WBX Emulator - real time data, onboard diagnostics and tuning

[DigiMatrix]

[hans j]

Finally got mine installed today but haven't messed around with anything else yet. I have Marco injectors and 1.25 rockers on my 2wd automatic to play with. It currently gets pretty good fuel economy and power is decent, but might be able to do a tiny bit to it.
_________________
1986 Canadian Syncro Westy TDI - 1989 Syncro Single Cab - 2001 Audi S4 - 1981 VW Caddy ABA - 1980 VW Caddy EV - 1973 VW T-181

[natejohn]

So I made what I considered a valiant attempt at soldering the emulator wire in my ECU, but it just didnt work out that well for me. I'm no stranger to soldering, and have what i considered the proper tools, but it looks as though I was a little too hot and heavy with my iron and made some mistakes. I boxed it all up and sent it to Digimatrix to see if he could un-screw what I had screwed.

After inspection, I had managed to:
1) Tear the wire off the emulator (in an attempt to strip the casing back for fresh wire after I couldn't fit it through the hold in the ECU board)
2) In doing that, rip the solder pad off the emulator
3) Bugger up the ECU solder pad on the backside where the wire solders to

Very thankfully he was able to repair what I'd done and got it back to me in working condition. I am forever grateful! Thanks again.

I remounted the ECU in my van the other day and took a video of it connected and warming up. I've set my dashboard to as close to the one in the video provided by DigiMatrix, and can post the video here at some point.

As it stands right now, my (bone stock, 95kmile) engine is running what I consider to be rough at idle, plus a little rumbling on deceleration. Almost sounds like backfire, but not quite as loud or poppy if that makes sense.

In the last year, it's had:
1) Plugs, rotor, cap, wires
2) Ignition coil
3) Coolant sensors
4) Fuel Pump
5) New fuel line kit
6) New O2 Sensor

Now, a lot of this was done because I'd just bought the van and as a mechanic I wanted to tinker, as well as being due for it by mileage (89k when I got it), and not necessarily because it was all failing. While replacing much of this, I found oddities like the 02 sensor being unplugged, the cooling system being filled with straight water (nice, PO was shocked when I told him that). I'm hoping that there may be some indicators of why it's running a bit rough in the warmup video.

In the interest of getting a good library of running and runability data from these emulators, what would be the best way you think to gather it? Should we start a thread for videos or otherwise recorded data to share, and any changes or mods you have on your engines?

Exciting stuff in any case, I look forward to seeing what everyone has to contribute.

Screenshot of my first successful connection:

_________________
1990 Vanagon Westfalia

[bobbyblack]

What Voltage are y'all seeing when initially connecting the Bluetooth (ALDLDroid), prior to starting the engine? Mine was in the mid 13's when running.. before starting, I'd see something in the 11's even though my other voltage readouts were showing well into or in the high 12's.
_________________
'87 Westy 'Flossie','86 Westy 'R1','86 tintop GL - Subi2.2 'J2','83.5 stock tintop L 'ZoomBus','74 Karmann Ghia, '63 Notch

[Steve M.]

[montanasurfer]

[DigiMatrix]

I just looked at my video of warm up from cold. ECT = 40 degC, IAT = 14.3 deg C, RPM = 938 Battery voltage = 13.6 and Advance = 14.72 deg BTDC.

The advance does fluctuate from 10.5 deg BTDC to 16.83 deg BTDC.

Please note, the advance code for idle is separate from the 2D table I posted earlier, so don't expect it to follow that. If your throttle switch isn't working then the 2d table is used. Anyone that has had an intermittent throttle switch, you will know the idle is much better when the switch is working properly.
_________________
_________________
'91 Syncro Westfalia
soon to be 2.5 liter stroker WBX 10:1 comp
Digifant ECU with knock sensor and custom
cylinder selective knock control by me

[DigiMatrix]

[Steve M.]

[natejohn]

Here's the video I did earlier today. Complete cold to warmup. I spent most of the time on the O2 screen but flip over to the first page occasionally.


Link

_________________
1990 Vanagon Westfalia

[DigiMatrix]

natejohn, your video with the stock injectors definitely shows that the Mansi injectors are a higher flow rate than stock. On my engine (2.1 L and 1.25 ratio rockers) with your ECU the integral gain (long term offset) settled out at -80 while yours is showing a value of zero. That is showing the stock tune and injectors are well matched. Looks like some improvements can be made (not as rich during warmup) by adjusting the fuel table if you are running the Mansi injectors.

Note to self: finish the XDF file!
_________________
_________________
'91 Syncro Westfalia
soon to be 2.5 liter stroker WBX 10:1 comp
Digifant ECU with knock sensor and custom
cylinder selective knock control by me

[natejohn]

[DuncanS]

This all exciting news. Only wish you hadn't sold one to Steve M who then doesn't even need it 'til Tgiving! Mita moved me up a couple of minutes on when I get mine.

Thank you Santa. Whatta Christmas this will be.

Duncan

[DigiMatrix]

[Steve M.]

[jberger]

[DigiMatrix]

Ok, so I have been delayed in working on the next 20 Emulators. I had a few people with issues with the first 20. I have had 3 people send them back with their ECU so I could have a look. In all 3 cases the Emulator was working properly, but the connection to the ECU was poor. Once I had corrected the issues by re- soldering or repairing the messed up connection all was fine. So... may I suggest that if you are not comfortable soldering or don't have the proper tools to do a proper job then please make arrangements for somebody skilled at this sort of work to do it for you. I am more than happy to do it, but it can be expensive to ship to me. I will also update the documentation to clearly show the 3 possible locations the single wire can be soldered to and indicate the skill required for each and some extra information like soldering heat etc.

On another note, I was online to a few component suppliers today thinking about ordering parts for the 3rd run. Bad news, the required microcontroller is on back order and not available until February 2022. I will do some more looking, but it is not looking good. I will not substitute with questionable components.
_________________
_________________
'91 Syncro Westfalia
soon to be 2.5 liter stroker WBX 10:1 comp
Digifant ECU with knock sensor and custom
cylinder selective knock control by me

[DuncanS]

When I was a kid and wanted something I had reasonably good luck with my North Pole supplier. Have you tried writing Santa? I hear he may now respond to emails, but not texts. Hope he doesn't have to disappoint many this December.

[DigiMatrix]

Documentation for soldering the single wire to the ECU has been updated with pictures (3 options). If you don't have a solder sucker, I would recommend option2 provided you have a fine pointed soldering iron. I set my soldering iron temperature to 295 deg C on my soldering station.

I have ordered a batch of the required micro controllers today. Estimated ship date is Feb 04, 2022. I don't have time before Christmas anyway. Still work full time and we have 4 projects on the go right now that we need to finish before Dec 17th.

Working on the next 20 tonight and tomorrow.
_________________
_________________
'91 Syncro Westfalia
soon to be 2.5 liter stroker WBX 10:1 comp
Digifant ECU with knock sensor and custom
cylinder selective knock control by me

[hans j]