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'''Overview''' 2.6 litre ADV I5 in a VW Microbus Syncro ceased due to oil starvation. Rebuilding a second hand AFU (2.3l 10V) and want a modern ECU with knock sensors and lambda control, hence this project site. * Engine: Audi (VW SA) AFU 2.3 litre I5 with Motronic 1.5.4 ECU. * Goal of rebuild: I want to re-build the engine with low-end torque in mind and max power around 4500 - 5000 rpm. Normal cruising speed at around 4000 rpm. . ---- '''Engine Build''' * Block (measurements) * Crank (measurements) * Pistons (measurements) * Conrods (measurements) * Oil Pump * Head (measurements) ** Porting or not? ** Port matching opinions? ** Camshaft timing for torque @ ~3000 rpm ** Inlet Manifold options? Flowing, smoothing, coatings? ** Exhaust manifold options? Flowing, smoothing, coatings? See[https://www.enginelabs.com/engine-tech/exhaust/performance-exhaust-system-design-and-theory/ EngineLabs] for info on exhaust header design. * Balancing opinions? ---- '''*VEMS Info*''' ---- '''Input Sensors''' ---- * '''60-2''' Hall on rear main crank seal. VAG Sensor PN: '''030906433Q[?] or 030957147L''' and trigger wheel '''030103171L[?]''' as used by MembersPage/NorbitronAudiAanSixty See [http://vems.hu/vt/help/v3/v3_primary_trigger_settings.html/ V3 Primary Triggerv Settings] for trigger info. <Triggerlog file and images> **<as .... (image, link to another page) shows **TDC of cyl1 (and cyl4) comes **83 degrees after the point, when **the first tooth after the missing tooth just passes the trigger (considering the rotational direction). **that is 8 tooth and a little on the 36-1 wheel. **we place trigger_tooth to 20 degrees (02 teeth) **so 63 degrees remains for ign_tdc delay **so the sum is 83 degrees> **http://imagizer-cv.imageshack.us/v2/xq90/268/y2i2.jpg * 2x '''Knock''' sensors. Bosch PN: '''0 261 231 006''' See [https://phormula.com/knock-frequency-calculator/ phormula.com] for knock frequency calculator. See [https://www.hpacademy.com/previous-webinars/083-understanding-knock/ hpacademy.com/Understanding Knock] for info on engine Knock. * 1 x '''WBO2''' (Wide Band Oxygen) '''Bosch LSU4.9''' * 1x '''EGT''' (Exhaust Gas Temp). * '''Cam Sync''' - Dissy or Cam sprocket sensor? No fitment points on head though. * '''MAF''' (Mass Air Flow) in place of MAP or both? - PN: * '''MAP''' (Manifold Absolute Pressure) sensor - PN: * '''MAT''' (Manifold Absolute Temp[?] sensor - PN: '''<part number>''' * '''Oil temp''' - PN: '''<part number>''' * '''Oil pressure''' - PN: '''<part number>''' * '''Coolant Temp''' - PN: '''<part number>''' * '''TPS''' (Throttle Pisition Sensor) - Part of throttle unit VAG PN: '''1HS 133 064''' . ---- '''Other Input signals''' ---- * A/C Control e.g. A/C demand and output control with idle pre-adjustment? Is this a standard VEMS feature? . ---- '''Outputs''' ---- * '''Ignition:''' ** Intend using '''active COP Coils''' with mounting holes to enable mounting on custom made bracket. Controller option for coils therefore '''0 IGBT + 8 logic-level outputs''' PN: '''<part number>''' . * '''Injectors'''[http://users.erols.com/srweiss/tableifc.htm#WEBER/ Injector Info] ** Weber/Marelli IWP025 190cc/min. May need to go a bit bigger if engine HW optimizations contribute to efficiency. . * '''Idle control:''' Part of throttle unit VAG PN: '''1HS 133 064''' . ---- '''Controller configuration''' ...
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