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 1973 96v4 with a modern twist

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T O P I C    R E V I E W
AnttiKPosted - 30 Nov 2020 : 18:17:22
This car was bought by my dad when it was new. It was daily driven until 2002 it was stored to a barn for 5 years. In 2007 it was taken in to use as a wedding car in my wedding. In 2010 I decided to install EFI to it and had to make full restoration to it.

The was quite a lot of work to do, but I managed to build up the car one metal piece at the time.

Starting point in 2011:

In 2014:

In the beginning of summer 2019 I was finally able to drive the car with Megasquirt 1 installed with following features:
-Peugeot 206 1.4 engine throttle body with ~39mm diameter installed to 1 barrel intake manifold
-Peugeot 306 1.6 fuel injectors 156cc
-Volvo740/Saab900 fuel filter
-Ford EDIS4 controller and edis coil pack
-QSP fuel pump in tank with 3/8" feed and return lines
-36-1 trigger wheel installed to balance axle pulley
-Volvo740 2 wire bosch idle pwm valve (same as in Saab9000?)

Here is a picture of the throttle body and fuel rails:

And engine bay:

It was fun to drive the car last summer. Better throttle response, better startup, less fuel consumption, milder exhaust fumes and so on..

In the end of last year I decided to fit 7.2 cam, sport exhaust from swedish saabclub modified with larger mufflers and Megasquirt 2 for more precise engine control and sequential injection. And the car works even better than last summer. Exhaust produces less noise inside the car, more power and less fuel consumption.


15   L A T E S T    R E P L I E S    (Newest First)
AnttiKPosted - 23 Aug 2021 : 06:20:44
Thanks, engine mounts are 30mm taller than the original, so engine mounting brackets have to be modified as can be seen in pictures above. No other modifications needed.

I had two sets of mounting brackets and then I was able to compare the original vs. modified.
PYM35Posted - 22 Aug 2021 : 10:00:09
Hello AnttiK,
I'm amazed by the great work you share with us and you're knowledge that allows you to experiment the usage of other car make parts !
About the 306 hydraulic engine mounts : do they fit with no modification on the V4 platform ?
AnttiKPosted - 08 Jul 2021 : 12:18:30
Have driven few hundred km's with Peugeot 306 hydraulic engine mounts and I think those are very good improvement Much less vibrations now. Few pictures:

BorstlapPosted - 19 Jun 2021 : 19:13:41
I reread the topic I found on the troublesome signals and there were more issues in the setup; best to read everything without me in between forgetting or making up tings :

AnttiKPosted - 17 Jun 2021 : 19:07:35
Here they install the sensor typically with 0.5 - 1.5mm gap to trigger wheel. If I understand correctly they do not recommend it to be installed like in the picture (and like I have installed).
AnttiKPosted - 17 Jun 2021 : 18:07:08
At the moment VR sensor is about 1.5mm away from crankshaft tooth. I would guess it would work at least +-0.5mm crankshaft longitudinal play. This could be verified by removing/installing shims under the sensor and making the measurement with tunerstudio toothlogger.

0.2mm play sounds very small and I would guess the sensor distance from trigger wheel has not been optimal.
mellePosted - 17 Jun 2021 : 17:21:34
Interesting point Alex, if I remember it next time I'm in the workshop, I'll measure the crank backlash on a few engines.
BorstlapPosted - 17 Jun 2021 : 16:44:41
Potential downside of that construction is that you run the risk of losing signal in case of backlash of the crankshaft. I read someone with a Beetle experienced this. The backlash was not more than 0,2mm, but the temporary signal loss caused very erratic running. But maybe there are sensors that are more sensitive than the ones that are normally used on Ford Edis 36-1 setups.

mellePosted - 17 Jun 2021 : 11:13:12
That's a good point, but I still think what you've done is easier because it doesn't require any modifications to the bellhousing. I think with your pattern a sideways sensor should still work, but I don't see any benefit over your current set-up.

With the sensor in that position it's also fairly easy to just drill a series of holes in the flywheel if you don't have access to CNC equipment, much easier at least than drilling a hole pattern in the side of the flywheel. Like this:
AnttiKPosted - 17 Jun 2021 : 11:03:14
Originally posted by melle
Nice! My initial idea (of which I've never really researched the feasibility) was to place the VR sensor sideways just above the starter, but your solution is much easier and neater.

I probably would have installed the sensor sideways above the started in the first place like those are usually installed in the cars I have seen. But this time I had to make pattern in this way, because flywheel was already lightened and there was no material left in flywheel to make pattern to that direction.

If I had used stock flywheel I would have made the pattern sideways, because there would have been need to remove less material in that case.

mellePosted - 17 Jun 2021 : 10:05:51
Nice! My initial idea (of which I've never really researched the feasibility) was to place the VR sensor sideways just above the starter, but your solution is much easier and neater.
AnttiKPosted - 16 Jun 2021 : 18:47:12
Balance shaft gear lost its teeth and I decided to purchase new hybrid gear set from Motomobil. At the same time I decided to change to flywheel trigger. 36-1 pattern was milled to flywheel. Actually the size of the teeth became quite huge in the end, but main thing is that the trigger works Those did not look that big in CAD program.

Sensor was installed to clutch bellhousing:


I can see the RPM signal is now more stable. Not dramatically, but clearly less ripple.

At the same time I installed Peugeot 306 2.0 hydraulic engine mounts, which are about 30mm taller than the original, so engine mounting brackets had to be modified. And now there is clearly less vibrations. Probably mostly because of improved engine mounts and maybe a little because trigger wheel (extra weight interfering the balance shaft) is now removed from balance shaft pulley.
AnttiKPosted - 18 May 2021 : 13:15:23
Yes, it is Opel Astra / Saab 9-3 320mm hose with banjo fitting in the caliper end and there is enough length or even too much length. The original hose length is about 250mm, but because of banjo fitting hose must be longer anyway.
DerekPosted - 18 May 2021 : 12:43:07
Very smart. I can't see behind the calliper but is the brake hose long enough to cope with full lock and suspension movement? Or both in extremis!
AnttiKPosted - 18 May 2021 : 06:14:26
Hub conversion is now inspected by finnish vehicle inspection engineer. So it is street legal now I had to use a hammer to the rear hub cap to make some more space for rear axle.

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