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Summary of change:
Teppo Kalske from Finland, born 1972 My daily drive is a 1986 VW jetta into wich I couple of years ago transpalnted a full 16v drivetrain. Used it for about a year until head cracked. Then it was quite natural to take engine to pieces and make a total rebuild wich included 1,5mm oversize piston and getting rid of CIS to make place for Megasquirt. After 7 months of driving with MS Miska talked me over to swap it for VEMS. Main reason was internal UEGO for WB-lambda. Specs: * 1.85L 16v (4syl), 136Hp stock + tube header, base engine KR, with ABF intake and very light (3,5kg) flywheel * 4 cyl fuel injection, Hi-Z injectors about 200cc, INJA, B, F, G * Ignition with distributor, IGN03 * PWM controlled idle valve, INJE * 1xWBo2 * trigger from hall in distributor, 1 pulse/cylinder * Running with firmware v12, vemsv3.ini r017 '''Shopping list:''' * 1 x GenBoard v3.2 * 1 x Econoseal36-PCB * 1 x Econoseal36-Wire * 1 x Econoseal18-PCB * 1 x Econoseal18-Wire * 1 x Alubos1600 * 1 x Alubos EC frontplate transparant * 1 x Alubos Endplate transparant * 2 x Alubos gasket * 9 x FETs Injector driver, WBO2 heater driver (FQFP..) * 5 x Ignition driver (IGBT) * 1 x Ignition driver insulator sheet * 1 x 2.5 bar MAP sensor * 1 x Wideband connector ---- '''29.08.2005''' Copied this page from here: http://www.vems.hu/wiki/index.php?page=MembersPage%2FMiskaPeippo%2FJettaGT Due to the too light flywheel I'm having quite a head ache with idle setup. For last 5 months I've been trying infinite number of various idle settings and never seem to get a setup wich works in all engine temps. Main problem seems to be with warm or almost warm engine. Ecu starts Idle stabilation too late, after revs drop under idle rpm setting that is. Due to light flywheel revs drop so fast that enigine dies before ign. adv. and isv changes have any effect on it. Has anybody any hints? On the shelf I have 4 audi 1.8t COP:s waiting (06B905115L) and a vag-original wiring harness with plugs for those (1J0971658L) wich costs only 38eur in Finland compared to 16eur per each plug housing. Main problem is that I haven't had the time nor energy to install trigger wheel nor hall... '''14.06.2005''' Idle is now close to perfect with cold and half-warm engine. Also previous RPM undershooting (RPM falls down to ~500rpm when releasing throttle rapidly from high RPM) problems are gone. The trick was to set IAC ref position table a few steps over needed values and limiting iac_integral_limit_dec to very small value. With warm engine there is still a problem with rapidly falling RPM. Ref position table ends to 77C, does this affect to all temperatures above 77C? '''07.06.2005''' CLT and MAP readings are incorrectly, at +7C outside temp after night CLT says -16C MAT -6C. Incs are generated using EasyTherm using 2k7 bias resistor and following measured values: 100C, 350ohm 23C, 5400ohm 0C, 16000ohm and 100C, 343ohm 6.4C, 12600ohm -16C, 37300ohm Note that resistance is appr. double compared to standard GM sensor. This is not a problem, just good to know. Generated thermfactor.inc is [http://www.vems.hu/files/MembersPage/MiskaPeippo/Jetta/thermfactor.inc here] Verify that inc file has following "firmware_temp_value" at given "adc" indexes: * adc=29.26 firmware_temp_value=252 temp=100 celsius_or_fahrenheit=C ohm=350 * adc=170 firmware_temp_value=113.4 temp=23 celsius_or_fahrenheit=C ohm=5400 * adc=218.18 firmware_temp_value=72 temp=0 celsius_or_fahrenheit=C ohm=16000 * adc=28.74 firmware_temp_value=252 temp=100 celsius_or_fahrenheit=C ohm=343 * adc=210 firmware_temp_value=83.52 temp=6.4 celsius_or_fahrenheit=C ohm=12600 * adc=237.79 firmware_temp_value=43.2 temp=-16 celsius_or_fahrenheit=C ohm=37300 These were made with firmware/bin/therminc.pl (in CVS head). (TODO: complete it to make complete inc files, and publish some inc files with different resistor values). If the AVR AREF reference voltage and the pullup voltage are significantly different (they should be roughly the same, appr. 4.86V .. 5.05V. Easy to measure with just endplate off) that would explain things and would be easy to make an inc for. '''02.06.2005''' With updated ini (r017) and small kpa formula fix also idle is functional and possible to tune with MegaTune. '''01.06.2005''' Victory in tuning battle! Car runs now pretty well with firmware v12. Almost only thing we missed was idle, because of some bugs in MT profile (r016): * Idle settings, bits in iac_conf are not ok * MAP scaling is incorrect (kpaoffs scale) * battfac is missing from menu, no scaling either '''31.05.2005''' Severe problems keeping the engine running nicely. Tried STABLE1_0 with config below, engine hardly runs. Same SW & config with older compiler and car runs almost nicely, but ign advance is for some reason limited to ~24degrees and changes in ve table doesn't seem to affect AFR at all.. * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mcd.txt mcd.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mct.txt mct.txt] Please publish * compiler version avr-gcc -v ( very suspicious ) * compiled zip, that also includes vems.hex (not relese on GenBoard/UnderDevelopment/FirmwareChanges or MegaTune page!) (rm *.o *.asm *.lst *.elf cleans the slate for zipping) Earlier test were done with release v11 and gcc3.4.1/libc1.0.4 (WinAVR 20040720 distribution). Updated to firmware v12 release and compiled with gcc3.4.3/libc1.2.3 (latest WinAVR) and problems are gone. '''22.05.2005''' Car is now running, both fuel and ignition (dummy with distributor). Latest config dumps from board with STABLE1_0 firmware (20.05.2005) * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mcd.txt mcd.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mct.txt mct.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/datalog200505212239.zip logfile] from a small test ride. '''09.05.2005''' It's alive. Engine was running yesterday, board was only delivering fuel. Latest config files: * [http://www.vems.hu/files/MembersPage/MiskaPeippo/config.txt config.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/tables.txt tables.txt] '''12.04.2005''' Problem below was solved by updating a perl. With perl v5.8.6 make_ini.pl works smoothly. Yesterday we made some initial tests in the car. MT configuration started to look somehow acceptable after a couple of hours, basically using old configuration from B&G MS. However TPS readings were not ok, values were either 16% at idle or by adding some throttle value jumped directly to 100%. In the LCD TPS values were ok. '''11.04.2005''' Some problems with perl. I use a activestate perl under Win: ''This is perl, v5.6.1 built for MSWin32-x86-multi-thread'' When trying to run ''perl bin\make_ini.pl global.h doc\megatune\config.xml doc\megatune\vemsv3.ini'' I get an error message <code> "strict" is not defined in %XML::Simple::EXPORT_TAGS at C:/APPS/Perl/lib/Exporter/Heavy.pm line 75 Exporter::heavy_export('XML::Simple', 'main', ':strict') called at C:/APPS/Perl/lib/Exporter.pm line 45 Exporter::import('XML::Simple', ':strict') called at bin\make_ini.pl line 10 main::BEGIN() called at C:/APPS/Perl/site/lib/XML/Simple.pm line 10 eval {...} called at C:/APPS/Perl/site/lib/XML/Simple.pm line 10 Can't continue after import errors at bin\make_ini.pl line 10 BEGIN failed--compilation aborted at bin\make_ini.pl line 10. </code> I tried to download XML-Simple from activestate and installed it ''ppm install XML-Simple.ppd'' without any warnings etc. but obviously something is still wrong. Any hints? '''04.04.2005''' Board/case assembly is now mostly completed after some not-so-active period. * Partially commented configuration files added here. These are not in any proper shape yet, mostly copied from GRM's config but will update once I get to the some real business. ** [http://www.vems.hu/files/MembersPage/MiskaPeippo/config.txt config.txt] ** [http://www.vems.hu/files/MembersPage/MiskaPeippo/tables.txt tables.txt] '''03.03.2005''' Completing of the controller begins. Although board has a most of the parts already soldered on it, a few components still needs to soldered by hand. * Injector driver FETs (TO220) * Ingition IGBTs (TO220) * WideBand LSU4 sensor heater driver (we use TO220 FET, same type as for injector drivers; except the WBO2 channel has no onboard place for flyback diodes) There are also several items to check before even thinking to plug the board to the car. * items to check listed here.. '''01.03.2005''' Ordered items arrived ---- more details will follow..
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