Opel AstraF C20XE M2.8 -> C20LET

[Pet]

Hi all,
 so my car description:

 - Opel Astra F 1996, X16SZR (the default engine, 1.6 8V 55kW
 - rebuild nr. 1 to C20XE M2.8@turbo - KKK16 turbo + chiped ECU -> very rare setup, but it worked somehow
 - rebuild nr. 2:

   * stock KKK16 turbo, stock tophat
   * FMIC, 52mm pipes
   * C20XE inlet cam + Vernier pulley
   * Woesseners pistons 86.00mm
   * H-rods
   * F28 6-gear gearbox
   * Brembo 4 piston brakes 298x28
   * Megasquirt ECU, wasted spark, batch injection

 - due spark offset/bad maping the 2 pistons were damaged
 - rebuild nr. 3 (nowadays is finishing the engine assembling)
   * block rebored
   * JE Pistons 86.50mm
   * crank balanced
   * T3 .63/T04e .50 turbo
   * external WG
   * 70mm downpipe
   * Cossi head revised, new seats, bigger exhaust ports
   * Regal tophat 60mm
   * 630ccm Siemens Deka
   * steel flywheel 4.7kg
   * Helix 4 paddle clutch + Helix cover plate
   * F28 Quaife ATB diff
   * Walbro intank pump 255l/h
   * Wasted spark now / VW COPs ready to install
   * Vems GenBoard v3.6 - nr. 3287
   * wish tu run with 1.1.81 FW   

   * target is 350PS+, 380-400PS is nice to have :]   

[MWfire]

your IC is to small
BTW i have starting map for c20let

[Pet]

your IC is to small
BTW i have starting map for c20let

Thanks, yes this IC is relative small (but is 76mm deep and aprox. 6L volume), there is plan to use 600x300x76 one.
 Anyway I'll very appreciate any help with config/maps. Pls what's the best injection sequence for C20LET and how to setup it in 1.1.81, I am a bit confused with Vemstune now.

I plan: firing sequence 1-3-4-2
 Output 1 - cyl1
 Output 2 - cyl2
 Output 3 - cyl3
 Output 4 - cyl4
 Output 5 - Idle valve
 Output 8 - Boost valve

   Is this correct then? Thanks.

   
 

[MWfire]

put ref table
0
90
60
30

Edge for hall sensor falling

And injector h table
inj 1
inj 2
inj 4
inj 3
And angle 360deg for start.

[Pet]

put ref table
0
90
60
30

Edge for hall sensor falling

And injector h table
inj 1
inj 2
inj 4
inj 3
And angle 360deg for start.

Thanks, you mean h table looks like ?:
h[0]=01 02 08 04 00 00 00 00
h[1]=00 5A 3C 1E 00 00 00 00
h[2]=00 01 00 01 00 00 00 00 ; edited - for wasted spark 00 - cyl1&4, 01- cyl2&3

and 2nd trigger raw value 24 ?

Note: this is my 2nd trigger

[MWfire]

h[3]=00 01 00 01

[Pet]

Uff now I am totally perplexed with that settings...... Why there isn't any help for reference tooth table and injector firing order in VemsTune ? Are all the tables read from backwards (from bottom) like in old FW's and Megatune ??
So, once again:
 - 60-2 + CAM, for now wasted spark 
 - spark order is     : 1-3-4-2
 - injection order is : 3-4-2-1  ??OK??

then h[] tables:

 h[0] = 01 02 08 04 00 00 00 00  ; out1=cyl1, out2=cyl2....
 h[1] = 00 5A 3C 1E 00 00 00 00 ; or it's reversed 1E 3C 5A 00 ??  60-2 + CAM
 h[2] = 00 10 00 10 00 00 00 00 ; 00=I259-0=cyl1&4, 10=I259-1=cyl2&3

 h[3-5] is what ??

 it means, cycle start with injection to cyl 3 and spark on the cyl2(3) it's strange, isn't it
 
Thanks a lot.
 

[MWfire]

in vems tables are read from botton to up.

[Pet]

Little up; before end of last year I finished my engine rebuild, some final photos:
Now engine has done about 600km on stock turbo and ECU, new COPs are ready to install.
Hope the weather will be better (warmer:) in short time
Optrand pressure sensor should help with proper tuning...

[Pet]

Litlle up:
 COP setup is working for me; I've checked it on scope before. But I am not clever from that settings, see picture bellow. Anyway, car is pulling very well with that settings...

Note: Stepper A = cyl 1, Stepper B = cyl 2 etc., CAM pulse raw 25 (rising edge), inj angles 360deg


 

[Pet]

Litlle up:
one day before tuning day (with Optrand sensor), the main crank bolt was loosen up (when I was checking the exact TDC position, I left E12 socket on the crank and started the engine; engine was running fine, socket was falling to the floor imediately, but bolt was loosen up). Another day, after engine was warming up on idle, I was cruising (around 2500rpm) to my test hill, when trtrtrtrtrtrrrr sound comes...... of course 14 valves dead, as well as valve guides are cracked......bad day.....bad day


Anyway, I have prepared software for analysing combustion pressure from Optrand sensor, it was already tested on a few engines (fiat 20VT, fiat 1.6 T with good results), small preview: (knock cycle

[MWfire]

can you give more details of that program?
I also have optrand sparkplug.

[Pet]

The idea is simple:
 there is MCU circuit generates measuring window (pulse) on required VR wheel positions (for ex. 60BTDC to 60ATDC)
 (Vems could generate this pulse, it would be very very very usefull for that way of tuning; anyway now this MCU circuit is de facto only another VR wheel decoder)
 - this pulse is sampled simultaneously with another signals - Optrand + IGN + MAP signal + knock signal etc. to PC
 - and then the PC software makes the rest - compute crank position, advance, rpm, peak pressure etc.

When I am looking on that description, it looks like very easy, but there is a lot of work on background indeed

[MWfire]

Vems can generates that signal and it's easy to collect signal(i'm doing that with laptop and 3 usb sound card(6ch)).

But what is that program for signal processing(finding PPP)?

[Pet]

Program is created by using LabView 2009; there are lot of function for analysing signals (waveforms). In my case, I am finding maximum in amplitude (pressure) array -> result is time index, then goes with that index to positon array to read crank position. That's all.