Audi-AAN/ADU/ABY installs are usually quite easy and smooth nowadays. Rarely (these are almost always home-modified setups) there are some issues. This is one of those cases.
Conclusion:
- apparently there are 2 types of HALL sensors, even from the factory
- "mostly 5V" that we've seen so far
- and "mostly 0V" as on this engine. This in itself does not cause a problem if other parts are stock.
- a significant modification in this case is the 7A flywheel.
- AudiTrigger/CamHALLInverter was made to filter out the noises of the 7A flywheel. But that assumes the HALL signal is mostly 5V as the on the image on InputTrigger/AudiTrigger with the German text shows - and also as we've seen on many-many audis before
- without a normal flywheel one would never notice. But with the 7A flywheel this gets important.
- There were many trigger errors originally. After changing the 2 VR sensors the engine runs much better now, but there are still a few trigger errors.
- Even though changing signal thresholds (by switching to other VEMS box, or moving or replacing the sensor) might apparently help a little,
- the good solution is to change the HALL sensor to a "mostly 5V" type, or get rid of the internal cam-HALL inverter that is not appropriate for this HALL-sensor.
We'll investigate how we can tell in advance if an engine has this type of HALL sensor or the "mostly-5V".
- It's of less importance normally, but critically important for the 7A flywheel because of the notches.
- Thank you for the cooperation and pointing this out. Without the scopeshots this would have been much harder !
Motronic is apparently less sensitive on VR-HALL relative position.
- With VEMS, the VR must be in the HALL window. That is a hard requirement. We cannot make a software workaround for that.
- For the offending 7A pulses (that are best filtered out with the correct choice of cam-HALL-inverter or no-cam-HALL-inverter) software filtering is theoretically possible. We are investigating that possibility so future cases can benefit.
Scopeshot of crankhome-VR and HALL:
- Scope pictures are all taken at the sensor plugs.
- [s2forum] page shows the crank pulse is almost perfectly in the middle of the cam sensor window when i zoomed in with the scope
- you probably have to log in. but I believe you. Now that we have the overall picture most of the speculation there is outdated.
In any case,
- this HALL signal is mostly 0V. That means it would be more noise tolerant without the cam-HALL inverter
- and 360 degrees offset in config, configured "without cam-HALL inverter" if it is now configured "with cam-HALL inverter").
- It would have been great to see this scopeshot before sending out the new, motronic55 ECU to help investigation. Than we would have had set that up without the internal cam-HALL inverter HW !
The cam sensor is stock AAN unit. I tried replaceing it with ABY but there was NO diference to performance.
But what kind of HALL sensor is that ?
- Factory or some aftermarket sensor ?
- Is the HALL sensor in the distributer or at the front of the head at the sprockets ? (Its a sensor at front of heat at cam pully. Stock audi AAN)
- What is the exact engine code the HALL sensor and the 1 window wheel came off ?
- does the 1-window wheel have a small window, or a giant window (mostly empty, and metal for a few % only ?) (Mostly metal with small gap. Again stock AAN)
The VR noise signal (4 evenly spaced noise)
- 7A flywheel i have has holes near where the pin is. Not inline but on the back. I will post picture of this flywheel before i welded on the larger pin on s2forum thread
- the noise is very likely because of the notches of the 7A flywheel (to clear the tool). These would be filtered out completely if we'd seen earlier that this HALL is different from the usual, mostly 0V and hadn't applied the cam-HALL inverter.
Can i remove this inverter ? I have some electronic skills and am willing to try if showen with a picture what to do. Thanks des
Yes.
- removing the inverter is extremely simple, ~10 minutes
Image is from GenBoard/Manual/InputTriggerHardWare
- a small SOT23 PNP resistor at the bottom of the board, around the middle must be removed, and replaced with 0 Ohm
- the "base" or protecting resistor (~2k7 marked 2701 or 272) can stay (need not be replaced by 0 Ohm)
Disassembling+assembling the Motronic-55 device requires a bit skill or patience, appr. 20+20 minutes
- disassembling+assembling the Econoseal-36+18 box is much easier. It would be better to do that (or do that first). The cam-HALL inverter (and the whole circuit) is same.
Thank you for the cooperation !
If you link your vemscfg actually used accessible from here (so one does not need to register), I can help changing ignout sequence with 2-3 positions and trigger tooth by 9 so the final effect is 2.5*144=360 degrees.
- Should my timing be 58 or 53 teeth for TDC?
- "TDC after the trigger" = 58 degrees is closer to realistic