ECU upgrade including coil on plug conversion.

Post here for mechanical and engine topics such as fuel issues, transmission problems, rough idle, exhaust, electrical issues, etc

Moderators: GRNSHRK, ron, bfons

GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

ECU upgrade including coil on plug conversion.

Post by GazM3 »

Finally!!

At long last, the long awaited ECU upgrade is happening. In a nutshell, the plan is to totally replace the old Bosch 055 DME with a modern EcuMaster EMU classic, and upgrade to a MAP and TPS based input, along with a wideband exhaust sensor. The other benefit is to delete totally the old and restrictive airflow meter, and troublesome crank sensors. In addition I will be upgrading to coil-on-plug setup rather than the single coil, and will be installing as part of the loom an input to run a flex fuel sensor for possible E85 fuel. I will be using the Audi coils, and have had 30mm extensions fitted so they fit flush with the top of the spark plug tunnel and making good connection to the spark plug. The coils need minor modification to fit, but they are reasonably cost effective, and have their own ignitor.

The main benefits of doing this are improved ignition, timing, and spark control, which will not only improve the drivability and fuel economy, but also increase the power throughout the rev range. Most who have done the conversion have reported 40-50rwhp gains which is pretty dramatic, but having the engine run to its optimum is the main reason to take this task on. The other real benefit will be total freedom for the intake, where initially i'll run a heat shielded dry filter with a silicone adaptor direct to the OEM plenum, but I have a 2nd plenum where I can potentially open it up with a bigger opening, or even run open (filtered) trumpets to listen to the M88 intake without any sound attenuation.

Unfortunately, there are no 36pin female adaptor blocks so we have taken the decision to fit a total new engine loom which makes it more expensive, but modernizes the wiring to hopefully to improve reliability and eliminate the dreaded "no start" issues that can plague the early Bosch motronic cars. I guess the benefit of using a new loom also it will work in all series2 M30 based cars and also in the E28 and E23 models, along with the E30 m3, which all use an 36pin setup. Hopefully Rama will make this commercially available as a semi plug and play for all to benefit.

It seems ages since planning this upgrade for the E24. Originally planning to some major upgrades as far back as 2014!! I'm glad now I have maintained the mechanicals as standard, and concentrated on chassis and brake improvements, but the M88 for a long time has always felt strangled and restricted, like its almost like its been factory de-tuned as 286bhp was seen as outrageous in 1984. I'm really exited to finally get around to doing this.

The M635csi is heading to Rama's (RHD-Engineering) in Sydney. Taking the trip by road from Melbourne on next Wed 15/3, and will fly back same day. Flight is booked, money is stockpiled so no turning back now. We are looking to have approx. 2-3 weeks turn around so hopefully sometime early April it will be back. He is also doing the standalone conversion for my supercharged E34 540i straight after, as i'll be driving this up to pick up the E24. This is a much simpler upgrade as I can use the OEM loom.

Watch this space.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
User avatar
hornhospital
Platinum Member
Platinum Member
Posts: 2931
Joined: Sun Jul 11, 2010 6:46 pm
Location: Silverhill, AL
Contact:

Re: ECU upgrade including coil on plug conversion.

Post by hornhospital »

Holy cow, what a project! :shock:

Is this just for the M88?
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann"; '95 M3 "Ashlyn"
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

It should work fine on the m30 also, with single factory ignition coil but programming and timing will be different. It’s probably very worthwhile converting to individual coils also but a little harder to package in an m30 as u can’t use the pencil style coils
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
Grizlii
Posts: 11
Joined: Sat Nov 12, 2022 10:10 pm
Location: ONTARIO

Re: ECU upgrade including coil on plug conversion.

Post by Grizlii »

I admit my knowledge on coil packs is limited, I was considering the same conversion and found this bracket for coil on plugs.

https://e28goodies.com/product/coilpack-rail-stainless/

Are these the pencil style you are referring to?
1978 633CSI
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Grizlii wrote: Thu Mar 09, 2023 12:23 am I admit my knowledge on coil packs is limited, I was considering the same conversion and found this bracket for coil on plugs.

https://e28goodies.com/product/coilpack-rail-stainless/

Are these the pencil style you are referring to?
Yes. That bracket could work well, but it looks like the Audi coils will still need some alterations to work.


They have a nice weld on 60-2 trigger wheel, and a varialble TPS with adaptor on this site also
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
User avatar
jps635
Platinum Member
Platinum Member
Posts: 872
Joined: Sat Feb 27, 2010 10:50 pm
Location: NZ

Re: ECU upgrade including coil on plug conversion.

Post by jps635 »

Hope it all goes well Gaz. Good decision to use a custom loom. My set up uses 60-2 trigger, cam sensor, air temp, TPS and MAP. Also runs the fan and makes fine tuning the on/off cylce easy reading off temp sensor in the thermostat housing. I had to change the cold air valve to the later B35 3-wire model, don't know anything about the M88. If you've got upgraded injectors your tuner will need the dead-times, I had to go back to Five-O to retrieve from their archives and held things up a tad.

The power tuning was easy but took some time to get a smooth transition on over run. For later tuning adjustments you could install a female usb slot in one of the spare switch blanks below the radio. I've just left the USB cable plugged in that tucks between the steering column and lower dash panel.
'85 635csi JPS (RA2-66)
GRNSHRK
Platinum Member
Platinum Member
Posts: 3710
Joined: Thu Apr 08, 2004 3:24 pm
Location: Gilroy (SF Bay Area) CA

Re: ECU upgrade including coil on plug conversion.

Post by GRNSHRK »

Here's what a guy out my way did on his M6, appears to be an S38 but I really wouldn't know if that matters or not :-k

I could put you in touch with him but would want to contact him first and take the discussion off line :-"

I would ask him to post as well, of course, but I'm not sure if he's on Big Coupe or not :roll:
Attachments
IMG_4402.JPG
IMG_4402.JPG (1.2 MiB) Viewed 3306 times
:mrgreen:
Bobbo
1980 633 CSi Cypress Green/Pearl Beige
2017 X5 M Sport Xdrive 35i Carbon Black/Ivory White
2005 330 Ci ZHP Cabrio Imola Red/Bone/Black
Image
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Like the idea of installing a female usb slot in the blanks or I’ll just run a cord into the glovebox. I’m probably running similar to the setup in the pic with the 25mm black ducting hiding all the wires, but I’ll be using no airflow meter or maf. It will be based on map, tps, and wideband.

The beauty with the wideband is the auto tune function which allows just do dial in your required mixture settings and it will automatically calculate the injector duty %. Doing the timing maps will be pretty straightforward also (hopefully) but to get max results I’ll need to fine tune on the dyno setting up timing for the load points.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Car now is at Sydney. We are putting in bugger injectors for potential e85 use.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
User avatar
RossDinan6
Posts: 295
Joined: Mon Jan 29, 2007 2:35 am
Location: SW FL, USA

Re: ECU upgrade including coil on plug conversion.

Post by RossDinan6 »

What ECU are you using? Inquiring minds want to know.
Ross
'84 633 Dinan turbo
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

RossDinan6 wrote: Wed Mar 15, 2023 11:01 pm What ECU are you using? Inquiring minds want to know.
ECUMaster classic from RHD engineering. He is doing all the wiring loom work as well.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
Mamod17
Posts: 124
Joined: Sun Aug 30, 2015 8:41 am
Location: Sydney

Re: ECU upgrade including coil on plug conversion.

Post by Mamod17 »

Hey Gaz, looking forward to how this all works out. Once My engine is built I'll hopefully be heading out to Rama also. Can I ask what you're doing with exhaust? Are you running headers or stock? As mines going in an E12 chassis headers are looking difficult to source. Most likely will be going custom. I could go stock m88 temporarily but I'm not even sure they fit on e12 chassis!
316739251_2029776570745506_777467145991805618_n.jpg
316739251_2029776570745506_777467145991805618_n.jpg (1.47 MiB) Viewed 2777 times
1980 JPS635csi Group C Tribute
1986 635csi 5speed Alpine White M-Tech Aust Del
2001 325ci Auto Orient Blue

Previous
1988 635csi Auto Zinnerbot
1988 320i Convertible
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Hey Dennis.

I run the fritz bitz headers for the uk. The e12 based cars are very similar to the e9 chassis, or alternatively you could go and modify a set of s38 e34 headers to make them fit (that’s what Josh Parsons done) who has a s38b38 in e12 based chassis.

The loom now is finished and currently being installed in the car. Hopefully it will be running early this week and be ready for me to pick as early as late this week
Attachments
A2DB48B2-3985-4006-8B25-03161781EE24.jpeg
A2DB48B2-3985-4006-8B25-03161781EE24.jpeg (556.37 KiB) Viewed 2776 times
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
Pod
Platinum Member
Platinum Member
Posts: 4492
Joined: Tue Mar 16, 2010 8:32 pm
Location: usually in the barn, Kent, England.

Re: ECU upgrade including coil on plug conversion.

Post by Pod »

Wow! This is very interesting. Please keep us posted with the progress!
User avatar
jps635
Platinum Member
Platinum Member
Posts: 872
Joined: Sat Feb 27, 2010 10:50 pm
Location: NZ

Re: ECU upgrade including coil on plug conversion.

Post by jps635 »

Looking good
'85 635csi JPS (RA2-66)
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Car has fired and run for the first time but needs to run on resistor plugs. Lucky I kept the old NGK ones so sending them up to Sydney otherwise all is good
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
Griphish
Posts: 15
Joined: Sat Nov 21, 2020 3:56 am
Location: Charlotte NC

Re: ECU upgrade including coil on plug conversion.

Post by Griphish »

GazM3 wrote: Sun Mar 26, 2023 5:14 am The loom now is finished and currently being installed in the car. Hopefully it will be running early this week and be ready for me to pick as early as late this week
That looks great! I'm doing some similar work on my '88 M6 but I haven't been able to come across any of the grommets or injector rubber bits. Did you buy these or have them made somewhere?

Thanks!
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Griphish wrote: Thu Mar 30, 2023 1:44 pm
That looks great! I'm doing some similar work on my '88 M6 but I haven't been able to come across any of the grommets or injector rubber bits. Did you buy these or have them made somewhere?

Thanks!
I’m running new modern 440cc/min injectors for future E85 use and a more modern injector has a better spray pattern. In addition Rama has installed a cam sensor and distributior blanking plate. The car will be running full sequential injection which will give drivability and fuel efficiency benefits. Not long now to I pick it up. Can’t wait.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Well it’s all done just doing another cold start tomorrow morn. I’ll be travelling up to Sydney tomorrow morn and hope to be there about 3pm to pick it up which is about 18hrs time. Tanking my e34 540i with supercharger install to get the same treatment except I only need a jumper harness so it will be much simpler but as it runs 16 psi of boost, with a variable boost valve and flex fuel it may be a little more complicated to tune
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
Griphish
Posts: 15
Joined: Sat Nov 21, 2020 3:56 am
Location: Charlotte NC

Re: ECU upgrade including coil on plug conversion.

Post by Griphish »

GazM3 wrote: Sun Apr 02, 2023 6:20 am
I’m running new modern 440cc/min injectors for future E85 use and a more modern injector has a better spray pattern. In addition Rama has installed a cam sensor and distributior blanking plate. The car will be running full sequential injection which will give drivability and fuel efficiency benefits. Not long now to I pick it up. Can’t wait.
Nice! I'm using some OE type Bosch injectors.

What about the rubber parts on the harness. Where did you get the rubber grommets for the firewall or the one that seals the wires going to the injector plug bar?

Thanks!
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

Rama sourced the boots going through the firewall.

Had the car back for a few days just with a road tune. It drives so much better and feels much stronger. It’s also extended the usable rev range from originally 3500-6000, to 2500-7000rpm so going through your mountain pass you can drive briskly using a gear taller to maintain pace than before or hold on to the gears much longer to as much as 7500rpm. On the cruise back from Sydney it’s much smoother and easier to modulate the throttle to maintain speed. In the city you can even hold 5th as low as 1000rpm and the car copes well.

It’s still early days and has only been conservatively road tuned. Over the next few weeks I’ll optimise the road tune. Just fitted up the wideband gauge and at full throttle it’s cosistrntly at 12:1 so I can lean it off a little perhaps to 13:1 blending to 12.6:1 as revs get up. Haven’t even plugged the laptop in as yet as I’m too busy enjoying it.
Attachments
2BF59756-2F07-46F3-A1B8-77250E7E2773.jpeg
2BF59756-2F07-46F3-A1B8-77250E7E2773.jpeg (3.49 MiB) Viewed 2457 times
2C6430FC-895F-45B4-AA0C-849762FF8D93.jpeg
2C6430FC-895F-45B4-AA0C-849762FF8D93.jpeg (3.66 MiB) Viewed 2457 times
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
GRNSHRK
Platinum Member
Platinum Member
Posts: 3710
Joined: Thu Apr 08, 2004 3:24 pm
Location: Gilroy (SF Bay Area) CA

Re: ECU upgrade including coil on plug conversion.

Post by GRNSHRK »

Nice =D>

Looks so clean by comparison to all of the plug wires and whatnot \:D/

Unrelated question, what's a widebody Z3 :-k
:mrgreen:
Bobbo
1980 633 CSi Cypress Green/Pearl Beige
2017 X5 M Sport Xdrive 35i Carbon Black/Ivory White
2005 330 Ci ZHP Cabrio Imola Red/Bone/Black
Image
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

GRNSHRK wrote: Sun Apr 09, 2023 8:19 pm Nice =D>

Looks so clean by comparison to all of the plug wires and whatnot \:D/

Unrelated question, what's a widebody Z3 :-k
The 2.8ltr has a wider rear body than the 4cyl models in the z3. Great little underestimated car in manual form, especially when you give it some extra breathing via the m50 manifold and a nice cold air intake.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
GRNSHRK
Platinum Member
Platinum Member
Posts: 3710
Joined: Thu Apr 08, 2004 3:24 pm
Location: Gilroy (SF Bay Area) CA

Re: ECU upgrade including coil on plug conversion.

Post by GRNSHRK »

The 2.8ltr has a wider rear body than the 4cyl models in the z3.
I guess I never noticed :-k

In the states we have (had?) 2.3L and 3.0L versions, as well as M versions with both the S52 and S54 mills =D>

I bet that S54 is a hoot \:D/
:mrgreen:
Bobbo
1980 633 CSi Cypress Green/Pearl Beige
2017 X5 M Sport Xdrive 35i Carbon Black/Ivory White
2005 330 Ci ZHP Cabrio Imola Red/Bone/Black
Image
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: ECU upgrade including coil on plug conversion.

Post by GazM3 »

A few weeks have gone by now, and the car works really well. I have the cold start working nice with no intervention from the accelerator pedal, and mixtures are pretty good and have now closed loop control for part throttle maintaining perfect 14.7:1 at all times, and runs out to around 12.6:1 at full throttle at peak rpm. Ive kept timing pretty conservative with 25deg at WOT from about 3500rpm up. I guess I can start playing with the timing, adding small increments to see if it improves, but may get it professionally done on a dyno.

I still have the flex fuel loom, upgraded pump, and bigger injectors to look at E85 if I get bored. Just have to add the flex fuel sensor and new rubber lines
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
Post Reply