Fuel injection installation for Pinzgauer
By Jim LaGuardia

This system will work with many Engine management computer systems and is intended for those who have the technical knowledge and wish to fuel inject a Pinzgauer on thier own .
These instructions detail installation using an EMS Stinger 4, or EMS 8860 Sequential Injection computer system
To install fuel injection on a Pinzgauer you will need to first obtain all the required parts, and remove the fuel tank to install a fuel return line.

   After tank is out, you will need to drill a hole big enough for a 5/16" steel tube to fit through to the right of the fuel supply pipe flange(use bendable brake line), and braze or weld in place and test for leaks.The line should hug the tank on the outside and go at least 8-10" into the tank.
  Next replace the gasket and secure modified fuel supply/return line to the tank, and re-install tank.
                                             PARTS LIST

 Now you will need the following items ; EFI Manifold and Crank sensor mount  kit with tone wheel, Accellerator cable kit with brackets and Air cleaner adaptor ring(available from WWW.GOATWERKS.COM)
   In addition to the main hardware kit, you will need a 20amp 12/24 power converter or larger) EFI computer of your choice , (http://www.emsnorthamerica.com/ecu_specifications.htm)
 4 standard sized Bosch 30lb injectors(Accel #150130, or 150830 work great),
1 electric fuel pump (Bosch # 0580464048, or Pierburg # E3000-49687, Carter #P72018),
 1  2.5 bar Fuel pressure regulator (Bosch # 0280160214 works, Niehoff #21717),
1 throttle body from a 98-01 Ford explorer 4.0l v6 #F77Z 9E926 AD  www.ford-auto-parts-dealer.com,
Crank sensor(Wells#SU4214)
Sync sensor (optional) I used a Modified VW MSD distributor#8485
Coolant (oil) Temp sensor (Wells#SU109)
Air intake temp sensor (Wells#SU107)
Throttle position sensor (Wells#TPS265)
 For batch fire use 97-2000 1.8 liter Saturn Coil pack(Duralast#C1235) and module(Delco # 21024773, Duralast# SA102),
 for Sequential ignition use 4 seperate coils with built in ignitors,
1 or 2 fuel filters(pre and post pump prevents injector damage if pump fails),
 about 3 ft of 3/8" fuel hose (supply side), and 6-7ft of 5/16"High pressure fuel injection hose with full radius clamps , a few assorted fuel fittings and
 1 24v 30amp relay
 
Installation instructions
Step 1, sensor ring installation

The "Tone wheel" is indexed to the adaptor ring and the TDC mark on the crank pulley.
The pulley must be cut on a lathe(or brake lathe) to snug fit of sensor ring adaptor. Align the index mark of the adaptor ring with the TDC mark on the pulley and Drill and tap the first hole ,Use the aluminum ring for the template and install first screw loosely, repeat till all screws(at least 4) are tightend. Install the Tone Wheel onto locating pegs and secure with supplied screws. Re-install crank pulley to engine.

Crank Sensor and bracket

Remove both upper Fan housing mounting bolts and replace with bolts bracket and spacer.
  Secure crank sensor to bracket and adjust the air gap to the top of the teeth to .020"-.040" and secure all attaching bolts.

Engine preperation

 Start by removing air filter assembly, post , Carbs and fuel pump, use a VW pump block off plate to cover hole(or leave pump in place, loop a hose ,inlet to outlet).
Remove plug wires and Mil spark plugs(leave dist and cap) but disconnect and remove Ignition Coil(power wire will be used for injection system)
secure or cut off fuel solonoid wires.
Remove all accellerator linkage, and fuel lines.

Coolant(oil)temp sensor
Install computer oil temp sensor in block  above pan rail or at lower boss on thermostat housing, or in oil pan.
Air intake temp sensor

Install the sensor into the airhorn base of the air cleaner inlet.

Intake manifold

Before bolting down check for even seating on gaskets, mounting holes may be enlarged if necessary, as there are minor engine production variances.
It is easier to tighten the front mounting nuts with the front shroud tin removed.
Accellerator cable bracket ataches to last mounting stud on driver side.
Tighten all 8 mounting nuts(My computer grounds to the engine at intake).

Installing injectors to manifold
Remove fuel rail link fasteners and install fittings for fuel inlet and return lines.
 Lube the injector o-rings with oil or vasaline. After seatng the injectors into the manifold with connector ends on driver side, press fuel rail onto injectors(wiggle them to get the rail seated), and secure fuel rail with link fasteners. 

Fuel delivery and return

Install the fuel pump on the gunnel wall between the air filter mountings, use 3/8" fuel hose from source to pump, and (optional) pre filter.
 Use 5/16" high pressure fuel injection hose and full radius clamps for delivery side. I used #6 AN fittings on both ends of the fuel rail and counter bored the return fitting to use a hose from a Mercedes gas engine to attach the fuel regulator on mine. You can also use a 1/4' 90 deg pipe fitting and carefully retap it to 14mm 150 pitch and clock the regulator into it so the return line faces to the rear of the engine. Attach 5/16" high pressure fuel injection hose and full radius clamps from regulator to fuel return line on tank(route return hose along dipstick tube).
Fuel rail pressure should be 32-36psi
 
Accellerator cable

Using the supplied cable and adaptor, attach the cable to the throttle body and engine bracket(mounted at rear intake mounting bolt).  Attach front bracket to cable and align cable with accellerator adaptor, drill and pop rivet bracket to the lip on the body, or secure with screws, cut cable to lenth and secure into adaptor with set screw. Adjust travel at adaptor end.

O2 sensor
To tune most EM systems you need an o2 sensor for optamal results. Locate this sensor at the muffler inlet.

Batch fire coils and module mounting
 I used a GM ignition module and coil pack from a 97 Saturn 1.8L
Mounted to the body abve the heater control valve behind the spring mount on the heat sink provided in the kit.

Computer 
Install the computer of your choice or use an EMS Stinger or 8860 (I have running maps for these systems)
I used the coil power wire to trip a 30amp 24v relay to power the 24/12 voltage converter to the computer (I ran a seperate 24v power feed  from battery to relay supply.
Fuel economy

I am getting the same milage as carbs using batch fire 12-14mpg, but I was using oversized injectors, I just changed them out for 30 lb ones and expect to get a little more with them, and may see 16-18mpg when I switch to sequential., All I have is 2hrs dyno time to get these results.
Feel free to e-mail questions to info@goatwerks.com