I am almost finish with my install, it requires little more tuning but it starts easy and I use the car as my daily driver
Have my car passed goverment inspection 2010-03-24 incl emission test
I will try to share as much info as possible about this project.
Only stock/OEM sensors are used, and OEM wire harness modified/cutoff at the OEM ECU.
Used ignition-strobolamp to check trigger angle but there is NO mark on the flywheel. There is a good hole beetween gearbox and engine though. I put the engine at TDC then painted a litle white on the flywheel in the hole. That worked very well.
I adjusted the TP idle stop screw so it idled at about 800+ rpm. Then only using the IAC when cranking and during warmup. It idled at about 600-700 from beginning at this engine is suppose to idle at 775-825 rpm per defintion.
TPS calibrated as 51 at idle and 235 at full throttle.
Engine spec:
- Engine code: AAF (this is basically an Audi I5 engine but with 16mm higher deck and stroked crank)
- Size: 2459 cc, 5 cylinder, 81.0mm bore, 95.5 mm stroke
- cylinder block in grey cast iron, six main bearings
- two valves per cylinder each with two concentric valve springs, 10 valves in total(NOT crossflow)
- belt-driven single overhead camshaft (SOHC)
- common rail multi-point electronic fuel injection system with intake manifold-sited fuel injectors
- 110 PS (81 kW; 110 hp) at 4500 rpm 190 N·m (140 lb·ft) at 2200 rpm
- Distributor with HALL sender and locked from beginning (stock ECU also controlled ignition)
- Volvo Ignition Coil (Bosch xxx)
- PCB v3, ECU v I, Msextra 029y4 (I think)
- One VB921 mounted internally and drives a single coil and dizzy
- TIP122 mounted instead of Q5 in place of one high current resistor(R43?) to hanlde the VDO 2-pin Idle valve
- Using HALL input circuit modified with "12v pullup circuit" using 1k resistor. Took 5v from the MS and powered the sensor with it and set the trigger as falling edge.
- Injectors(OEM): VAG: 044 906 031, Bosch: 0 208 155 604, size: 146, 14.5 Ohm all parallell connected at 2.6 Ohm together
- Fuel pressure regulator at 3 bar
- Stock dizzy is locked sinced OEM ECU handled spark as well. Taking input from this. 5 signals per 720 degree crank.
- Trigger Angle is 90 degress, could not enter this so I entered 89 for now. Will look into it later
- Distributor: HALL pin#1:earth[red/black], pin#2:0 (Hall-signal, ~5v)[brown/white], pin#3:+12v feed[green/white]
- TPS VAG 044 907 385 A: pin#2:signal[red/blue], pin#?:earth[brown/white], pin#?:5v ref[blue/black]
- Ignition Coil: pin#1:earth[brown], pin#2:control signal[green], pin#3:+12v feed[black]
- CLT: VAG 025 906 041 A blue 20mm, 100 degrees C @ 200Ohm, 25 degrees C @ 2000Ohm, 0 degrees C @ 6000Ohm.
- IAT: pin#1:co pot.(not used in MS), pin#2:temp signal[brown/white], pin#3:earth[blue/yellow]. hmm wonder if this is right...
- IAC: VDO 037 906 457: pin#?:+12v feed[black], pin#?:earth/control[white]
- CSV: 9.8 Ohm, pin#?:+12v feed[black], pin#?:earth/control to ECU[black/red] NOT yet connected
DB37#36 to earth/control signal on the ignition coil[OEM_ECU-pin#27 green]
Megasquirt software setup
Required fuel set at 22ms (will up this a little as the idle values are at about 50:ish now)
Squirts per engine cycle: 1
All injectors fire together as they are 5 and connected in the OEM setup
Injector open time: 1.0 ms
battery voltage correction: 0.20
PWM limit: 100%
PWM time: 25.5 ms
fast idle threshold: 89.9 degrees C
Exhaust gas settings:
EGO_ narrow band
EGO switch point: 0.510
ign events per step: 20
step size: 1%
Controller authority: 7%
active above 72 degrees C and above 1100 rpm
Codebase/setup
Distributor setup: MSnS
FIDLE as Idle control
LED17(D14) as Spark Output A
LED18 as Warmup
LED19 as acceleration
Multiplex ign: normal (?)
X2 (JS0) as Fan control (not used)
X4(JS2): output1 (?)
Output3/sparkD: output3 (?)
pin10 shift: Shiftlight (?)
knock in /spark F: spark output F (no idea why?)
Warmup settings:
prime pump: always
fire priming pulse: after 2 sec
priming PW source: table
using CLT only
Cranking table(not yet finish tuned):
-40C=25.0;-29C=25.0;-18C=25.0;-7C=25.0;4C=12.0;16C=8.0;27C=6.0;38C=4.0;54C=3.5;71C=3.0
Crankning ROM: 300
TPS for flood clear: 190
extra cranking fuel enrichment: 50%
use firts start enrichment: on
ASE timer: cycles and 200
ASE mode: fixed then decay
MAp mode during ASE: normal MAP
use fixed ASE/MAP when CLT below 7.2
Fixed ASE/MAP time period: 5
table:
-40C=150%;-29C=130%;-18C=120%;-7C=100%;4C=70%;16C=70%;27C=12% ?? ODD
First startup not mapped:
http://www.youtube.com/watch?v=HCIJ4Kek9wg
/M