VW Eurovan/T4 1993 2.5l MSnS I 029t

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magloman
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Posts: 1
Joined: Tue Jan 26, 2010 2:08 am

VW Eurovan/T4 1993 2.5l MSnS I 029t

Post by magloman »

Hi everyone !

I am almost finish with my install, it requires little more tuning but it starts easy and I use the car as my daily driver :D
Have my car passed goverment inspection 2010-03-24 incl emission test :-)
I will try to share as much info as possible about this project.
Only stock/OEM sensors are used, and OEM wire harness modified/cutoff at the OEM ECU.
Used ignition-strobolamp to check trigger angle but there is NO mark on the flywheel. There is a good hole beetween gearbox and engine though. I put the engine at TDC then painted a litle white on the flywheel in the hole. That worked very well. :D

I adjusted the TP idle stop screw so it idled at about 800+ rpm. Then only using the IAC when cranking and during warmup. It idled at about 600-700 from beginning at this engine is suppose to idle at 775-825 rpm per defintion.

TPS calibrated as 51 at idle and 235 at full throttle.

Engine spec:
  • Engine code: AAF (this is basically an Audi I5 engine but with 16mm higher deck and stroked crank)
  • Size: 2459 cc, 5 cylinder, 81.0mm bore, 95.5 mm stroke
  • cylinder block in grey cast iron, six main bearings
  • two valves per cylinder each with two concentric valve springs, 10 valves in total(NOT crossflow)
  • belt-driven single overhead camshaft (SOHC)
  • common rail multi-point electronic fuel injection system with intake manifold-sited fuel injectors
  • 110 PS (81 kW; 110 hp) at 4500 rpm 190 N·m (140 lb·ft) at 2200 rpm
  • Distributor with HALL sender and locked from beginning (stock ECU also controlled ignition)
  • Volvo Ignition Coil (Bosch xxx)
Megasquirt mods & info:
  • PCB v3, ECU v I, Msextra 029y4 (I think)
  • One VB921 mounted internally and drives a single coil and dizzy
  • TIP122 mounted instead of Q5 in place of one high current resistor(R43?) to hanlde the VDO 2-pin Idle valve
  • Using HALL input circuit modified with "12v pullup circuit" using 1k resistor. Took 5v from the MS and powered the sensor with it and set the trigger as falling edge.
Other data:
  • Injectors(OEM): VAG: 044 906 031, Bosch: 0 208 155 604, size: 146, 14.5 Ohm all parallell connected at 2.6 Ohm together
  • Fuel pressure regulator at 3 bar
  • Stock dizzy is locked sinced OEM ECU handled spark as well. Taking input from this. 5 signals per 720 degree crank.
  • Trigger Angle is 90 degress, could not enter this so I entered 89 for now. Will look into it later
Pinouts of sensors and ECU:
  • Distributor: HALL pin#1:earth[red/black], pin#2:0 (Hall-signal, ~5v)[brown/white], pin#3:+12v feed[green/white]
  • TPS VAG 044 907 385 A: pin#2:signal[red/blue], pin#?:earth[brown/white], pin#?:5v ref[blue/black]
  • Ignition Coil: pin#1:earth[brown], pin#2:control signal[green], pin#3:+12v feed[black]
  • CLT: VAG 025 906 041 A blue 20mm, 100 degrees C @ 200Ohm, 25 degrees C @ 2000Ohm, 0 degrees C @ 6000Ohm.
  • IAT: pin#1:co pot.(not used in MS), pin#2:temp signal[brown/white], pin#3:earth[blue/yellow]. :? hmm wonder if this is right...
  • IAC: VDO 037 906 457: pin#?:+12v feed[black], pin#?:earth/control[white]
  • CSV: 9.8 Ohm, pin#?:+12v feed[black], pin#?:earth/control to ECU[black/red] NOT yet connected
The setup:
DB37#36 to earth/control signal on the ignition coil[OEM_ECU-pin#27 green]

Megasquirt software setup
Required fuel set at 22ms (will up this a little as the idle values are at about 50:ish now)
Squirts per engine cycle: 1
All injectors fire together as they are 5 and connected in the OEM setup
Injector open time: 1.0 ms
battery voltage correction: 0.20
PWM limit: 100%
PWM time: 25.5 ms
fast idle threshold: 89.9 degrees C

Exhaust gas settings:
EGO_ narrow band
EGO switch point: 0.510
ign events per step: 20
step size: 1%
Controller authority: 7%
active above 72 degrees C and above 1100 rpm

Codebase/setup
Distributor setup: MSnS
FIDLE as Idle control
LED17(D14) as Spark Output A
LED18 as Warmup
LED19 as acceleration
Multiplex ign: normal (?)
X2 (JS0) as Fan control (not used)
X4(JS2): output1 (?)
Output3/sparkD: output3 (?)
pin10 shift: Shiftlight (?)
knock in /spark F: spark output F (no idea why?)

Warmup settings:
prime pump: always
fire priming pulse: after 2 sec
priming PW source: table
using CLT only
Cranking table(not yet finish tuned):
-40C=25.0;-29C=25.0;-18C=25.0;-7C=25.0;4C=12.0;16C=8.0;27C=6.0;38C=4.0;54C=3.5;71C=3.0
Crankning ROM: 300
TPS for flood clear: 190
extra cranking fuel enrichment: 50%
use firts start enrichment: on

ASE timer: cycles and 200
ASE mode: fixed then decay
MAp mode during ASE: normal MAP
use fixed ASE/MAP when CLT below 7.2
Fixed ASE/MAP time period: 5
table:
-40C=150%;-29C=130%;-18C=120%;-7C=100%;4C=70%;16C=70%;27C=12% ?? ODD

First startup not mapped:
http://www.youtube.com/watch?v=HCIJ4Kek9wg

/M
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