It's about time for an update, and like many it's been a busy last few weeks in the shed. First on the list of to-do's was sort out the fuel system.
A return line would be needed for this injection setup and unfortunately the tank that was in the car was one that did not have a drain bung that I could tap into. I added one up the top in a position that I thought would cause least disturbance to the fuel float from fuel returning back in to the tank. I also lopped off the original feed tube as it was probably too small for this application. I added the same 1/4" BSPT screw in fitting to the bottom there. Silver soldered in by a radiator repair place.
Fuel lines were run and the fuel pump and filters were installed on the rear subframe. I've since added rubber grommets to protect the fuel lines as they go up into the boot.
(in this photo you can see an extra breather that I added that goes from the old dist hole to the filler neck -> catch can that you can see in some other photos mounted on the firewall)
I didn't think that a swirl pot/surge tank was really that necessary for this build. It'll be seen to be believed but if I needed to add one in, it would be relatively simple to plumb it in. Once the fuel tank was installed it all looked nice and neat.
Ignition coils from a Toyota Yaris were recommended for me to use in the build and they fit the head pretty well and will be relatively easy to wire up (only requiring 3 out of the 4 pins to be used). I just needed to make up a mounting plate for them to keep them secure. Some aluminium flat stock cut, drilled and tapped to size did the trick.
Starting the wiring was next and to start I decided to get rid of anything that I didn't need. All I really had to remove was the wire directly to the coil from the ignition switch, and the wire from the coil to the distributor. This turned out to be a more difficult job than I thought - largely because all of the wires were covered in 44 years of dirt and woo that made them all indistinguishable so a few hours was dedicated to sorting and cleaning all of the old stuff. I have found that the wiring diagrams in my Gregories manual for different variants of Clubmans are all
similar, but none of them are exactly the same as the way my car is wired or the colour of the wires - there's not much evidence that my car wiring has been stuffed with in the past so I am at a loss to why some things are different. I still have one dark green wire that runs along the front side of the the engine bay that has two female spades on it about a meter apart that don't seem to go anywhere. It comes straight from the original fuse box. Spotlights maybe?
It was only mildly daunting at this stage but things got a little more daunting once I added the wiring loom from the Haltech Elite 550 and fuse box into the engine bay.
While it all looks like complete chaos, it is all relatively simple. once the wires were routed roughly where they needed to go, it was easy to see what I needed to wire up and what I didn't need in my application. All the wires hanging out of the drivers side of the car (with the exception of 3 or 4) won't be needed for me.
The fuse box and ECU is mounted underneath the parcel shelf and is tucked away but still allows easy access to the USB connector for when tuning and access to the fuse/relay panel. Excuse the horribly ill fitting carpet!
The ECU is quite small and fits there nicely. I am incredibly impressed with the quality of the Haltech stuff that I am using so far. the wiring harness is awesome and the fuse box and relay panel already comes ready to go with main and fuel pump relays. All I really have to do is terminate the wires I am using and reassign or remove the wires that I don't plan to use.
I will need to add an inlet air temp sensor but other than that, everything that is already installed on the mini engine should be enough to get the car running. Anything else (such as exhaust temp or really anything) is just an extra reference point for the ECU to either self tune or use as a reference for engine scheduling as the tuner sees fit.