984-1985 318i or 1982-1992 5 series M30 cars (3 bar): BMW Part number 13531707731

Throttle Body:

Option 1- e30 318i throttle body that comes with the intake, easiest option, intake boot and stock cold start fits that way

BMW Part number: 13541287302

Option 2- e30 325i throttle body. BMW part number: 13541716065 Build an adaptor or use 02again's nicely made adaptor

http://www.02again.com/?page_id=30 <-- look for throttle body adaptor. *note* don't use a 528e or 325e throttle body, they are small. the "i" TB is correct.

Injectors: You can use the 13lb injectors that come from the e30 318i (BMW P/N:13641279665) or any Bosch style injector you can get your hands on. A good one is from an early to mid 1990s ford Crown Victoria, they have yellow 19lb injectors.

Idle control: You can use the stock e30 318i idle control solenoid and stuff. Do yourself a favour and buy new piping/plastic bits: See below diagram

*note* no need for AFM with megasquirt. or for the cold start injector. on my old intake I simply filled in where the cold start injector went with Jb weld. you can see the fitting just to the left of number 10 on the diagram below. (its the trangle thing that bolts to the manifold)

Number 13: idle control solenoid (BMW P/N:13411709898)

Number 14: hose (11631286273)

Number 11: hose (11631286274)

Number 12: Reducer (11631278833)

piping.png

*NOTE* when using 325i throttle body, it is advisable to use a Jeep stepper motor and the 02again IAC control block. http://www.02again.com/?page_id=30

Jeep IAC: From a 1991-1997 Jeep Cherokee, Wrangler, Comanche and Grand Cherokee with the 4.0 six cylinder engine. Wells AC320. As you can see from pics below, this is a very nice solution. It gives you near perfect idle control. The BMW solenoid basically just opens a hole.

iac1.jpg

IAC.jpg

Throttle Position Sensor: MS needs a throttle position sensor, not a throttle switch. Bosch Part number :0 280 122 001 will fit the shaft, but will not bolt up to the holes. It is too small. I suggest building an adaptor. Measure the old throttle switch , note where the holes sit and measure the new one. They are around 90 degrees out from one another. Build your plate, drill some holes and mount the new sensor to the plate and then mount the plate to the throttle body.

A few other options are: E36 325i 1993+ TPS, needs an adaptor built too. (BMW PN: 13631726591)

**Update, thanks to 2002faq user "themoose"** This is a tps that should bolt right up!!!

This is the TPS with the round 6-pin plug/connector

BMW part #: 13631707320

Bosch part #: 0280120402

Pin 1-black wire-5volt in

Pin 2-shielded wire-ground

Pin 3-yellow wire-signal out

Pin 4-ground

Pin 5-WOT switch

Pin 6-Closed switch

Coolant neck and sensors: You need the 318i coolant neck. It is offset to provide room for the 318 manifold. You also need two sensors and a block off plug.

Coolant neck: (BMW PN: 11531274009) You might want a new one, they are commonly fairly corroded.

You need a water temperature sensor for the MS. (BMW PN:13621357414)

Get a brand new 2002 water temp sensor for your instrument cluster: (BMW PN:62110788115).

E30 Screw plug (BMW PN: 07119919228).

Copper ring gasket thing (BMW PN:07119963130).

Copper ring gasket thing (BMW PN: 07119963200) Buy a few of each, can't remember which size is which, but they are cheap.

Intake Air temp sensor: I bought mine when I bought my MS stuff, but use a GM AX1 sensor (it just goes in the intake boot or somewhere)

http://www.diyautotune.com/catalog/gm-open-element-iat-sensor-with-pigtail-p-62.html

Fuel pump: I used a late E30 (>1988) In-tank pump. They fit, but are short , so you need to extend the pickup a bit, or realize you never can get the fuel all the way to the bottom of the tank. (BMW PN: 16141184022) Sender is BMW PN: 16141152266. Sender from an E28 might be a bit longer. Experiment.

Megasquirt Controller Parts: Depending on what you are doing, you will use either an MS1, MS2, or MS3 controller. It is heavily recommended to pick up the relay board and use that to wire up the fuel pump etc. I purchased everything from http://www.diyautotune.com.

Ignition: I will try to simplify this a little bit, you have quite a few options for ignition and i've used or will be using several.

Option 1: Points/Pertronix: So, this is the simplest way, really nothing special, you are sending a tach signal to the megasquirt and your ignition works way it always did when the car was carbed. I did this at first, no real benefit, and can be troublesome to get the MS to pick up a clean signal.

Option 2:single coil controlled by MS: You can use a pertronix, magnet and hall sensor on your crank pulley, or some other methods to tell the MS when you are at TDC. The MS will switch your coil for you. You get more reliable dwell but still have a distributor etc. You can use some pretty awesome coils this way though since its electronically switched.

Option 3:Ford EDIS: This is a favourite, using easily available ford stuff, you can have a great wasted spark system on your car. (see pic)

Parts needed: EDIS Controller (top left) Pull from a pyp car, make sure it says EDIS-4. take wiring. Usually early to mid 90s escorts have the EDIS-4

EDIS Coil pack (centre top) Pull from PYP car or purchase new. Ask napa for 1993 escort 1.9l coil. Get wires from PYP car.

EDIS wiring (on top right). your old 2002 wires won't fit, so either grab some from a pyp car or just get new ones.

EDIS VR sensor. (bottom left). Pull from pyp car and get wiring as well.

36-1 trigger wheel: comes from crank pulley of ford car, presses right off: alternatively, (and I really think this is the way to go). Pick up an EDIS pulley for your 2002 from http://02again.com this will really save you a bunch of fabbing and the possibility of having an unbalanced pulley once you figure out how to get it on your 02 crank pulley.

edis.jpg

Option 4: Coil on plug: This requires a bit of work, which has been nicely documented here: http://77e21.info/mscop.htm

Megasquirt wiring: When I put my system together I just built the injector harnesses myself. My first run was using butchered e30 318i harnesses, the next run, I used injector pigtails from Diyautotune. http://www.diyautotune.com/catalog/fuel-injector-pigtails-bosch-ev1-p-48.html. I had gone to PYP and taken a few electrical connectors from e30s, e34s and such so that the temperature sensor has a proper connector. You can actually

use one of those injector connectors.

If you have an E30 318i wiring harness, use it. I recommend taking out the wires you don't need, but you can get a pretty good looking EFI harness this way. Its a good start.

I brought all of the intake manifold wiring (throttle body, injectors, sensors) to a plug on the back of the intake, and then plugged it in to a plug on the firewall that went to the relay board. Really, all this gave me was the ability to remove the intake manifold without unplugging everything.

I may do this again, but using something like the amphenol 97 series of plugs and receptacles to make things look a little nicer:

http://www.amphenol-industrial.com/new/97.asp?BU=2

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One correction for you. The late 80's 325 TPS for an automatic bolts right on and is a variable resistance. I'll find the pinout for you if you want it.

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One correction for you. The late 80's 325 TPS for an automatic bolts right on and is a variable resistance. I'll find the pinout for you if you want it.

Really? Sweet that would be great. I had an auto 528e but it used a throttle switch. I'd love a pinout.

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This is the TPS with the round 6-pin plug/connector

BMW part #: 13631707320

Bosch part #: 0280120402

Pin 1-black wire-5volt in

Pin 2-shielded wire-ground

Pin 3-yellow wire-signal out

Pin 4-ground

Pin 5-WOT switch

Pin 6-Closed switch

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This is the TPS with the round 6-pin plug/connector

BMW part #: 13631707320

Bosch part #: 0280120402

Pin 1-black wire-5volt in

Pin 2-shielded wire-ground

Pin 3-yellow wire-signal out

Pin 4-ground

Pin 5-WOT switch

Pin 6-Closed switch

Awesome! Thank you. I'll add that too my text.

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Guest Anonymous

Hi

I should need the magnitude of the volt signal output at idle speed for the

0280120402 13631707320 Pot (6 points).

I think that it should be zero due to the idle switch integrated.

Thanks.

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Hi

I should need the magnitude of the volt signal output at idle speed for the

0280120402 13631707320 Pot (6 points).

I think that it should be zero due to the idle switch integrated.

Thanks.

Hi, I am not 100% sure, but I think megasquirt provides a +5v signal to run the TPS pot. you can check at http://www.megasquirt.info

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Guest Anonymous

Hi, I am not 100% sure, but I think megasquirt provides a +5v signal to run the TPS pot. you can check at http://www.megasquirt.info

Yes thank you, the input is +5V but i was asking for the idle speed output (idle switch closed, butterfly closed).

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Hi, I am not 100% sure, but I think megasquirt provides a +5v signal to run the TPS pot. you can check at http://www.megasquirt.info

Yes thank you, the input is +5V but i was asking for the idle speed output (idle switch closed, butterfly closed).

Francs, I'm not sure offhand, although it is a variable resistance unit, not a switch like old cars. When I have my stuff reassembled I'll take a few readings.

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Guest Anonymous

Thanks.

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Guest Anonymous

It is not necessary anymore cause i bought a 0280120418 (or 433) which is perfect for my application.

Cheers and happy tuning.

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I would like to point out that you can use the EDIS coil(s) without the EDIS electronics.

Just let MegaSquirt do the switching. Less stuff, fewer things to go wrong.

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I just lucked on an intake by chance and am going to ditch my carb (ex Tii) and megasquirt. Starting my build SOON~!

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