I just wanted to update and let you guys know I finished the full 95 DSM wire harness/ecu swap. The van started up 2 days ago. The stock EFI relay is exactly the same as a 95 DSM EFI relay. I used my factory wiring harness from the ecu to under the hood, re-pinned/swapped. I ran new wires in the engine bay and either added wires, spliced/lengthened wires or rearranged wiring under the hood where needed. So I guess technically I have a hybrid wire harness, 96 Eagle Summit/95 DSM harness with a 95 eprom ecu.
For those of you that don't remember I built/forged the factory 4G64 sohc motor. Turbocharged it using factory DSM/Evo parts, a few aftermarket parts, LC1 wideband and a SAFC. My van is a AWD 5 spd model, I used an ACT PP and Southbend clutch.
The second revision of the build included a built 4G63 DOHC with cams, and a custom machined distributor to fit the 4G63 DOHC head on the 4G64 motor. The distributor used the factory plugs and ecu, so no ecu swap was needed or 4G63 cam angle sensor. The highest boost I ever got this setup to run was 16 psi on a old school FP green with 775cc injectors, SAFC. The timing was borderline out of control, and unstable imo for long term usage. Thus the final change to the setup.
The third revision and final hopefully was a 95 DSM wiring harness swap/95 eprom ecu, coil packs, ignitor, and cam angle sensor under camshaft gear. Crank positioning sensor wiring is the same, most other sensors the same, different color wiring and I had to swap around wires on the 2G tb from my factory. The stock distributor has all the wiring needed for dsm 95 camshaft sensor, ignitor, coil pack. They just need to be extended and ran to the correct location. I compiled most this information needed from DSM forums, Galant forums and factory service manuals.
The only problem I had with this whole swap was the fuel pump. I had a relay mod on my fuel pump (before the harness/ecu swap) and figured out a day later that it was not completing the circuit for the EFI relay. Pulled the fuel pump relay mod, put the fuel pump wiring back stock and the van fired right up.
Edited: I read somewhere in the past that the tach would not work with a swap.
(After going out and checking the stock tach against a volt meter at the same rpm's, it seems I'm only getting half the tach signal, the tach is off more the higher the rpm's build????)
I'm sure there is a gazillion things I'm leaving out which understandable. I've done everything to my van mechanically, even a fully auto body restoration and paint (now satin black w/ gloss black cladding, wheels, bumpers) after it was hit by a F5 tornado when it was SOHC turbo. But the ole girl started up after being dented and smashed, I drove it home afterwards from the subdivision that was leveled.
Any how the van runs great with the new setup. Boost is turned way down since I left the FP green on there and put 450cc injectors in. I figured this would be the best way to get it running stock like, work the bugs out before the wire/ecu swap to start up. Now that I have it running the ECU will be getting the DSMlink treatment. 950cc injectors swapped in and shooting for max flow on the FP green (I believe its 47 lb/min on the old school green).
Really looking forward to spring/summer this year
http://www.cardomain.com/ride/3240205/1996-eagle-summit