New project on the now classic Audi ABZ v8 4.2

[Dangerrous]

Just thought I'd introduce my project that requires a standalone ECU
Kit car using the Audi 1995 ABZ v8 4.2 married up to an 01X 6 speed gearbox

Current specs from the engine:
Make: Audi
Year: 1995
Engine: ABZ
Type V8 4.2ltr

Sensors:
Throttle position sensor: 3 wire potentiometer controlled by ecu
Closed throttle position : two wire, ground sent back to ecu when closed
Engine speed sensor: 2 wire inductive sensor with ground shield
Cam Position sensor: 3 wire Hall sendor 5v? supplied by ECU
2 Knock sensors: piezo- electric 2 wire with ground shield
Wide Band Oxygen sensor: 5-wire LSU4 (to be purchased)
Engine coolant temperature sensor: 2 wire sensor
Intake air temperature sensor: 2 wire ptc resistor
Manifold air flow sensor 4 wire, 2 for heater and two for feed back to ecu resistance measured
Manifold Absolute Pressure sensor: not installed -Please advise-


Outputs

Injectors:
2 wire 12v supply on/off saturated type 15ohm resistance

Coils/plugs:
 Final output stage from ecu  step up transformer to coil

Coil on plugs (CoP)  supplied with 12v ignition signal from final output stage


Idle air control valve: 2 wire variable voltage to a motor, loaded against a spring

Evaporative emission canister purge regulator valve: 12v solenoid valve pulsed when the engine is running, started after oxygen sensor has warmed up

AC signal to ECU
Output signal to Coolant fans relay if possible three stage

I need to draw up a purchase bundle
Any advice
Cheers
Guys
Darren

[Dangerrous]

Purchased my vems and associated bits.

[Dangerrous]

Hi all, I'm currently wiring up the vems unit to all the sensors but can't find the second knock input, I ordered this in the purchase bundle. I notice that some wiring schematics possibly use analogue channel 1 (EC18), my pin out spec just says 'Wire in (depending on spec)' The bottom of the pin out page even says knock sensors- 2
Any help would be appreciated
Darren

[mattias]

With your ECU you got a paper, this tells you in detail what pins on the EC18 connector are customized to your setup and you should find the knock sensor input pins there.

Given that this feature doesn't even work with current firmwares I would bother with the knock sensors much later but make the wiring 99% done.

[Dangerrous]

The 'wiring schematic' for my bundle is the paper specific to my purchase, there's only one knock sensor input although I requested two due to it being a v8.
I'm just wondering if analogue channel 1 on the EC18 is wired up for knock sensor two but not defined on my pin out paper



I'm trying to clear up any doubts before I run power into the ecu and test the sensors
Cheers
Darren

[mattias]

There are always two papers, you're looking for a spreadsheet with the EC18 pins listed top to bottom.

It does specifically say this in the webshop for the knock options :
Knock signal: EC18/1 (knock1); EC18/2 (knock2, only if dual-knock option selected). Knock GND: EC18/17 (also used for RS232 GND, internally connected to EC36pin26).

[Dangerrous]

thanks, checked the other info (found under the keyboard) pin 2 is knock 2 and not channel 5
 

[Dangerrous]

I've got some valves for the ecu to control
i) variable change over manifold valve 13.4v/28.5ohms=0.47amps or 470mA
ii) charcoal evap recovery valve 13.4v/28.5ohms= 0.5amps or 500mA
iii) variable air control valve (idle valve) 13.4v/8.3ohms= 1.615amps

I read that (protected against spikes) the p259 pull up/down can handle 350mA safely or fries!
The stepper can handle 1amp, plus dnb has abused these without a problem
I'll control the first two using the steppers (rated at 1amp) but I'm concerned about the idle solenoid. I understand that it's roughly controlled using pulse width modulation ie flashing light effect but at 100% it will draw over 1.5amps  is this fry time for the stepper controlling it    If so what can I use to control the solenoid, all the fets and igbts are used
cheers
Darren

[mattias]

I would  fire injectors in pairs, and get four injector outputs available for other use. It won't affect the running of the engine even to a small extent, you'll probably not notice. Especially if you fire them every revolution and pair the injectors in the "wasted spark" pairs.

[Dangerrous]

Thanks, that's definitely an option, If I have to I'll go down the wasted spark route.
Cheers
Darren

[Dangerrous]

 I have VEMStune installed and now I'm checking the sensors, both the clt & mat sensors are showing -40c, I have read loads of documentation and cannot make head nor tail of it, am I missing a utility program to make sense of the hex tables and guidline instructions, my computer (tried on both - workshop using xp, home using win7) open them in notepad/noteword and/or excel, I need some giudance as I'm going square eyed trying to get around this very simple task. Is this task detailed anywhere for the latest software as most guides seem at least 4 years old and don't relate to VEMStune.

I've drawn up a realtime table of my bosch clt sensor, and I'm happy with the result for a 2063 table, but which one?
hope someone can direct me to a good guide that I've missed
cheers
Darren

[GintsK]

-40 usually means open circuit. You can see the signal voltage point in CLT and MAT graphs. If it is 5V you have open circuit.

[Dangerrous]

Cheers, found a break in an original joined earth path for the clt, mat and knock sensor shield, diagnosed within 2 mins, this was the only earth branch I hadn't renewed (Soldered together), also decided to use my own sensor table for clt and mat, I've got two detailed graphs drawn up from testing the sensors, both now reading within 1degC.

Thanks for the help again guys
 

[Dangerrous]

It's alive!!!!
Although running really rich and not ticking over yet The throttle response is amazing, When I bought the Audi I drove it for a couple of days and it was a very smooth gradual drive, It now seems like a totally different power plant. Very pleased
I'll post a vid of the engine running when I've sorted the VR tables etc out.. EFI express have posted a video on youtube with the same sort of throttle response
D

[Dangerrous]

opps!
tried driving too much through steppers, plus accidently left on valves
I've blown the control/stepper chip
What do I do now?


Can I just buy a new one?
Cheers
Darren