2016.11.20
This is an other AAN 60-2 trigger config
http://www.vems.hu/files/Norbitron/AAN%2060-2/v3.3_u003371-2015-08-06-16.45.15.triggerlog
This triggerlog made in 2015 before first start, without spark plugs.
tdc_delay setup correctly with strobe light to 88degree.
Now the engine upgraded and got new camshafts and adjustable camshaft gear.The primary trigger wheel and sensor haven't been changed. Before the first startup a triggerlog was recorded. http://www.vems.hu/files/Norbitron/AAN%2060-2/v3.3_u011908-2016-11-08-16.45.39.triggerlog
I had to change the tdc_delay from 88 to 71degree. It was about -10degree ignition advance. But how and why?
other trigger settings have not been changed in software and in hardware.
Heavily modified/rebuilt 5cyl AAN engine 2.5L, 60-2 HALL setup
Custom made flywheel, factory (VR+Auditrigger) flywheel not present.
Some [file attachments].
5cyl 60-2 is very common in Audi-s and Volvos. Usually install is smooth. HALL sensor seems to have failed in this case, after some successful starts. HALL sensors are very reliable nowadays. When they fail, usually some serious circumstance cause them to fail.
It is strongly suspected that insufficient engine ground damaged primtrig HALL sensor.
(The exhaust workshop removed engine ground, and not informed the builders ?)
Primary Trigger
Current stage: failed HALL sensor
- (it was when the engine warmed up)
Expensive VAG *(partnr: Sensor: 030906433Q and trigger wheel/crankcase gasket 030103171L) ... HALL sensor was fitted on crankshaft (not the more usual cheaper aftermarket sensor).
Original harness was modified for sensor pinout, to have +5V at proper place (so the HALL sensor was not connected with wrong polarity even for a second... But insufficient engine ground might have caused problem)
- I made more new and 'stronger' engine grounds!
Changed the original RPM sensor's pinout for the new sensor follows:
- pin1=+5V EC36/28
- pin2=signal EC36/27
- pin3=GND EC36/26
- Crank sensor got a new shielded cable
During (not very systematic) attempts had some tendency to work
- was the triggerlog good with primtrig=falling ? (when capturing HALL trigger, please add primtrig_falling or primtrig_rising in the filename for later ref)
for some time (engine even started at one point), but than it deteriorated RPM=10 (config problem was suspected => random attempts without wiki page and without taking notes => hard to follow and clearly insufficient for support) now primtrig HALL pulls output to 0V all the time, HALL sensor seems to have failed
Primtrig HALL DVM and scope measurements will follow.
Remember to use 2k7 .. 4k7 pullup resistor to +5V if sensor is not connected to VEMS. Without any pullup resistor the sensor output will most likely will be 0V, without any information.
Trigger config
See [FTT] and note that 10 or 11 is not good (nor is it needed or appropriate) for first trigger tooth in this 5 cyl 60-2 setup.
2016.08.12 - Problems solved.
From the first time we had some problem with the primary trigger. I see the trigger teeths on triggerlog but the RPM didn't show. I tried to setup some different settings but didn't help. At the end the battery voltage became too low so we changed to a high loaded. On higer crankning RPM I saw the rpm value, i have had ignition so i could setup the TDC delay and ignition order with strobe light. It wasn't what i was waiting but works . The engine was running while it warmed up and stopped unexpectedly. After this i could start the engine 3times for 2-5second but came trigger error and the engine stopped again. After i couldn’t started the engine again and the sensor didn’t work. When the engine cold down the sensor was working again while it warmed up.
I made a new cable but didn’t help.
I tried to measure voltaes on sensor pins. Measured values: Pin1(+5v)=0.6V with connected sensor/11.6V(disconnected) Pin2signal=0V connected sensor and 4.7V disconnected), pin3=GND
The +5V regulator becam wrong. We had to repair the ECU and after this we applied an outside +5V supply to save the VEMS’s regulator and we changed the primary sensor to another new.
Since the car running well without problem.