A neurotic over-engineer does a K24Z swap
#1
Senior Member
Thread Starter
iTrader: (1)
Join Date: Dec 2007
Location: San Jose
Posts: 658
Total Cats: 340
A neurotic over-engineer does a K24Z swap
I can't believe I don't already have a build thread here, but I guess I never felt my Miata was interesting enough to merit a thread. Now I think it will be.
This is my Miata. It's currently running a VVT motor using a Megasquirt 3. It puts down around 138 horses to the wheels on 91. It has some good torques too.
By day, I'm an engineer at a medical device company in the Bay Area. I write software of all kinds and chase those insidious little problems that **** off our test engineers. I also try and prevent those errors before they happen. You have to be a little crazy to stay in this job as long as I have. I've never worn both a belt and suspenders at the same time, but you get the idea.
The goal for this build is to have a dead-reliable HPDE or TT car that slots nicely into the pointy end of NASA ST/TT4. I've chosen 4 because I've already installed the MK60 ABS, which is freaking amazing, and puts me in no less than 4. I'm leaving my mind open to go into ST, but I don't think I'll be doing that right away.
The car as it sits today, with me and about 3/4 tank of fuel, weighs 2300lb. With NASA-template <266mm, 100TW tires, that will allow me 205 "max average horsepower" with about a quarter tank of gas (rough projection). I hope this engine will get me there.
I've placed an order for all the KPower parts, as well as the trick SuperMiata clutch and flywheel. My bank account hurts.
While wasting away a COVID evening (who am I kidding, it's not like I'd have been doing anything different if things weren't shut down), I came across a low-mile engine at a wrecker in San Francisco. 2012 TSX wagon that was smashed at both ends. I bought it the next day and had it delivered. At $536 delivered, plus a tip for the delivery guy, it's the cheapest part I've bought so far. I'm glad I jumped on it - it looks very clean inside and it has a Honda brand oil filter. I'm hoping that means it was dealer-serviced, which I would think might mean it was actually maintained.
The last NASA event of the season is the first weekend in October. I'm hoping to be there with the car in its current configuration. I'm currently screwed in the "getting to the track" department because I typically rent a truck through Enterprise and CalFire currently has every single one of their pickups rented. I tried a U-Haul pickup for the last event and won't do that again. The truck was the bottom-of-the-barrel kind of stripper you'd only find in Atlantic City. It didn't even have trailer brakes, which made hauling my 20' enclosed trailer up to Sonoma probably one of the dumber and more dangerous things I've done lately. Never again.
In the meantime, I'll be planning. I'm a big fan of proper wiring harnesses and data-logging. I also have a Daniels crimper and TH1A turret just itching to be used.
The Numbers I Don't Want To See
This is my Miata. It's currently running a VVT motor using a Megasquirt 3. It puts down around 138 horses to the wheels on 91. It has some good torques too.
By day, I'm an engineer at a medical device company in the Bay Area. I write software of all kinds and chase those insidious little problems that **** off our test engineers. I also try and prevent those errors before they happen. You have to be a little crazy to stay in this job as long as I have. I've never worn both a belt and suspenders at the same time, but you get the idea.
The goal for this build is to have a dead-reliable HPDE or TT car that slots nicely into the pointy end of NASA ST/TT4. I've chosen 4 because I've already installed the MK60 ABS, which is freaking amazing, and puts me in no less than 4. I'm leaving my mind open to go into ST, but I don't think I'll be doing that right away.
The car as it sits today, with me and about 3/4 tank of fuel, weighs 2300lb. With NASA-template <266mm, 100TW tires, that will allow me 205 "max average horsepower" with about a quarter tank of gas (rough projection). I hope this engine will get me there.
I've placed an order for all the KPower parts, as well as the trick SuperMiata clutch and flywheel. My bank account hurts.
While wasting away a COVID evening (who am I kidding, it's not like I'd have been doing anything different if things weren't shut down), I came across a low-mile engine at a wrecker in San Francisco. 2012 TSX wagon that was smashed at both ends. I bought it the next day and had it delivered. At $536 delivered, plus a tip for the delivery guy, it's the cheapest part I've bought so far. I'm glad I jumped on it - it looks very clean inside and it has a Honda brand oil filter. I'm hoping that means it was dealer-serviced, which I would think might mean it was actually maintained.
The last NASA event of the season is the first weekend in October. I'm hoping to be there with the car in its current configuration. I'm currently screwed in the "getting to the track" department because I typically rent a truck through Enterprise and CalFire currently has every single one of their pickups rented. I tried a U-Haul pickup for the last event and won't do that again. The truck was the bottom-of-the-barrel kind of stripper you'd only find in Atlantic City. It didn't even have trailer brakes, which made hauling my 20' enclosed trailer up to Sonoma probably one of the dumber and more dangerous things I've done lately. Never again.
In the meantime, I'll be planning. I'm a big fan of proper wiring harnesses and data-logging. I also have a Daniels crimper and TH1A turret just itching to be used.
The Numbers I Don't Want To See
$1,864.08 SuperMiata RaceTwin clutchNever reached production- $4,916.71 KPower
- Flywheel Bolt Set
- Type S Oil Pump Upgrade for K24Z3
- Karcepts K Series Fuel Rail
- FUELAB Fuel Pressure Regulator -6 AN
- 3" Race Exhaust System for NA/NB Miata - NA
- K Series Heater Port Adapter
- K24Z3 Miata Race Swap Package - Miata 6-speed
- $536.13 ENGINE 2012 ACURA TSX 4 CYL USED
- $45.10 Bishko OEM Digital Repair Maintenance Shop Manual CD for Acura TSX L4 - Sedan & Sport Wagon 2011 - 2012
- $207.58 Honda Accord Starter & Alternator, eBay reman by rr_alternators-starters
- $69.92 TSX starting/charging harness
- $178.85 Maintenance(ish) parts
- Small upper timing chain guide for modified valve cover
- Water pump (Aisin)
- Front, rear crankshaft seals
- Valve cover gasket with plug tube seals
- Thermostat housing/water outlet/thermostat
- Lower radiator hose
- Timing cover gasket
- Water pump gasket (possible duplicate, but cheap)
- Thermostat housing seal #2
- $11.06 Genuine Honda OEM Hondabond 4 liquid gasket
- $750 6-speed, with shifter, from East Street Racing
- $31.68 Accelerator pedal, 2010 Honda Fit, used, eBay.
- $171.87 Bosch DBW 74mm throttle body, FCPEuro
- $106.18 DW200 Fuel Pump for NA/NB Miata, FlowForce
- $348.15 Acura parts from AcuraExpressParts.com
- Cam chain tensioner (I prefer OE for things like this)
- Two chain guide bolts whose hex sockets I stripped when removing because I'm an idiot
- Acura RDX injectors (410cc)
- $1,932.25 Haltech
- Elite 1500 ECU
- WB1 - Single Channel CAN O2 Wideband Controller Kit
- $331.02 Flyin' Miata
- Rebuildable driveshaft for 1.8 Miatas
- Seal, rear tailshaft, 5- and 6-speed
- $1,018.24 Haltech
- IC-7 Dash
- Mounting Bracket with Integrated Visor
- $389.19 SuperMiata
- Supermiata Sport Clutch 94-05 Miata 1.8 - Sprung Puck
- $9.82 GM 3-pin connector for pressure sensor - Amazon
- $9.83 GM 3-pin connector for pressure sensor - Amazon
- $29.99 GlowShift Oil Filter Sandwich Plate Thread Adapter - 20mm x 1.5 Thread - Amazon
- $24.02 Acura 14540-PRB-A01 Engine Timing Chain Guide (smaller one for modified KPower valve cover) - Amazon
- $43.74 NGK 5787 ILZKR7B-11S Laser Iridium Spark Plug, Pack of 4 - Amazon
- $18.54 4x Acura RDX 2-Pin Fuel Injector Connector Plug Clip RSX Honda 410cc - eBay (ksvlooms)
- $100 Blink Marine CAN 8 button custom control panel PN PKP2400-LI - eBay (lewh9131)
- $144.07 RockAuto
- ACDELCO 2134333 (213-4333) Temperature Sender / Sensor $ 14.96
- AISIN THH003 (THH-003) Thermostat Housing / Water Outlet $ 26.79
- DAYCO 71718 Radiator Lower Hose $ 10.38
- DELPHI TS10080 Air Intake / Charge Temperature Sensor $ 15.65
- GATES 19498 Heater Hose / Pipe $ 3.42
- GATES 23184 Radiator Upper Hose $ 25.79
- MAHLE C32022 Thermostat / Thermostat Housing / Water Outlet Seal $ 2.37
- WIX 57356 Oil Filter $ 4.69 x 2
- $71.69 Mouser
- PX3AN2BS100PAAAX - Honeywell 100psi pressure sensor - oil
- $68.64 Newark
- PX3AN2BS100PAAAX - Honeywell 100psi pressure sensor - fuel (purchased at different times)
- $29.28 McMaster-Carr
- 4545K162 37 Degree Flared Fitting for Steel Tubing, Male Adapter for 1/4" Tube OD x 1/8 BSPT, 4500 PSI $4.89
- 9151K253 High-Pressure Nickel-Plated Brass Pipe Fitting, Plug with Hex Drive, 1/8 BSPT Male $0.86
- 50785K112 High-Pressure Brass Pipe Fitting, Plug with Hex Drive, 1/8 NPT 4x $0.83 (lost the plugs for the stupid sandwich adapter)
- 50715K171 37 Degree Flared Fitting for Stainless Steel Tubing, Adapter for 1/4" Tube OD x 1/8 NPT Female $10.73 (ouch)
- $8.64 McMaster-Carr
- 92235A432 Flanged Socket Head Screw, Black-Oxide Alloy Steel, M6 x 1 mm Thread, 40 mm Long, Packs of 10 (for throttle body)
- $560.63 Summit
- FRA-481426-BL Fitting, Hex Head Port Plug, -6 AN O-Ring, 9/16-18, 1/8 NTP Female Port, Black Anodized
- FRA-602006 Hose, P.T.F.E., PTFE Lined, Braided Stainless Steel, -6 AN, 20 ft. Length
- FRA-606006 Hose, P.T.F.E, Braided Stainless Steel, -6 AN, 6 ft. Length
- FRA-484106-BL Fitting, Straight, 3/8 in. Barbed Hose End to -6 AN Male, Aluminum, Black Anodized x2
- FRA-491989-BL Fitting, EFI Adapter, Straight, Male -6 AN to 3/8 in. Female Spring Lock, Aluminum, Black Anodized x2
- FRA-499268BL Fitting, 90 Degree, Male -6 AN to Male -8 AN O-Ring, Aluminum, Black Anodized
- FRA-499206-BL Fitting, 90 Degree, Male -6 AN to Male -6 AN O-Ring, Aluminum, Black Anodized
- FRA-680106-BL Fitting, Hose End, Real Street, Straight, -6 AN, Aluminum, Black Anodized, Each x10
- FRA-900006 AN Wrench, Aluminum, Red Anodized, -6 AN
- FUE-81801-1 Fuel Filter, 818 Series, Inline, 10 microns, Billet Aluminum Housing, Black Anodized, Paper Element (FueLab)
- $85.15 Summit
- FRA-689006-BL Fitting, Hose End, Real Street, 90 Degree, -6 AN, Aluminum, Black Anodized x3
- FRA-999306 Fitting, Replacement Olive for P.T.F.E. Fitting, Aluminum, Natural, -6 AN x3
- $38.21 Summit
- FRA-495100-BL Fitting, Adapter, AN to Straight Cut, Straight, Aluminum, Black Anodized, -6 AN, -6 AN
- FRA-684506-BL Fitting, Hose End, Real Street, 45 Degree, -6 AN, Aluminum, Black Anodized
- $88.45 Summit
- FRA-681206-BL Fitting, Hose End, Real Street, 120 Degree, -6 AN, Aluminum, Black Anodized x2
- DAC-80080 Fuel Injection Hose, Nitrile Rubber, Black, 3/8 in. Diameter, 18 in., 100 psi. Max
- $1279.47 KPower
- Hybrid Racing Heater Delete Kit
- Modified K24 Valve Cover for NA Hood (Might be able to recoup $150 by returning the core.. it's been a while though)
- KMiata Flywheel (version 2)
- $153.84 Mazda Motorsports - various shifter rebuild components
- $86.29 Mazda Motorsports - heat shielding
Last edited by thebeerbaron; 07-23-2021 at 10:51 PM. Reason: Updating expenditures (ouch)
#6
Senior Member
Thread Starter
iTrader: (1)
Join Date: Dec 2007
Location: San Jose
Posts: 658
Total Cats: 340
Wow, thanks for all the subscribes and cats, I'm honored!
All the MK60 info is in the thread on that subject. I should add a few more pictures, but it's really not a big deal once you get the sensor mounting sorted out. You're going to love it.
After I made this post last night, I found an amazing piece of software that I've just got to share. It's called RapidHarness and it's perfect for designing wiring harnesses. It has a database of connectors, knows the number of pins/cavities in each connector, and helps you to track basically all of the things you'd track while making a harness. There's a good tutorial here - https://www.youtube.com/watch?reload...ature=youtu.be
You can see some of my progress so far - I'm creating placeholder connectors and making connections between them. My first pass is to create all the connectors I'll use, with the correct number of cavities in each connector. Once my TSX factory service manual arrives on Friday, I'll have an authoritative source for identifying the pins in each Honda connector.
I've decided to use the Haltech 1500 Elite as the ECU - I'm uninterested in the KPro half-answer, and I have not found confirmation of anyone running a K24Z3 on Megasquirt, using stock sensors. The Haltech is popular with Honda owners and there's rumor of a Z3 base map.
What I haven't figured out yet is power distribution. CAN-driven power management is a very attractive idea, but it is far from cheap. There are some options, but the current draw of the MK60 is in question - the documents I've found suggest that it uses a 30A circuit - what I don't know is if it needs all of those 30A or if there are other loads on that circuit. 30A is quite a bit of power for solid-state drivers.
All the MK60 info is in the thread on that subject. I should add a few more pictures, but it's really not a big deal once you get the sensor mounting sorted out. You're going to love it.
After I made this post last night, I found an amazing piece of software that I've just got to share. It's called RapidHarness and it's perfect for designing wiring harnesses. It has a database of connectors, knows the number of pins/cavities in each connector, and helps you to track basically all of the things you'd track while making a harness. There's a good tutorial here - https://www.youtube.com/watch?reload...ature=youtu.be
You can see some of my progress so far - I'm creating placeholder connectors and making connections between them. My first pass is to create all the connectors I'll use, with the correct number of cavities in each connector. Once my TSX factory service manual arrives on Friday, I'll have an authoritative source for identifying the pins in each Honda connector.
I've decided to use the Haltech 1500 Elite as the ECU - I'm uninterested in the KPro half-answer, and I have not found confirmation of anyone running a K24Z3 on Megasquirt, using stock sensors. The Haltech is popular with Honda owners and there's rumor of a Z3 base map.
What I haven't figured out yet is power distribution. CAN-driven power management is a very attractive idea, but it is far from cheap. There are some options, but the current draw of the MK60 is in question - the documents I've found suggest that it uses a 30A circuit - what I don't know is if it needs all of those 30A or if there are other loads on that circuit. 30A is quite a bit of power for solid-state drivers.
#7
I've decided to use the Haltech 1500 Elite as the ECU - I'm uninterested in the KPro half-answer, and I have not found confirmation of anyone running a K24Z3 on Megasquirt, using stock sensors. The Haltech is popular with Honda owners and there's rumor of a Z3 base map.
#10
__________________
#11
Senior Member
Thread Starter
iTrader: (1)
Join Date: Dec 2007
Location: San Jose
Posts: 658
Total Cats: 340
As mentioned in the thread Emilio referenced above, I've been farting around with the Haltech software. I'm surprised at how quickly I have used up the available IO pins. The assigned pins have the empty checkboxes next to them - I guess you're supposed to print this page out and use it to wire everything up. I'd really prefer to get it in a spreadsheet format, but this is better than nothing by far.
I'm planning on using the Haltech CAN wideband module, which saves me an analog voltage input. I could probably get away without alternator control, but I figure I may as well use it.
I'm planning on using the Haltech CAN wideband module, which saves me an analog voltage input. I could probably get away without alternator control, but I figure I may as well use it.
#12
Senior Member
Thread Starter
iTrader: (1)
Join Date: Dec 2007
Location: San Jose
Posts: 658
Total Cats: 340
Here's a little progress on the harnesses. I'm really liking the ability to capture info like connector part numbers and wire gauge and length. It will make sharing this info easier. I don't actually plan to use the Ballenger parts for all these connectors - I have many from the cut harness that came with my motor. But there's that neurosis - I enjoy the completeness of identifying the necessary connectors.
I'm planning on running the Bosch 74mm DBW throttle that "everyone" uses. I think I knew the part numbers for that connector at one point, but I may have misplaced it. I'll figure it out again I'm sure.
I still haven't settled on whether I'll use a fancy race PDM or just a decent wiring block. AIM has a model called "AiM EPM Power Distribution Interface" that was supposed to come out at the end of August. It seems to be a cheaper version of their PDM-08. I need to reach out to them to ask for more info.
https://www.aimshop.com/collections/...tion-interface
I'm planning on running the Bosch 74mm DBW throttle that "everyone" uses. I think I knew the part numbers for that connector at one point, but I may have misplaced it. I'll figure it out again I'm sure.
I still haven't settled on whether I'll use a fancy race PDM or just a decent wiring block. AIM has a model called "AiM EPM Power Distribution Interface" that was supposed to come out at the end of August. It seems to be a cheaper version of their PDM-08. I need to reach out to them to ask for more info.
https://www.aimshop.com/collections/...tion-interface
#13
That software looks awesome, great work so far. If you feel like sharing that file when you're done it would definitely save me some time haha.
The only thing that I saw about the trial version is that it has a limit on how many connectors you can have or something like that? Has that given you any issues?
Side note, this thread is already living up to the title. In a good way.
The only thing that I saw about the trial version is that it has a limit on how many connectors you can have or something like that? Has that given you any issues?
Side note, this thread is already living up to the title. In a good way.
#14
Senior Member
Thread Starter
iTrader: (1)
Join Date: Dec 2007
Location: San Jose
Posts: 658
Total Cats: 340
Dammit, I edited out the bit about the software cost and limitations. Yes, the “30 connection” limit has bit me in the ***. That’s essentially a 30 wire limit, which is why I only have a partial sub-harness defined. I would happily pay something to remove that limit, but I can’t afford even their most basic paid plan. I may reach out to them, but in the meantime I have sub-harnesses. This would be fine if I could alias the main ECU and power connectors across all sub-harnesses, but I haven’t figured out how to do that yet, if it’s even possible. So I have copies.
I’d be happy to share the files. Until I get things more nailed down though, the connection spreadsheet images I’ve put up are probably the most useful.
When I worry that I’m worrying too much about some detail on a project like this, I head over to Blog | Tom Yang's Ferrari Restoration and read about vintage Ferrari projects. It gives the engineer and skeptic inside me (and maybe my not-so-inner *******-ness) a feeling of superiority. Man, those cars are slapped-together, poorly-designed, and overanalyzed. The fastidiousness of restoring and maintaining them is amazing, especially when you consider that this level of attention was clearly not the norm at the factory when they were produced. Hey, this software is expensive, but at least I’m not chrome plating anything or worrying about the direction the cotter pin is facing...
I’d be happy to share the files. Until I get things more nailed down though, the connection spreadsheet images I’ve put up are probably the most useful.
When I worry that I’m worrying too much about some detail on a project like this, I head over to Blog | Tom Yang's Ferrari Restoration and read about vintage Ferrari projects. It gives the engineer and skeptic inside me (and maybe my not-so-inner *******-ness) a feeling of superiority. Man, those cars are slapped-together, poorly-designed, and overanalyzed. The fastidiousness of restoring and maintaining them is amazing, especially when you consider that this level of attention was clearly not the norm at the factory when they were produced. Hey, this software is expensive, but at least I’m not chrome plating anything or worrying about the direction the cotter pin is facing...
#15
Senior Member
Thread Starter
iTrader: (1)
Join Date: Dec 2007
Location: San Jose
Posts: 658
Total Cats: 340
I just discovered that Toyota Prius throttle pedals currently sell for about $25 on fleabay. That's about the same as a VW throttle pedal goes for, but it obviously has more acceleration. I'm sorely, sorely tempted to use one as my loud pedal, just for shiggles. I mean, a resistor is a resistor, right?
#17
Senior Member
Thread Starter
iTrader: (1)
Join Date: Dec 2007
Location: San Jose
Posts: 658
Total Cats: 340
Connector Pin Assignments
My factory service manual arrived today. I'm going to add pinouts for the relevant engine connectors to this post. This post will be edited several times as I find and consolidate the data.
Honda identifies the pins on each connector as they are viewed from the wire side of the connector.
As you can see, they are numbered from left to right. The only two-row connector in this chart has its own diagram (alternator).
On the subject of grounds...
I have identified the two sensor grounds for your convenience. These are directly from the Acura manual.
The three pulse sensors use what Honda identifies as "Logic Ground - Ground circuit for ECM/PCM". I take this to mean something other than a dirty nasty power ground. YMMV.
Rocker Arm Oil Control Solenoid
1. Ground
2. ECU
VTC Oil Control Solenoid
1. Ground
2. ECU
Coolant Temperature Sensor
1. ECU
2. Sensor Ground
MAP Sensor
1. 5V
2. ECU
3. Sensor ground
CKP Sensor (Crank Shaft Sensor)
1. ECU
2. Ground
3. 12V
CMP Sensor A (Intake Cam Sensor)
1. ECU
2. Ground
3. 12V
CMP Sensor B (Exhaust Cam Sensor)
1. ECU
2. Ground
3. 12V
Injectors
1. 12V
2. ECU
Coils
1. ECU
2. Ground
3. 12V
Alternator
1. 12V
2. C - Alternator control by ECU. Tie to ground to turn off charging.
3. L - Lamp - voltage regulator ties to ground to indicate a fault
4. FR - Alternator load indication
My description of these terminals comes from here: https://www.autoserviceworld.com/car...rging-systems/
My factory service manual arrived today. I'm going to add pinouts for the relevant engine connectors to this post. This post will be edited several times as I find and consolidate the data.
Honda identifies the pins on each connector as they are viewed from the wire side of the connector.
As you can see, they are numbered from left to right. The only two-row connector in this chart has its own diagram (alternator).
On the subject of grounds...
I have identified the two sensor grounds for your convenience. These are directly from the Acura manual.
The three pulse sensors use what Honda identifies as "Logic Ground - Ground circuit for ECM/PCM". I take this to mean something other than a dirty nasty power ground. YMMV.
Rocker Arm Oil Control Solenoid
1. Ground
2. ECU
VTC Oil Control Solenoid
1. Ground
2. ECU
Coolant Temperature Sensor
1. ECU
2. Sensor Ground
MAP Sensor
1. 5V
2. ECU
3. Sensor ground
CKP Sensor (Crank Shaft Sensor)
1. ECU
2. Ground
3. 12V
CMP Sensor A (Intake Cam Sensor)
1. ECU
2. Ground
3. 12V
CMP Sensor B (Exhaust Cam Sensor)
1. ECU
2. Ground
3. 12V
Injectors
1. 12V
2. ECU
Coils
1. ECU
2. Ground
3. 12V
Alternator
1. 12V
2. C - Alternator control by ECU. Tie to ground to turn off charging.
3. L - Lamp - voltage regulator ties to ground to indicate a fault
4. FR - Alternator load indication
My description of these terminals comes from here: https://www.autoserviceworld.com/car...rging-systems/
Last edited by thebeerbaron; 09-30-2020 at 02:29 AM. Reason: Finish adding connectors, notes