Introduction and project, Rowan's Saxo 1.6 16v Turbo

[Rowan]

I'm Rowan, from the Netherlands. Former 1 st mechanic at a Citroen dealer, where the love for cars began.
Since then I've had 2 Saxo's and a new job at parts sales for Hitachi (excavators).

The last year I've been gathering parts and building up an engine from scratch to turbocharge and fit in my car.

Specs:

PSA (citroen/peugeot) TU5J4 engine.
-low compression forged pistons (Wiseco)
-new crankshaft and rod bearings
-measured and honed cilinders
-new valves, valve seats, seals and vacuum tested
-head skimmed and cleaned
-MLS headgasket
-all seals replaced, internal bolts genuine new, external bolts stainless

Custom stainless equal length tubular manifold
T2 turbo with T25 hotside
Tial MV-S 38mm wastegate (genuine)
Custom screamer pipe, downpipe and exhaust
Custom stainless boost piping
Toyosports intercooler with Viper silicone couplers
HKS SSQV bov (genuine)

Megane 225 (390CC) injectors
MSD ignition
NGK br8es R plugs

Clutch-Specialists 5 paddle clutch kit

Brembo 4 pots with 283mm discs
Ferodo pads

Mocal oil cooler

VEMS 3.3 standalone
Bosch WB02
3-way electronic boost controller














































Old firmware



Updated to latest firmware



It is a bit overwhelming as a first time dealing with this sort of thing.
But it's just another challenge to tackle

[Rowan]

Since I'm new to using Vems and mapping/configuring in general, I wil be spending a lot of time on this forum trying to learn as much as I can.

So please be patient with me 

My first goal is trying to get it started.

[fphil]

I am alright to swap my small Vems knowledge against you mechanics skill.
Good deal for me since I am still learning Vems, but my car (biturbo Mase) at least starts!

[Rowan]

You've got a deal! Anyway I can help, I will


Been messing around a bit and I think my VR sensor wires are switched.
In primary trigger settings I've selected -RISING-, went to record a triggerlog, no trigger...
So I've tried -FALLING-, went back to recording and suddenly it shows something.
Doesn't look completely healthy, but it was only while cranking since the engine doesn't start yet.

Here is the triggerlog and config file.

https://docs.google.com/file/d/0Bx5FHeJh6KK6bVVSazJGRGREakE/edit?usp=sharing
https://docs.google.com/file/d/0Bx5FHeJh6KK6VVJXWFc3WThpNVU/edit?usp=sharing

Any thoughts would be more than welcome!

[Rowan]

Ok, I've  switched the triggersensor wires and I think the signal is right now.

But I still can't get it to start.

Could somebody look at the log and config and tell me what I'm doing wrong?

https://docs.google.com/file/d/0Bx5FHeJh6KK6cDJJaEI1ZnBsWm8/edit?usp=sharing
https://docs.google.com/file/d/0Bx5FHeJh6KK6TTQzNTFTMjEtTkU/edit?usp=sharing
https://docs.google.com/file/d/0Bx5FHeJh6KK6SlcxbThHdDFVd2s/edit?usp=sharing

[fphil]

Need permission to open these files.
Do you have looked/recorded triggerlogs? This shows the triggers actually seen by Vems and the spark events which are sent by Vems. Very useful.
Other tools which were much useful for me : a scope and bench testing. There is a tool in VT which makes triggers waveforms from the PC .

[Rowan]

Whoops, my bad , changed the permission so you should be able to get them now.

-triggerlog
-config file
-triggerlog PNG

I've recorder this whilst cranking.

I would greatly appreciate if anyone can tell what I'm doing wrong

[GintsK]

At top side of VT screen you will find Validate Config button. Press it and try to sort out reported problems. You have more than few.
And why you start with experimental firmware? Go for well proven 1.2.11
You can do experiments later. It is easy to migrate to new f/w.

Gints

[Rowan]

Thanks for the help!

There used to be a lot more which I've sorted, the problems that are still there shouldn't affect starting imho.
I'll get the 1.2.11 and upload it, didn't realise I was toying around with experimental firmware.

Any thoughts on the triggerlog?

[GintsK]

Why not? Hall filter directly affect triggering.
Trigger log is full of interrupts.
Safest way is to start with default config for given fw. You can found them in Vemstune folder under Program Files.

Gints

[Rowan]

You are correct, filter was enabled. My bad

Also the sensor was fubar, so switched it with another and disabled the filter.

Solved the problems I could solve, only the following remains:

H22_dummy has INVALID value (1)
Following dialogs are using this symbol:

Same for H23-H24-H25-H26 and H27

Any idea on this, tried search but it ended up blank.


On the brighter side, the engine finally started!

http://youtu.be/FV6Z18ZSKfw

Thanks for the help so far!!

[GintsK]

You are correct, filter was enabled. My bad

Also the sensor was fubar, so switched it with another and disabled the filter.

Solved the problems I could solve, only the following remains:

H22_dummy has INVALID value (1)
Following dialogs are using this symbol:

Same for H23-H24-H25-H26 and H27

Any idea on this, tried search but it ended up blank.


On the brighter side, the engine finally started!

http://youtu.be/FV6Z18ZSKfw

Thanks for the help so far!!

Congratulations!

Those H: temporary enable 8 ignition outputs and change INVALID values to something else.

Gints

[Rowan]

Thanks for the help!

The validation button is now green

Next problem, cilinder 4 isn't firing.

I've tested the injectors and plugs, and they work when when actuated.

Any ideas?

[Rowan]

A wee update.

When it first started it didn't idle and the 4th cilinder wasn't really puttin as much effort into it as the other 3.

Hence I decided to clean the injectors and sparkplugs. Altered some bits in the Vems and started it up.

All 4 cilinders purring and it even idled! (at +/-1200 rpm and only when warm )

And so the first test around the block came to be :oops:
Even though it's not as smooth as it could be, it already is a huge difference.
I've set the wastegate to .5 bar boost for safety reasons, since it's not really mapped.

This also means that de screamer pipe comes in really fast, and that sound is just pure porn. Which is followed by the HKS bov, and I feel like a little kid again

New tires are being fitted as we speak, then it's of get aligned and the wait for the 1st october when it is getting mapped bij Pieter at DP-Engineering.

A few pics to round it off.

[Rowan]

Teaser:



(not dyno'd, running on a safe basemap)