My name is Paal, working and playing with toy cars in Bergen, Norway.
Time to update progress in 2009....
The goal
Apply a GenBoard/VerThree (V3.3) to my Polizei-golf's new engine.
The car:
The engine:
- 16v KR engine with S2 pistons
- S2 intake manifold with S2 TB throttlebody [TPS schematic] - pinout: pin 3 = signal, pin 2 = signal gnd, pin 1 = +5v
- OEM 60-2 trigger wheel, HALL sensor - pinout: pin 3 = signal gnd, pin 2 = signal, pin 1 = +5v
- K24 turbo
- 440cc (high impedance) injectors and 3,5 bar FPR
- 034EFI idle stepper motor [link]
- 034EFI wasted spark coil [link]
- 034EFI IAT sensor [link]
- OEM "blue" water temp sensor
- Walbro fuel pump (original G60 fuel pump not sufficient, will remain in tank as lift pump)
![[TPS schematic]](http://www.s2central.net/images/3B_ECU_Schematic.jpg){kind=link}
VAG 60-2 (BOSCH) Hall trigger:
![[Trigger wheel fitted to my crank, illustration overlayed showing 85 degrees between missing tooth and sensor]](http://i43.tinypic.com/nwmott.jpg){kind=link}
German thread: http://www.golf1.info/forum/thread.php?threadid=14109&page=2#post151865 and [ELSAWIN screenshot here stating it is a Hall sensor, (ro/gn) goes to G40 pin#1 (which we know is Hall), and EGR-potentiometer pin#2 (reference voltage) (TeroK)])
![[ELSAWIN screenshot here stating it is a Hall sensor, (ro/gn) goes to G40 pin#1 (which we know is Hall), and EGR-potentiometer pin#2 (reference voltage) (TeroK)]](http://jeje.je/creative/polizei/vems/elsawin-polo-axu-hallsensor.jpg){kind=link}
- 85° BTDC with cyl1 at TDC [reference]
![[reference]](http://i43.tinypic.com/2rf8zyc.jpg){kind=link}
- OEM parts numbers:
- sealing flange with 60-2 trigger wheel and plastic clip to align wheel with housing: 030103171L (~65 EUR)
- Hall sensor with ~15 cm wire: 030906433Q (~40 EUR)
- Steel backing plate: 030103647E (~20 EUR) - [some modifications needed] -- also possible to use OEM PG (g60) plate, with minor cutting.
- [image of connector + crimped wires] - part numbers:
- connector: 1J0973723
- 3x crimped wires: 000979133A
- 3x rubber seals: 357972741A
![[image of connector + crimped wires]](http://photos.fotki.lv/photos/4/W0001903/000190213/000019021289_%23_3_%23_GintsK.jpg){kind=link}
trigger settings example from emil (2007):
- Falling, Multitooth
- with trigger tooth 3
- TDC After the trigger = 62 degrees
- is this measured or speculation ? verified via strobing ?
- it's easy to get into the ballpark (+-6 crankdeg) with InputTrigger/TriggerLog, but it's really a good idea to verify via strobing anyway
VEMS specifications
Hardware:
GenBoard/VerThree V3.3
Assembled v3.3 controller
- 1-wire interface: no
- Flyback: 30V flyback
- ignition driver: 4+4
- Knock and EGT: yes
- LCD connection: no
- MAP connection: offboard(electronic)
- mounting-style: screws
- primary_trigger: HALL
- PS2 connection: no
- secondary_trigger: HALL
Additional hardware
- Control boost with 3way pneumatic valve [webshop]
- v3harness, I4 with relays
- MAP sensor (6/4mm 400kPa)
- EGT sensor (6mm), placed before turbo
- WBO2 sensor
Todo:
- Figure out how to get TACH signal (MembersPage/SteinOvePrestmo did this?)
Sensors used / calibration data
Borrowed from MembersPage/TeppoKalske:
IAT (audi 1.8T 20v sensor):
-40°C 80000 Ohm
20°C 2400 Ohm
130°C 100 Ohm
--
Progress / worklog 2009
- Engine is in car
- Pipeworks, welding intake / downpipe is soon done
- Ordering VEMS unit + sensors + harness
20.04.09
VEMS has been ordered with above specifications. Ordered via Jörgen.
16.08.09
MAP, TPS is calibrated. IAT + CLT needs calibrating, and Im getting ready to try out some configs to see if it starts.
Using the V3harness on the engine I had to reverse the injector
order since the main harness is on the transmission side of the engine. E.g cyl 1 is labeled inj D, cyl 4 is inj A.