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Air Pump Simulator DIY for $12.45
Published by xxxJohnBoyxxx
11-18-2008
Default Air Pump Simulator DIY for $12.45

I have completed my final version of my air pump simulator and it passed the testing this morning with no error codes. All parts from Radio Shack and total cost $12.45. No more $150-$200 to buy these online. I will post the complete DIY this evening when I get home from work. Here's a picture of the unit:




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  #1  
By marko on 11-18-2008, 01:59 PM
Default

wait, what? why are you removing your secondary air pump?
just curious...
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  #2  
By xxxJohnBoyxxx on 11-18-2008, 02:32 PM
Default

Quote:
Originally Posted by marko View Post
wait, what? why are you removing your secondary air pump?
just curious...
Been removed for 1.5 years. Needed the room in my engine bay to hide my meth system where the pump was, it's heavy, no use for it when you don't have a cat converter. Track headers don't have the hook-up for the air pump either. Lots of reasons like the ugly piping going accross the front of the engine to the header, etc. I remove all items not needed in my setup. Weight reduction is free excelleration and everything adds up when you do a lot of small things.

The air pump only runs for 2-3 minutes during warm-up to help the cat reach operating temp sooner. That is it's only purpose and I bet it weights 10 pounds.
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  #3  
By marko on 11-18-2008, 02:44 PM
Default

are you sure Nick G cant incorporate the elimination of the SAP into his software, as he does with the DISA valve?

also, how did you plug up the hole for the secondary shut off valve??

Quote:
Originally Posted by xxxJohnBoyxxx View Post
Been removed for 1.5 years. Needed the room in my engine bay to hide my meth system where the pump was, it's heavy, no use for it when you don't have a cat converter. Track headers don't have the hook-up for the air pump either. Lots of reasons like the ugly piping going accross the front of the engine to the header, etc. I remove all items not needed in my setup. Weight reduction is free excelleration and everything adds up when you do a lot of small things.

The air pump only runs for 2-3 minutes during warm-up to help the cat reach operating temp sooner. That is it's only purpose and I bet it weights 10 pounds.
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  #4  
By xxxJohnBoyxxx on 11-18-2008, 03:03 PM
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Quote:
Originally Posted by marko View Post
are you sure Nick G cant incorporate the elimination of the SAP into his software, as he does with the DISA valve?

also, how did you plug up the hole for the secondary shut off valve??
I'm sure Nick can do it but it is illegial to eliminate pollution control devises. Guess it depends on how good of a friend you are with him. DISA valve is not a pollution control devise it is a tuned intake manifold devise that is eliminated with a DASC. I removed everything (Pump, valves, etc) and plugged the hole from the header with a brass plug. When I install the metric motor I'm welding the hole on the header for the air pump and doing a header wrap to reduce heat.
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  #5  
By Xenocide on 11-18-2008, 04:14 PM
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Dude, chill out on the solder. Haha, use some flux next time and practice makes perfect!
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  #6  
By xxxJohnBoyxxx on 11-18-2008, 04:37 PM
Default

Quote:
Originally Posted by Xenocide View Post
Dude, chill out on the solder. Haha, use some flux next time and practice makes perfect!
Believe it or not I'm a expert at solding. Problem was I was not sober with very shaky hands when I did this. I normally use a air solder gun on pc boards but used a large tip trigger gun. I do hobby wiring on BGA (ball grid array) chips were there are 80 pin out's in the size of a dime, by hand. Also I had to add and remove pots, resistors, etc to get the correct resistance for the mv I needed. I couldn't use OHM's law because the O2 sensor is a voltage generator with no reading or data on watts or amps. If I did one today sober and a fresh board it would look sharp trust me. I would post some pictures of my hobby work but I don't want to expose who I am in the pirating world of smart cards.

John S
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  #7  
By xxxJohnBoyxxx on 11-18-2008, 09:05 PM
Default Air Pump Simulator DIY

DIY Secondary Air Pump Simulator.

Secondary Air Pump Parts Needed (All Purchased @ Radio Shack):

1 - Component PC board (#276-149 $1.99)
1 - Component Project Enclosure (#270-1802 $2.69)
1 - SPDT * PC relay miniature 12vdc 10V (#275-248 $4.69)
1 – 5V Voltage regulator (# 276-1770 $1.59)
1 - 100K – ohm Micro Potentiometer (#271-284 $1.49)

Tools Needed:

Soldering pen 7 watts or higher
Solder
Wire
Digital volt meter


Place relay, potentiometer and regulator on board as shown in picture. Solder all pins on back side of board. Go to wiring diagram and make connections. When finished test unit by hooking to 12 volts and set potentiometer with a screwdriver to 200mv from pin DME wire to ground. Potentiometer should be between 45,000 and 50,000 ohms if you want to ohm it out. Questions to jsmith50@tampabay.rr.com

***This is for off road use only***
***I accept no responsibility for items burned out or damaged by mis-use of this devise. The DME & O2 are sensitive devises and can be destroyed by sending the wrong voltage to the units***

Top Of Board




Bottom of Board




Wiring


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  #8  
By Jean H.318TI on 11-18-2008, 09:59 PM
Default

wtf i was trying to look for my SAP and i didnt find anything can someone tell me where is located (m44 engine)
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  #9  
By xxxJohnBoyxxx on 11-18-2008, 10:23 PM
Default

Quote:
Originally Posted by Jean H.318TI View Post
wtf i was trying to look for my SAP and i didnt find anything can someone tell me where is located (m44 engine)
Should be left side under the hose from the air filter. It's mounted on the strut just above the frame. PM sent back...
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  #10  
By Jean H.318TI on 11-18-2008, 10:26 PM
Default

well i guess i dont have one, weird
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  #11  
By Jean H.318TI on 11-18-2008, 10:55 PM
Default

some pics
Attached Images
File Type: jpg IMG00201.jpg (55.1 KB, 396 views)
File Type: jpg IMG00202.jpg (70.0 KB, 384 views)
File Type: jpg IMG00199.jpg (73.8 KB, 359 views)
File Type: jpg IMG00200.jpg (69.1 KB, 313 views)
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  #12  
By lpcapital on 11-18-2008, 11:12 PM
Default

I think the secondary air pump was added in 1997.
Your being a 1996 doesn't have it.
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  #13  
By Jean H.318TI on 11-18-2008, 11:14 PM
Default

mine is 5/96 production date
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  #14  
By lpcapital on 11-18-2008, 11:16 PM
Default

Quote:
Originally Posted by Jean H.318TI View Post
mine is 5/96 production date
Yea, I saw that and edited. It was 1997 then (or heck, maybe even 1998), but for sure the 1996 didn't come with one
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