Safari Turbo/Megasquirt Fuel Injection Project

[rubenski]

Gee Mike Don't discourage him

X2

hahahha

Verstuurd vanaf mijn SM-A528B met Tapatalk

[Clonebug]

I finally got my intake redone to fit the IAC valve and I can remove and replace the intake without having to pull the body or any major surgery!!!!
If I pull the turbo, oil filler, and the IAT sensor I can get the intake off and I can reinstall it with the IAC valve installed.......I like it!!!!!

Here is a pic of it all put together, painted and sitting on the vice ready to go back in.



All I need is the sensor plug and wiring harness to give it a quick test and I'll pull the buggy apart for my Winter Upgrades 2022 edition........

I have the 4 wires coming out of the ECU into my 35 pin plug already so it will be easy to wire it for testing. I'll just throw the wires across the buggy body for a temporary test then once the body is off I can tie it to the existing harness.
I might also add an oil pressure sensor so I can display it on my ADU5 dash along with a visible alarm if the pressure ever gets too low.

[buguy]

Very nice. The cold starts the one thing I've been disappointed with on my build. Fuel injection should be a just hit the key deal. Mine will usually start and idle with no throttle input, but just barely, and not always.... Kind of a bummer.

[Clonebug]

Very nice. The cold starts the one thing I've been disappointed with on my build. Fuel injection should be a just hit the key deal. Mine will usually start and idle with no throttle input, but just barely, and not always.... Kind of a bummer.

An engine needs more fuel and a higher idle when cold to run......whether it be carb or FI. The choke took care of that by holding the throttle plate open with the high idle steps and then creating more vacuum on the fuel jets with the closed plate.

A FI engine needs more fuel when cold also. The prime pulse, cranking pulse and after start settings are what take care of the extra fuel for us.

Getting them right is a trial and error especially if you have large temp swings. 20*F is going to require a different amount of fuel than say 80*F.
E-85 might add another level to the tuning for cold starts due to having to map for that. You might need to give a lot more fuel than E-10 needs and then flooding would be a critical point in adjustment.

I put the turbo and related parts back on Tuesday and fired up the engine in 40 degree weather. Without the IAC valve operational I have to give my engine about 5-10% throttle on the TPS and it will fire up quickly. It died once but then the next start it would stay running at that 5% throttle setting and give me about 900-1000 rpm. With about 30-45 seconds warmup it will idle on its own at about 650-700 rpm and once the warmup head temp hits about 100 degrees it will keep running with no input.

Once I get the IAC valve working I hope to let that give the extra air it needs and my fueling should only need a slight tweak to get rid of the initial first stall.

Do remember that those default settings are for a V-8 and are nowhere close to an air cooled VW engine. For you in Florida there is no reason your temp reading needs to go all the way down to -40* F......or up the 450*F at the high end.

You can either remap the numbers on the X and Y axis or just adjust the relevant ones that your engine encounters. My warmup is completely shut off by 130 Degrees using the warmup temp sensor that Mario sells for the #3 cooling tin screw.

I also found the prime pulse to be excessive and cut the default down. I then lowered the cranking pulse also.

If you need to give it a large amount of throttle to start hot or cold it usually means it has to much fuel and is basically flooded. I highlighted the whole map on the Prime and Crank graphs and started bumping it down until it would start without throttle input. when warm. Once that was fixed I then adjusted the cold start numbers to fire without much input and finally give it a bit of throttle to start at cold.
It did take a while but I'm pretty happy with the start.
My driving to work or driving home adjustments were an every day occurrence for a while but only would cover temps of 50 degrees to 80 degree starts.
Now that it is colder I need to adjust that area slightly but will hold off until the IAC is functional. I haven't driven it in a month so it's not a priority. I'm not much into driving in the cold any more.......I must be getting old.....

Watch how your water cooled car engine starts.....it will fire up and high idle for 10 seconds or so at 1200 rpm and then fairly quickly start to drop down to 900-1000 rpm.
Since all new vehicles are now DBW and don't even need an IAC valve the computer can control everything from transmission engage to throttle position when cold and drop rpm instantly when going into reverse so it won't jerk back due to a too high of an idle.
It's tempting to move up to the next level and go to DBW to keep up with the big boys. There is a throttle pedal control that is an easy fit into the VW pan and the EcuMaster Line has DBW control built into it.

[buguy]

For me i ended up adding cranking fuel and that helped a lot. I also just enabled idle VE and that seemed to help smooth out the idle everywhere for some reason. I think i also added a bit more timing to the cold start.
I also have been considering DBW. I was turned off to it before because i had a turbo jet ski and it had a weird lag to the tip in. Hopefully we would have more control to tune that out of it.
I'm interested to hear how your IAC works for you. One time i left a vacuum line off and forgot about it. Next time i started it, it fired up way better. Also something i found interesting was that the engine sounded bad ass. Had what sounded like a cool cam chop to it. Also revved up more quickly. I was so excited... Until i found the vac line off.

[Clonebug]

Reinstalled the intake to check for fit and it all works.



All I need is the plug and harness and I can test it.
Ran the engine for about 20-30 minutes to warm it up and it will run by itself at 750 rpm with an 84*F. warmup head temp and no throttle input after 108 seconds according to the log. It might have happened earlier but that is when I let off the 5 % TPS and let it go on it's own.

Here's a little video.....nothing really cool but shows the digital dash a bit and an overall walkaround.

[V8Nate]

Sounds and looks great Art!

[GS guy]

Gauges? We don't need no stink'n gauges!
Sounds good!
Jeff

[ucesario]

It took me almost a week, but I read the entire epic of his saga with little Buggy, it was inspiring for me.
Now it's time to get my tools and finish assembling my Kombi*

Thanks a lot for the whole report.
I had not yet registered here, but after this beautiful report, I was forced to offer my congratulations, publicly.

*Brazilian name for VW bus

[Clonebug]

It took me almost a week, but I read the entire epic of his saga with little Buggy, it was inspiring for me.
Now it's time to get my tools and finish assembling my Kombi*

Thanks a lot for the whole report.
I had not yet registered here, but after this beautiful report, I was forced to offer my congratulations, publicly.

*Brazilian name for VW bus

That's an Epic first post!!!!!
Thanks for joining and thanks for the congrats.......
I found by starting a build thread that I myself learned a lot about my build by going back and checking what I had and had not done. Putting a mileage on each update is great for checking to see how long some change or modification has worked.
I can't count how many times I myself have gone back and reread most of the complete thread just to remember what I did and did not do.
I hope it helps others so they can learn from my mistakes or errors.

[panel]

Great walk around vid Art , thanks !!

[Clonebug]

Weather was crappy here for the last week or two.
Had cold temps into the single digits with the dreaded Northeast Wind along with some significant snow accumulations.....then to top it off we had freezing rain for a full day with a quick rise in temperature to above freezing and raining.
Needless to say it made a nice mess of the Christmas Weekend.
The snow is mostly gone now except for the drifts that were plowed up onto the sides of the road but it is now back to a balmy 50 degrees......

I have been working on my cold starts with the new IAC valve and this morning's test went well. It will fire without any input of throttle and go into an 800-900 rpm idle. It does take a couple seconds to fire but I'll get that part fixed later.
My warm starts will fire almost immediately and go up to 1200 rpm and taper down to a 900 rpm idle in about 10 seconds. I had the taper set for 12 seconds but 10 seems a little more normal comparing it to our OEM vehicles.
That will take a little adjusting but it's good enough for now.

I'm debating on whether I want to tear it down at all this winter since I really don't have anything I need to do to it except run the wiring for the Idle valve. I could just jury rig it but My ADHD probably won't let that fly.

I have also been looking at LED headlights and am debating on whether to grab some for the buggy. It would look pretty cool but I'm not sure if it's worth it or not.

Hope everyone had a Merry Christmas.....Have A Happy New Year!!!!!!!

[Schweg]

LED head lights are hands down one of the best things I did on my
Baja! I have a set for the ghia waiting to go in! You can find pretty cheap 7” halo lights on Facebook marketplace.

[Clonebug]

LED head lights are hands down one of the best things I did on my
Baja! I have a set for the ghia waiting to go in! You can find pretty cheap 7” halo lights on Facebook marketplace.

The only thing I'm really concerned about is whether they will fit in my headlight buckets. After driving new vehicles with LED lights....the old style just doesn't cut it anymore.....especially when you get older and your eyes don't work as well at night.
Our Kodiak Crew Truck at work has the absolute crappiest headlights I have ever seen and I'm going to see if the shop will change them out for some better lights.

[Schweg]

LED head lights are hands down one of the best things I did on my
Baja! I have a set for the ghia waiting to go in! You can find pretty cheap 7” halo lights on Facebook marketplace.

The only thing I'm really concerned about is whether they will fit in my headlight buckets. After driving new vehicles with LED lights....the old style just doesn't cut it anymore.....especially when you get older and your eyes don't work as well at night.
Our Kodiak Crew Truck at work has the absolute crappiest headlights I have ever seen and I'm going to see if the shop will change them out for some better lights.

Yep! To all of those things!!

The head light buckets need a trim in the back sometimes but depending on the light you buy it can be a non issue.