The WOLF R 16v ABF Turbo on MSnS-e 13.6@111mph *170509*

[toyotec]

Name: Adlai Phillip
My car is a 1987 Monza Blue Golf MK2 16v which is called "The WOLF R" that is controlled by a MSnS-e single coil set-up using VAG ignitor and triggered by KR 16v hall sensor.


The WOLF R is an upgrade from what was called "The WOLF" based on a 2.0 16v ABF N/A engine in an atlas grey 88 16v. This car formed the "test bed" for the suspension and interior components now found in the WOLF R


Engine: 2.0 16v ABF code engine from Euro Mk3, converted to run on CIS K jet in The WOLF. This gave 160BHP@6400r/min and 145lbft@5500r/min


The 10.5:1 ABF motor had its compression dropped to 9.1:1 using 2 1.9mm metal gaskets.


2E Rods (bottom) unsured a greater margin of safety over the ABF units for the increased stresses that would occur when forced induced.


Balanced crankshaft,damper and flywheel,lightened 02A flywheel
Custom Lancia Delta Integrale 16v TB0385 turbo now modified to secret specs as of 06/01/07.

Toyotec custom built exhaust manifold.


Toyotec hybrid TT/S3/Cupra R to 16v inlet manifold, modified ABF 65mm TB, 440cc Bosch injectors on VAG 20vT fuel rail and digifant inserts.


Mitsubishi EVO3 FMIC custom fitted behind grill and custom boost pipes.


Blitz SSQV, Profec B boost controller, OEM CIS 16v fuel pump.
STD 053 103 373 D ABF head with STD ABF camset 10.8mm lift.

Corrado VR6 airbox and K&N panel hiflow filter.


Megasquirt V3 extra ecu built, installed and calibrated by Toyotec.
UK emission legal. No VB921s installed. Spark output is to OEM VW ignitor, hence megatune dwell settings is "fixed".
When the harness was installed and connected to the EMS the car started on the first turn. As the map values where assumed VEX generations calbration soon commenced until the car had the right "feel". With the majority of the calibration finished the car was taken to the smog center to ensure that it met the CO requirements for the year i.e 1987. I am happy to report that it passed at 2.0% CO with the limit being 3.5%. It still had a smooth idle with the AFR displaying 14.9 both on my LM1 and on the smog testers equipment.
Further refinement is soon to follow after the installation of new hybrid turbo.



Custom vehicle plug and play loom.

It Runs!!!!



Calibrated for 98ron pump fuel. KnockSence unit soon to be fitted and tested.


When last tested on the 12/09/06 this car did 0-60 in 5.8secs

and a 1/4mile in 14.2secs @ 104.65mph
Using a GtechPro Competition.


New figures with the hybrid turbo are coming soon.

Pre hybrid turbo output was;
Peak Power 250bhp @6800revs
Peak Torque 230lbft @4400-5100
Peak Boost pressue 7psig

Target Torque is 270lbft over this range of 4400-5100 or more.
This should result in peak output of 300bhp.
Maps need to be refined to approach LBT(fuel) and MBT(spark).
Keep watching this space
Thanks for viewing
Please feel free to ask any questions or you can contact me at the email address below to find out about building your own.

Adlai "Toyotec"

toyotec@hotmail.com

[chadr]

I've just completed my turbo 16v build as well. Can you share your msq?

Thanks.

[toyotec]

Since building the WOLF R project 8000miles ago, changes that would improve reliabilty and have some performance benefit, have been made.
To improve the exhaust mass flow to the turbine, and to reduce high EGT temperatures experienced at 200kPa boost levels pre turbo, a new turbo manifold was contructed.
This new unit which repalced the old log type unit seen above was made to position the turbocharger in the roughly the same position as the before. It was a challenge to get this fitted in a fairly compact location and retain a decent collector. More so as the car is a UK RHD vehicle and the brake servo gets in the way. In the end cylinders 2 and 3 were shorter and the outer cylinder runner lengths were increased to form the final design.
Here is picture the newly desgined manifold.

The turbo was also professionally rebuilt.
Here it is assembled to the new manifold.

And a trail fit of the assembly to the car.


While the heat flux would be decreased slighty with this new design, the exhaust gas exchange path and pecking order were improved. Especially as the maxium boost was increased from 200kPa to 220kPa.
A return to the M/S calibration (.msq file) showed that this new setup, more spark angle could be added to the 140-220kPa/ 4-7K regions without det. The maxiumm EGTs seen were 930ºC at 220kPa and 880ºC at "low boost" setting of 170kPa. λ was the same in both calibrations. More spark angle improved response and drive feel. Previously the EGTs with the log manifold and 200kPa was as high as 1050ºC.

So far this has been a very rewarding experience and lots of lessons have been learnt during this exercise.
There maybe one more challenge for this car and its powerpack. Once accomplished and update will be posted here.
Stay tuned...

Here is the WOLF R ABF 16v Turbo today 23/03/08.

[toyotec]

It has been over a year since this post was updated. Since the last update many changes have been done to the vehicle.
On the MS front Launch control and flat shift were added.
The vehicle was tested at AmD had recorded a peak of 285Ps@6100rpm
And a new Profec B 2 boost controller was installed
The vehicle was fully resprayed,

To add to the list of tasks a trip was taken to the UKs Santa Pod drag strip. In this outing the vehicle, being coaxed rather than driven agressively off the line, measured its best time of 13.6secs@ 111mph and 13.6@ 108mph. There were a number of reasons why the ET was a bit short on target, but no doubt these set the benchmark for a future trip to improve technique without the need for engine peformance updates.
So far after almost 10000 miles the built Megasquirt system as never missed a beat. With access to a Dyno Dynamics dyno becoming a reality, and because ABF motors come std with e 60-2 wheel and hall sensor pick-up, plans are to switch to this system and see if there are any benefits over the simple to fit and trigger TCI-h and 4 window dizzy from previous K Jet set-up.

Stay tune for more updates in the future. Here are some highlights of the car since the last time.

Clutch switch added for launch control. Switch was the WOT unit from an old digifant 11 throttle.


AmD CGTi rolling road day.


Body works


The WOLF R badge


Resprayed in original Monza Blue.


Engine bay unchanged


Santa Pod Staged

On the move. One of my 7 runs




I will post up the best time slips a bit later.

[toyotec]

As promised, the timeslips from the pod. Best 3 out of 7.
13.66@111mph


13.9@108mph


and
13.63@108mh

[Paul_VR6]

Plenty of room to grow with that trap speed. Good stuff.

[dirtytorque]

One of my favourite cars on the vw scene.
A hardcore engineering project.

Impressive time.

[toyotec]

Plenty of room to grow with that trap speed. Good stuff.

Thanks for the encouragement.
Hope to improve on this soon.
The little MS is the ECU that can.

[Paul_VR6]

You shouldn't have any problems we went 13.55 in our stock ABF powered n/a Mk2.

[dirtytorque]

You shouldn't have any problems we went 13.55 in our stock ABF powered n/a Mk2.

Really??

On megasquirt?
That's one hell of a time for an abf motor.
Toyotec should have buckets load to come then.
Maybe dip under 13.00 if he can get a good 60ft time?!?!??