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.

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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[EngineLabs] for info on exhaust header design.

* Balancing opinions?

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*VEMS Info*

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Input Sensors

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* 60-2 Hall on rear main crank seal. VAG Sensor PN: 030906433Q[?] or 030957147L and trigger wheel 030103171L[?] as used by MembersPage/NorbitronAudiAanSixty

See [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>

**

* 2x Knock sensors. Bosch PN: 0 261 231 006

See [phormula.com] for knock frequency calculator.

See [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

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Other Input signals

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* A/C Control e.g. A/C demand and output control with idle pre-adjustment? Is this a standard VEMS feature?

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Outputs

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* 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[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

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Controller configuration

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