Adaptronic 440 Install - Wires, heat shrink, cutting, splicing, crimping....

Working to 1am every night this week, plus two weekends.
The end result...I am very impressed but still a few things to do.  It is far from perfect.
But it is clean, functional and it's alive.
Fuel system is holding, no leaks.  Tune is running well, just a few issues with false knock.
From injectors to pump, filter, hard wiring relays, switches, ecu, O2 sensor.  There has been a significant change to the car.






 - I need to fix the temp sensor, I need a 28mm thermostat adapter (wire direct to ECU)
 - two stage LED indicators - one to show relay is armed (e.g. fuel pump) another to show it's running.





 - cleaner dash switch cluster (out of ally?)
 - extend stereo deck loom, just going to keep it simple - deck + 2 speakers
 - install Defi Link + gauges + custom warning lights
 - finally fit the bigger brake kit
 - fix up guards

list goes on......







My soldering iron I bought 8 years ago? and the one I bought for my mate
I swear it costs more now ($160) compared to when I got mine









Using what I could find at the local electronics shop.






















































The gauge wiring loom.






Just some of the mess.












Some of the tools.



Too many wires to make it look clean @_@

Love Juice Phase II - FPR 1200 - Fuel Pump DW300 - E85 300LPH

Fuel pressure kPa Vacuum hose connected Approximately 230 = 2.35kgf/cm2 = 33.36psi
Vacuum hose disconnected 289 − 299 = 2.95-3.05kgf/cm2 = 41.92-43.37psi








Part I
/love-juice-phase-i-fpr-1200-zeitronix-e.html

Historical:
GSS342 255LPH
/fuel-pump-install-z27ag.html
/e85-plans-fuel-pump-injectors.html

First and last time I will use AN fittings.  It was really expensive :(
For no real output.
In the aim of doing it right the first time, the outlay was $$$$
Also a pain to install and assemble

Special 1/4" hardline adapter from speed flow, I didn't like the other designs.
Unfortunately they only come in AN4, so I had to get a converter for AN6

SpeedFlow Tube Adapters 618-04-04
-4 to 1/4" Male

This is the new style that doesn't require flaring 37deg
It uses a compression olive, inside it has oring also.
Can be used on steel or aluminium hard line.


Just some of the items used on such a simple task.







New fuel pump, new filter, BUT NO NEW SOCK.
Fuel sock was too big :( I had to use OEM

Tube Nut 818-04
Tube Sleeve 819-04
Tube Adapter 618-04-04

Flare Expanders
951-04-06 Female -4 Male -6


Out with the old, in with the new.

Dont forget to cut the tabs off.











Changing the filter housing.













I also wired in some heavy duty cables and put the pump on its own relay.

The new filter, I was provided the wrong part number earlier.
As seen here -
/mr526974-filter-assy-fuel-tank.html

Z653 fitted, don't forget the rubber grommet on the fuel pump.

Gauge Cluster & Switch Panel - Adaptronic Install

Part of the overhaul is to clean up the switches.

Planning to run independent relays for pump and ignition etc.
After a lot of mucking around I found what I wanted.
Version 1 of the makeshift cluster thingy.

/custom-ecu-install-adaptronic-into.html







Using wood as its a good base.  Hope to eventually replace it for ally












I could fit 3 x gauges :)
My measurement device.









Templating

Love Juice Phase I - FPR 1200 - Zeitronix E-85 Flow Through Flex Fuel Sensor - 1000cc Injectors

A complete overhaul of the fuel system.  Engine bay side, yet to touch the pump and housing.
Decided to do it once and do it right. Using 200 series teflon hose and AN6 fittings.
I will add an inline fuel filter as well.

/fuel-system-design-turbosmart-fpr-1200.html




Injector info:
/e85-plans-fuel-pump-injectors.html

ID 1000cc Injectors upgrade
+
Fuel rail AN6 adapter

1 x AF816-06-02 - Male Flare -6AN to 1/8 NPT








Series 200 AN6 hose - fuel rail to reg

Making my own brackets for the flex fuel and fuel reg. I removed the charcoal canister.

1 x TS-0401-1003 - Turbosmart - FPR 1200 -6 AN
1 x TS-0402-1111 - FPR Fitting Kit -6AN to -6AN








The small things take the most time. Few hours of design and planning.

2 x AF808-02 - Push-On EFI Fuel Fitting 3/8" Hose Pressure Side - 3/8",-6AN

Custom ECU Install - Adaptronic into the Ralliart Colt

After issues with the 420, it was time to update the ECU.
I believe the 420 went in 2010ish.  It has done well, it has a few issues due to DBW and sharing board etc.
So a new loom and a complete rewire, a big tidy up.
Previous time the ECU went in - /heart-transplant-adaptronic-z27ag.html