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?
- 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 [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 [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[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
...