Overview
Trying to get VEMS to run in a plug and play fashion on a 1997 Seat Cordoba SX, with a 2.0-16V engine (engine code ABF). The current engine hardware:
- 60 trim T3 Garrett with 0.63 AR turbine
- Audi external wastegate
- Stacked headgaskets
- 440cc/min highZ injectors, with 750cc/min lowZ planned for later
- Just over 1 bar boost
- Mapped water injection with aquamist HSV solenoid
Sensors
- Hall-effect type crank sensor on a 60-2 trigger wheel (15th tooth at TDC; counting convention used is missing tooth#1 is 0th tooth and missing tooth#2 is 1st tooth)
- Hall-effect sensor on camshaft for camsync (1-window trigger wheel)
- Bosch coolant temperature sensor
- GM open element air intake temperature sensor
- Two stock Bosch 3-wire knock sensors
Standard actuators
- Single Bosch coil triggered by Bosch ignition module located just under the coil. Original ECU controlled the dwell. Now swapping to waste-spark using VAG coil from 2000 Golf 2.0-8V
- 2-wire 4-ohm Bosch idle control valve, operating at around 140Hz
- Currently 440cc highZ injectors, but hopefully the VEMS will be able to idle the new lowZ 750cc injectors without problems
- RPM signal from ECU to instrument cluster to drive tachometer
Extra actuators
- High current PWM driver for aquamist water injection high speed valve (HSV)
- 2 stage shiftlight using 2 large LED's
- Intake air temperature based output to drive intercooler spray solenoid
- Boost control using Cosworth or Saab boost solenoid
- one EGT using k-type thermocouple in exhaust manifold
- Noritake VFD 4x20 LCD-pin-compatible display to replace the blue LCD ordered from webshop
- One wideband bosch LSU4 sensor
Wiring
Proposed wiring for ABF to VEMS plug and play loom:
| Description | ABF ECU pinout | VEMS Econoseal pinout | VEMS channel |
| Main grounds | T68/1 | EC36-5,21,32,22 | |
| Sensor grounds | T68/33 | EC36-26 | |
| Air temp sensor | T68/36 | EC36-2 | |
| Coolant sensor | T68/14 | EC36-14 | |
| TPS signal | T68/40 | EC36-1 | |
| Crank sensor power | T68/68 | EC36-28 (for 5V) or T68/38-EC36-25 (for 12V) | |
| Crank sensor signal | T68/67 | EC36-27 | |
| Camshaft sensor power | T68/46 | EC36-28 (for 5V) or T68/38-EC36-25 (for 12V) | |
| Camshaft sensor signal | T68/44 | EC36-13 | |
| Switched 12v power | T68/38 | EC36-25 | |
| TPS reference voltage | T68/41 | EC36-29 | |
| Ignition coil output 1 | T68/8 | EC36-35 | I259_0 |
| Ignition coil output 2 | External wiring | EC36-33 | I259_1 |
| Idle control valve | T68/27 | EC36-18 | INJFET_7 |
| Injector 1 | T68/24 | EC36-7 | INJFET_0 |
| Injector 2 | T68/25 | EC36-19 | INJFET_1 |
| Injector 3 | T68/26 | EC36-8 | INJFET_2 |
| Injector 4 | T68/2 | EC36-20 | INJFET_3 |
| Injector 12V common | External wiring | EC36-23 | |
| Fuel pump relay | T68/6 | EC36-15 | P259_5 |
| Tachometer signal to cluster | T68/22 | EC36-10 | I259_7 |
| Knock sensor 1 signal | T68/34 | EC18-3 | |
| Knock sensor 1 ground | T68/32,10 | EC18-2 | |
| Knock sensor 2 signal | T68/57 | EC18-3 | |
| Knock sensor 2 ground | T68/55,56 | EC18-2 | |
| Boost control | T68/31 (Charcoal canister) | EC36-6 | INJFET_6 |
| Shift light 1 | External wiring (350mA) | EC36-4 | P259_0 |
| Shift light 2 | External wiring (350mA) | EC36-16 | P259_1 |
| Coolant fan | External wiring (350mA) | EC36-31 | P259_6 |
| ALS kicker solenoid | External wiring (Needs external flyback diode) | EC18-12 | SPECFET_0 |
| Water injection HSV solenoid (PWM) | External wiring | EC36-24 | I259_6 |
| Intecooler water spray solenoid (on-off) | External wiring (350mA + 5 pole relay for override) | EC36-30 | P259_7 |
Unused outputs:
- SPECFET_1
- WOT actuator
- RPM actuator
- WB heater#2
- INJFET_4
- INJFET_5
- I259_2
- I259_3
- I259_4
- I259_5
- Stepper S259_3, S259_4, S259_5, S259_6
- Idle solenoid P259_4
Input trigger
Proposed Primary trigger settings:
- Edge: Rising
- Type: Multitooth
- Filtering: Disabled
- Advanced filtering: Disabled (NOT SURE WHAT THE FUNCTION OF THIS FILTER IS YET; waiting for EricN's page to update?)
- Special N-1: Disabled
- Fiat Stilo: Disabled
- TDC after trigger: 60
- Number of teeth on wheel: 58
- Trigger tooth: 3
- Next trigger tooth: 30
- Crank min period: 3750 usec
- Angular width of tooth: 2
- Tooth relation Normal: 122 (irrelevant with multitooth advanced filter disabled)
- Tooth relation Missing: 181 (irrelevant with multitooth advanced filter disabled)
- Angular width of missing teeth: 6
- Engine phase: 240
Proposed secondary trigger settings (not very well documented in the manual, but I might not end up using this trigger):
- Active: Enabled?
- Edge: Rising?
- Edge while cranking: single?
- Filtering: disabled?
- Type: coil type?
- Use: Alien advance?
- Rising edge phase: ?
- Falling edge phase: ?
Fueling
Req fuel = 6.49 * (D / N / I) = 6.49 * (1998/4/506) = 6.4ms (42lb injectors)
Req fuel = 6.49 * (D / N / I) = 6.49 * (1998/4/862) = 3.8ms (72lb injectors)
It's recommended to halve this req-fuel, so the max VE entries will be (instead of 100) around 200 (or even up to 255) for better precision. Thanks for this suggestion, hence new req_fuel will be 3.2ms and 1.9ms for the two injector sizes respectively.
Ignition
For single coil setup (coil=>00):
ignchmax=00
h[2]=00 00 00 00 00 00 00 00
For wastespark setup (1+4=>00 and 2+3=>01 paired up):
ignchmax=01
h[2]=01 00 01 00 01 00 01 00
If COP used, then wire up coils to IGBT's as follows (assuming 1-3-4-2 firing order): 1=>00 4=>01 3=>02 2=>03
For COP running in normal COP mode:
ignchmax=03
h[2]=03 01 02 00 03 01 02 00
For COP running in wastespark mode (1+4=>00 and 2+3=>01 paired up):
IGN_DUALOUT=Enabled
ignchmax=01
h[2]=01 00 01 00 01 00 01 00
Idle valve settings
ISV details...
Boost control
Boost control settings...
ALS
Still figuring out (i.e combing wiki) how to wire up a switch to turn this function on, along with launch control.
Mapped water injection
Looking for the best hardware solution to (PWM) drive the water injection solenoid according to a 3D map, or at least in scaled proportion to the fuel injectors' pulsewidth (i.e. VE map).