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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:''' http://jeje.je/creative/polizei/polizei.jpg '''The engine:''' *16v KR engine with S2 pistons *S2 intake manifold with S2 TB throttlebody [http://www.s2central.net/images/3B_ECU_Schematic.jpg 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 [http://www.034motorsport.com/product_info.php?products_id=161 link] (Currently unused, using idle screw on TB) *034EFI wasted spark coil [http://www.034motorsport.com/product_info.php?products_id=40 link] *034EFI IAT sensor [http://www.034motorsport.com/product_info.php?products_id=117 link] *OEM "blue" water temp sensor *Chinese fuel pump mounted inside tank. Waiting eagerly to see how long it lives. ---- '''VAG 60-2 (BOSCH) Hall trigger:''' ''Mounting instructions'' After a miserable user-error during mounting, I had to remove the transmission + clutch assembly to re-align the trigger wheel. This happened at 2500 rpm, no load, and stopped the engine with a nice pop out the exhaust. ''Cause'' When I initially mounted it the ring got pressed too far onto the crank, and the result was rubbing against the oil seal --> trigger wheel skipped ~45 degrees. In addition I did a really poor job at modifying the steel cover to accomodate the trigger itself. ''Solution'' - Attach the oil seal / trigger assembly - Carefully push the trigger wheel onto the crank - Fit the flywheel onto the crank, and tighthen carefully. This will push the trigger wheel far enough onto the crank, and this ensures it wont rub against the oil seal. - Ensure there is no contact between steel cover and trigger wheel, and that the hall trigger itself has enough room. The orange plastic clip is nice to use for alignment, since it will give you a somewhat predictable "TDC after the trigger" in VEMS (it aligns the wheel at 85 degrees BTDC). If you need to remove the triggerwheel, use the screws holding the oil seal to the block, and screw them gently into the brass threads. This will push the ring out. -- [http://i43.tinypic.com/nwmott.jpg 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 [http://jeje.je/creative/polizei/vems/elsawin-polo-axu-hallsensor.jpg 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 [http://i43.tinypic.com/2rf8zyc.jpg 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) - [http://forums.vwvortex.com/zerothread?id=3516017&postid=45479900#45479900 some modifications needed] -- also possible to use OEM PG (g60) plate, with minor cutting. * [http://photos.fotki.lv/photos/4/W0001903/000190213/000019021289_%23_3_%23_GintsK.jpg 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 ** After strobing my engine I ended up at 64,5 degrees "TDC after the trigger". Any installation should be verified with strobing no matter what. ---- '''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: onboard 2,5kpa * mounting-style: screws * primary_trigger: HALL * PS2 connection: no * secondary_trigger: HALL Additional hardware * Control boost with 3way pneumatic valve [http://shop.vems.hu/catalog/product_info.php?cPath=1_13&products_id=85 webshop] (Currently unused) * v3harness, I4 with relays -- I am VERY satisfied with this harness. * EGT sensor (6mm), placed before turbo * WBO2 sensor Todo: * Figure out how to get TACH signal: instructions from Jorgen ''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): http://i29.tinypic.com/116khl0.jpg 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. ''18.08.09'' IAT+CLT is now calibrated using above hex files. Waiting for last check of MSQ file before attempting strobing to verify trigger settings. ''25.10.09'' Car is running pig rich, currently running boost control directly on wastegate (max 0,4 bar).
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