So...without further delay...this is an install on a customers car.
This is the "drosselklappe".
As you can see we use the stock mercedes one.
Just take it apart and silversolder a 8mm piece of axle to the TPS end and install the Haltech/Ford unit.
This is the fabled Honeywell 1GT101 Hall effects sensor.
We weld up a 4mm thick bracket for it at the lower two bolts on the camchain cover on the passenger side of the engine-just where the cover meets the oilsump.
Trigger is via two ferrous points that we drill and tap into the crankshaft dampner.(More often than not just some dressed M6 bolts-as that makes it extremely easy and cheap to replace if they get damaged.
Injector connectors and prong et al together with the Bosch weather seals for the connectors.
We basically route the "kabelbaum" per the original mercedes route.
This leaves us with a good,proven routing of wires.
From the picture it can be understood that we also take the time to route the main unit(ECU) into the car via the original routing of the wires,meaning that the ECU ends up approx at the glove compartment box where it´s out of harms way.
Coolant temperature sensor-which is fairly insensitive from a programing standpoint-is since a while back the standard GM one.
Main reason is that it´s cheaper than the Bosch and what´s more...it´s of sufficient size to dril and tap the original housing in an easy way.
To ensure a proper seal between the injectors and the intake bungs we turn some inserts in the lathe which we tap in place with a mallet and seal with some common permatex.
Works like a charm.(Yes,the fuelrail is my old ugly experiment which is based on a SAAB one.Customer wanted it that way?)
This is the stock "drosselklappe" in place.
As you can gather this means for the one so inclined..this conversion can be done with the stock airfilter and so on housing in place.
A treat that might come in handy to "fool" any and all athouritys if need be as apart from the connectors running for the inectors nothing really needs to be seen at a quick inspection.
Semi finished install.
Semi,as we´ve just hooked up a "whatever" throttle linkage to get the car going as the idea is to scrap most of it down the line anyways as the customer wants me to weld up and design a turbo intake manifold.No point in getting serious with something that is to be scrapped soon anyways.
None the less...this is what´s is left when the KE-jet is taken off the car.