16v COP conversion

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Joined: Wed Dec 02, 2015 6:45 am

16v COP conversion

Postby kazi » Wed Jan 11, 2017 1:18 pm

hay all.

Ive been asking around so I'm sorry if you've seen this already.

I'm going COP on my 16v and have never done anything like the before. Currently have 4AGE 16v GTI engine going into 86 JDM Trueno. engine has a 36-1 trigger wheel on crank pulley that was going to be used for EDIS trigger system.

Ill be using the Link G4+ Atom II ECU and most likely 1N Yaris/echo coil packs

so what I'm after is basically a dummies guide on ALL the parts i need (links on where to get them also if possible) and 'How to' guide on how and where to wiring them up.


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Joined: Fri Jan 11, 2013 10:21 pm
Location: Wellington, New Zealand

Re: 16v COP conversion

Postby jondee86 » Wed Jan 11, 2017 4:12 pm

I'll reply to your PM here, as the information may be useful to others.

The installation of any aftermarket ECU follows much the same rules, so if you
watch a few Youtube videos on the subject (regardless of what ECU) you will get
some good pointers on how you should plan the installation. This Haltech video
will give you an idea... https://www.youtube.com/watch?v=FqVgbENGxjU

First you need to decide on the type of load sensing you are going to use. There
are two options... MAP sensor or TPS. In the case of a 16V 4AGE running ITB's
the preferred option will be TPS (otherwise known as alpha-N tuning). The type
of ignition needs to be decided, and in this case we consider direct firing using
COP's triggered sequentially by the ECU.

To get your engine to start and run there are a certain number of sensor inputs
to the ECU required. As a minimum you will need to wire the following...

1. Crank position (this is your 36-1 trigger wheel and pickup)
2. Cam position (for example, reluctor in distributor base)
3. Engine water temperature (essential)
4. Intake air temperature (nice to have but not essential)
5. Throttle Position Sensor (TPS)
6. 12V ECU power supply (key switched)
7. 12V ECU power supply (constant - check if required)
8. ECU ground

You also need a certain minimum number of ECU outputs...
1. 4 x ignition
2. 4 x injection
3. Fuel pump relay
4. Cooling fan (if using electric fans)
5. Idle Speed Control VAlve (ISCV if using one)
6. Sensor low level (5V) power supply
7. Sensor ground
Plus anything else important that I have missed :D

Consult the manufacturers instructions for the ECU to see if you can use OEM
sensors. For wiring you need both the sensor and the matching plug. Usually you
will need to splice plugs onto the end of the ECU harness wires after you have
laid out the wiring and trimmed the wires to length. So make sure you have the
plugs with a few inches of wire hanging out so that you can make a soldered and
shrink wrapped join. Butt connectors can be used, however soldered joins are
neater and look more professional.

When you have everything hard wired and plugged into the ECU, double check
that you have good grounding, and that 12V will only go where 12V is supposed
to go. Getting the polarity mixed up will make some expensive smoke :shock: :? :cry:

So much for the easy stuff. To get the engine to run it is necessary to program
the ECU to work with your hardware. It needs to know the engine size, firing
order, injector size, basic engine timing, injector sequence, type of ignition,
sensor calibration and a few other things. This will all be covered in some detail
in the manufacturers installation instructions. You also need to have some basic
numbers entered in the fuel and ignitions maps.

The simple way around this is to obtain a 4AGE on COP's base map, and you will
find that most manufacturers will have base maps available. The base map should
have most of the required settings already entered up, but you will need to have
access to a laptop with the LINK ECU software (PC-link) installed to allow you to
communicate with the ECU.

Then, with a bit of luck, when you hit the key, the engine will burst into life.

Cheers... jondee86
Give a person a fish, they eat for a day. Suggest they search before posting, and they learn a skill for a lifetime.

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