Members Page/Paal Polizei - VEMS wiki www.vems.hu

MembersPage/PaalPolizei (2009-08-16 21:01:38)

My name is Paal, working and playing with toy cars in Bergen, Norway.

Time to update progress in 2009....

The goal

Apply a GenBoard/VerThree (V3.3) to my Polizei-golf's new engine.

The car:

The engine:

16v KR engine with S2 pistons
S2 intake manifold with S2 TB throttlebody [TPS schematic] - pinout: pin 3 = signal, pin 2 = signal gnd, pin 1 = +5v
OEM 60-2 trigger wheel, HALL sensor - pinout: pin 3 = signal gnd, pin 2 = signal, pin 1 = +5v
K24 turbo
440cc (high impedance) injectors and 3,5 bar FPR
034EFI idle stepper motor [link]
034EFI wasted spark coil [link]
034EFI IAT sensor [link]
OEM "blue" water temp sensor
Walbro fuel pump (original G60 fuel pump not sufficient, will remain in tank as lift pump)

VAG 60-2 (BOSCH) Hall trigger:

[Trigger wheel fitted to my crank, illustration overlayed showing 85 degrees between missing tooth and sensor]

German thread: http://www.golf1.info/forum/thread.php?threadid=14109&page=2#post151865 and [ELSAWIN screenshot here stating it is a Hall sensor, (ro/gn) goes to G40 pin#1 (which we know is Hall), and EGR-potentiometer pin#2 (reference voltage) (TeroK)])

- 85° BTDC with cyl1 at TDC [reference]

- OEM parts numbers:

sealing flange with 60-2 trigger wheel and plastic clip to align wheel with housing: 030103171L (~65 EUR)
Hall sensor with ~15 cm wire: 030906433Q (~40 EUR)
Steel backing plate: 030103647E (~20 EUR) - [some modifications needed] -- also possible to use OEM PG (g60) plate, with minor cutting.
[image of connector + crimped wires] - part numbers:
- connector: 1J0973723
- 3x crimped wires: 000979133A
- 3x rubber seals: 357972741A

trigger settings example from emil (2007):

Falling, Multitooth
with trigger tooth 3
TDC After the trigger = 62 degrees
- is this measured or speculation ? verified via strobing ?
- it's easy to get into the ballpark (+-6 crankdeg) with InputTrigger/TriggerLog, but it's really a good idea to verify via strobing anyway

VEMS specifications

Hardware:

GenBoard/VerThree V3.3

Assembled v3.3 controller

1-wire interface: no
Flyback: 30V flyback
ignition driver: 4+4
Knock and EGT: yes
LCD connection: no
MAP connection: offboard(electronic)
mounting-style: screws
primary_trigger: HALL
PS2 connection: no
secondary_trigger: HALL

Additional hardware

Control boost with 3way pneumatic valve [webshop]
v3harness, I4 with relays
MAP sensor (6/4mm 400kPa)
EGT sensor (6mm), placed before turbo
WBO2 sensor

Todo:

Figure out how to get TACH signal (MembersPage/SteinOvePrestmo did this?)

Sensors used / calibration data

Borrowed from MembersPage/TeppoKalske:

IAT (audi 1.8T 20v sensor):

-40°C 80000 Ohm

20°C 2400 Ohm

130°C 100 Ohm

More info about this sensor here MembersPage/SteinOvePrestmo/SensorPage

Blue water temp sensor curve (from G60 selfstudy pdf):

Hex files chosen for IAT/CLT:

cltfactor_2252_256.hex (based on sensor curve above)

airXfactor_2063_256.hex (based on prestmo sensorpage for 20vt IAT)

Progress / worklog 2009

Engine is in car
Pipeworks, welding intake / downpipe is soon done
Ordering VEMS unit + sensors + harness

20.04.09

VEMS has been ordered with above specifications. Ordered via Jörgen.

16.08.09

MAP, TPS is calibrated. IAT + CLT needs calibrating, and Im getting ready to try out some configs to see if it starts.

Using the V3harness on the engine I had to reverse the injector order since the main harness is on the transmission side of the engine. E.g cyl 1 is labeled inj D, cyl 4 is inj A.