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Lets get it on then, My 2.1 conversion

Discussion in 'A3/S3 Forum (8L Chassis)' started by Andrew@A.L.D, Dec 12, 2009.

  1. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Going to be getting the date sheet.

    i have seen a 2.0 gt30 billet wheel the same spec as mine on vortex and idle sounds well.

    Its a risk but let's see
  2. badger5
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    badger5 RIP S3dave Site Sponsor

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  3. superkarl
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    superkarl MAN OF STEEL

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    his injectors arent bosch though. Theyre Gen II right?
    did usrt not send you the flow data with them? they sent it with my 630s
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Bosch/Genesis are the same thing as far as I am aware...

    <tuffty/>
  5. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Flow rate is normally controlled by altering the holes of the injector... Just seen the ones on these... holy ****!!

    ec52729137b94f8341d2865fd047187b.image.733x550.jpg

    Thats gonna pour fuel out lol....

    Compared to 630's and OE

    f2f56c4bc768d88d09547290d565212c.image.733x550.jpg

    <tuffty/>
  6. superkarl
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    superkarl MAN OF STEEL

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    quote from scott@usrt:
    'Guys, here are facts about the line and the values behind it:
    a) Most Genesis injectors ARE based in some way on Bosch and Siemens cores. This has never been hidden. EVER. Anybody that knows the injectors will recognize this immediately. For that matter, the Bosch and Siemens logos appear on the bodies most of the time (as supermega1 verified for us).
    b) Some Genesis injectors are built by raiding the OEM parts bins. Nozzle tips, bodies, solenoids, o-rings, and such are mixed/swapped to produce proprietary configurations. This is EXACTLY how industry veterans, RC Engineering, produce their line, for instance. (A big difference is that RC is almost exclusively Lucas-based which imposes serious limitations for VAG. The parts just don't fit much of the time and spray patterns are not optimal
    c) Other Genesis injectors are modified for flow rate and spray pattern and are found nowhere else. They are completely proprietary and unique.'



    im just saying that comparing these to the bosch data bill found prob isnt reflective of these genesis ones.

  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Maybe not but will give a start point if they are at all based on the same injector... I suspect though that the linearisation issues will still remain... the best all round injector I have used to date is the Bosch 550 EV14's... its a different car with them in even at 4bar...

    ASNU use the same injector for pretty much the whole flow rate range but all the data does indeed change based on flow rate... voltage comps etc in particular... they list data for most of their injectors (ironically the 550's data was not on the site, I had to ask for it)... they just cut the end off a std bosch injector (for a snowmobile engine IIRC) and weld on different ends to alter the flow rates...

    Shame they are so non linear...

    <tuffty/>
  8. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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  9. BuuBBa
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    BuuBBa Member

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    That Leon runs with E85 so it needs ~30% more fuel than running with gasoline, so it "helps" to handle bigger injectors.

    Seriously looking forward to hear the results of Your new epic engine!
  10. Sam_
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    Sam_ Down under

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    I think I've seen the 1700cc's in action:

    [​IMG]
    kanecullen89, CHEZ, Scullies and 2 others like this.
  11. AVLO
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    AVLO Member

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    ive just read this thread from start to finish and have got too say hats off to you andrew for all the time and effort that has gone into this build!! :applaus:

    ohhh....... and not to forget to mention a s**t load of $$$$$$$


    I will look forward to having a look at this car if ya make it too some meets this year
  12. Scullies
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    Scullies Active Member

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    Any updates on your build?
  13. Rick @ Unicorn Motor Dev.
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    Rick @ Unicorn Motor Dev. Member Site Sponsor

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    The 870's idled as standard, which is comforting. These will be fun but I'm sure they can be made to work well.

    Rick
  14. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Sorry just been to busy really

    Engine block is sat in the bay, need to get the head over to the garage and hope to get that on over the weekend or bank holiday i hope.
  15. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Good to know Rick

    Bring on the boost
  16. s3dave
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    s3dave TFSI Hybrid

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    Aye AYE.............. Are things moving...:beerchug:
  17. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    A little done today, Got the head on, downpipe back on, Breather fitted, small battery fitted, repaired oil filter housing and fitted



    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG][

    Attached Files:

  18. badger5
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    badger5 RIP S3dave Site Sponsor

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    BUT, there is at least this performance and linearity data available for these Bosch injectors, which I have never seen for genesis units.
    this will be important when looking to size them and tune them on me7
    Linearity on low injector opening ms is where some injectors fall over...

    Thats why this information and test data is important.
  19. StaceyS3
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    StaceyS3 Active Member

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    Catch can looks wicked mate :)
    Hows things going you nearly up and running again?

    Bill did you get my email with some genesis info for 1000's and 630's?
  20. badger5
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    badger5 RIP S3dave Site Sponsor

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    recently?

    if not its buried in my 1000's of emails in the inbox
  21. superkarl
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    superkarl MAN OF STEEL

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  22. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Not up and running yet as I've been doing head work for people for the last 2 months.
  23. StaceyS3
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    StaceyS3 Active Member

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    Hopefully youll be up and running shortly, you coming gti international as would be good to meet ya
  24. StaceyS3
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    StaceyS3 Active Member

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    Yeah was a little while ago I sent them over bill will see if i can dig the email out and resend it

    Karl linky no worky as on my phone....probably me being special still not used to android, if I did send it to you then feel free to chuck it up mate ;)
  25. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    I should be but customers come first, I would love to go as i stopped going to Ten of the best now but i will be sat on a beach in Zante when GTI inter starts
  26. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    I'm a bit lazy when it comes to me updating my own thread as i'm doing lots of head work and engineering bits for others

    The modifications

    I thought it would be best to add a EGT/Boost gauge as mine has had the Wideband conversion but still using a modified APY loom so no EGT sensor like you find it later models

    Video of the gauge
    http://img.photobucket.com/albums/v...1D415C5C-605-0000009EA47425A6_zps1ea9768f.mp4

    The probe is sat right in the collector just before the turbo

    I then went onto bleed the coolant system and this happened rushing it for the MOT

    http://www.audi-sport.net/vb/a3-s3-...y-check-when-its-cold-warning-skin-burns.html

    Anyway it passed that weekend i burnt my arm.

    Due to me recovering i haven't been able to do much work due to lack of movement in my thumb as the skim was so tight. I was lucky i got Tufftys head all done and dusted and back to him, I just have to get on with sandwich's head

    As for the car i have left it in the garage and it could do with a new vernier pulley as the Cat cams ones are **** but i will wait to do that later as i'm getting a error code of 16727, My timing is out so it will sit there until my arm has fully recovered

    I have also had a lot of thinking about what to do with the engine to get a bit more power out of her so a 3 inch down pipe and system will be made, the 1600cc injectors will be fitted and i also hope the sell the GTX3076r turbo and step it up for a bigger turbo, I do like the EFR turbos but the GTX hasn't let me down?

    I was thinking about doing a engine swap but its finding one i like thats light and thats larger than 2.0, not cheap so that idea has been binned so i will be keeping the 2.1 unless i win the lottery.
    <tuffty/> and StaceyS3 like this.
  27. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Not much of a update really as i've been to busy working and buying new parts

    As some of you know i got a new turbo seen here
    http://www.audi-sport.net/vb/a3-s3-forum-8l-chassis/205083-my-latest-mod-jojo-style.html

    And i have something else on the cards to help lay down the power with a very tricked out stand alone Haldex controller from Germany

    So here is a copy, paste and translate, This info is for a lower spec one to the one i'm getting as the one i'm getting is one thats can read up to 5 bar of boost but i think i'll be running 2.5 bar for 1/4 only

    So now read on what this thing can do






    CRC Performance HC MK3 PRO Haldex controller descriptionPreface:

    The CRC Performance HC MK3 PRO Haldex controller is a new development of our firm CRC-Performance. The unit in question is a “Standalone” solution which enables to run vehicles retrofitted with a 4-motion drive train. It was our aim to develop a product which outclasses all steering which are currently available on the market. In months and months of development and countless kilometers driven, as well as cooperation with several quarter mile racing teams known in Germany, we have developed a steering which finally is a useful component also for quarter mile racing cars.

    Of course, the CRC Performance HC MK3 PRO Haldex controller has got a racetrack mode enabling it to take an influence on vehicle dynamics and to adjust power distribution to the relevant speedway optimally.

    Moreover, the Haldex controller is equipped with a dynamic street mode which is also completely new engineering by CRC Performance. Regarding performance, safety and equipping it is setting new standards. Also in communication between our Haldex controller and the rear axle differential we have been breaking the mold. As the first manufacturer/producer we can come up with a CAN-Bus Data communication. This nowadays absolutely essential technology makes it superfluous to convert or destroy the control unit located at the 4-motion drive train.

    This primarily benefits operating safety.

    Operating Modes

    Off Mode

    The Haldex controller is deactivated and by this, haldex clutch is completely open. The car responds in vehicle dynamics like a front wheel drive vehicle. Is the Haldex controller switched OFF, only boost pressure with max boost recall is shown on the display.

    Street Mode

    The locking level in street mode is programmed to a set level and depends on speed and boost pressure of front 95 %, back 5 % to front 50 %, back 50 %. Only by this it is warranted that for every driving situation there is optimum traction. Dynamic control makes it possible to gain speed, e.g. on wet roadway, because rear axle is being engaged even before boost pressure is build up. If speed increases, e.g. on an interstate, there is no necessity to supply much power on the rear axle. By doing this, locking level is reduced to 5 % on the rear axle with wide open throttle. Consequently, unnecessary frictional resistance is reduced as well as consumption. Letting go of the accelerator, and boost pressure falls below -0,5 bar, Haldex clutch is being opened completely and the vehicle responds like a front wheel drive vehicle.

    Since the Haldex controller recognizes current speed via GALA speed signal, we defined several speed ranges. The processor recognizes one of those and adapts locking level in relation to the current boost pressure. The speed ranges have been set with due regard to power and gear transmission ratio of most vehicles retrofitted with 4-motion drive trains. In street mode, current locking level, speed and boost pressure are shown on the display.

    If emergency brake is used or, to be more precise, stoplight switch is being activated, and by this, 4X4 drive is deactivated.

    For dynamic control

    Key data for dynamic control were collected during months and months of tests with several thousands of kilometers driven on a VW Corrado VR6 Turbo 4-motion with 474 PS / 640 NM. By this, all requirements concerning performance and safety on streets can be met.

    Race Mode

    The locking level in race mode can be adjusted from 0-100 % in steps of every 5%. This means that there is the possibility for maximum force distribution of 50 - 50%.

    In difference to street mode, Haldex clutch in race mode is closed when reducing gas. By that, the vehicle has permanent four wheel drive regardless of boost pressure or speed. With the possibility to block the rear axle, behavior on the road changes drastically. Instead of understeering, as it is usually the case with 4-motion vehicles, the car can be brought to oversteer in a curve by quick load cycle changes. With this, even drifts are possible. This property is to be welcomed especially by weekend racers. In race mode, the set locking level is shown.

    Haldex position ON/OFF

    In race mode, there is the possibility to choose the tuning in the setup menu to activate the haldex clutch alternatively at 0 km/h or 20 km/h.

    This answers the following purpose:

    If Haldex controller is set on race mode and the Haldex clutch is closed, there is going to be tensioning in the drive train which will be noticeable in turning or parking. Unfortunately, this is due to technics in 4X4 vehicles and cannot be prevented well. We have found a possibility to activate Haldex clutch only at 20 km/h because in hobby-racetrack use, in most cases there are no starts with standing vehicles. In case there are any, you can activate race stand ON function and Haldex clutch is closed already at 0 km/h.

    Quarter Mile Mode

    Our quarter mile mode presents an absolute novelty in 4- motion sector. As first producer we can please the needs of 4- motion quarter mile vehicles. In the setup menu you can choose in steps of 5 km/h 0-375 km/h to adjust the locking level in steps of 1% 0-100%. This makes possible to take off from the start with 100% blocked rear axle and, gaining speed, 4X4 intensity can sink to 0%. It is possible to reach optimum traction without giving away power. Each vehicle has its relationship between weight and power, so onetime setting has to be done by the customer for every vehicle. Having finished setting, data are saved, but can be changed at every point in time, e.g. using other tires. The onetime driven curve can be increased or lowered by 50 % in 1% steps in setup menu. This makes quick and uncomplicated reaction to changes of the roadway like wet roadway, ground waves or pasted track possible. Optimum grip is always guaranteed without giving away power. By this mode, racing cars can make optimum use of the benefits of the 4X4 drive in quarter mile. At the start, full traction is guaranteed and at higher speed levels, frictional loss is reduced, resulting in higher terminal velocity. You will always be one step ahead of your competitors!

    If emergency brake is used or, moreover, stoplight switch is being activated, Haldex clutch is opened and by this, 4X4 drive is being deactivated. When emergency brake is put on, burnouts are possible.

    Equipping

    Cable harness

    Cable harness is supplied with the Haldex controller. It can be plugged in individually for any type of car, e.g. at the rear axle differential or for the plug of the speed signal which is located at the gearbox. It is not necessary to cut off any plugs or something like that, because our Haldex controller controls the rear axle via CAN-Bus output signal. By that, no changes in the original Haldex electronics located at the rear axle differential are necessary. This is for the benefit that no parts will be definitely destroyed as it is the case in other all steering which are currently available on the market. Furthermore, the cable harness is equipped with a fuse. Installation Einbau is done in no time. Only power supply, boost pressure hose, emergency brake switch / stoplight switch and the plugs at the rear axle differential and speed sensor located at the front of the gearbox have to be plugged in. Additionally, wiring harness is equipped with a K-Line, which enables a diagnosis function of the rear axle.

    Display

    The CRC Performance HC MK3 PRO Haldex controller is equipped with a 60 x 37 mm display, informs all the time about the most important parameters and leads you quickly and easily through all setup menus.

    Blue displays with white indication or white displays with black indication are available.

    The better readability of the white display is due to a wider viewing angle.

    Display survey

    Off mode – boost pressure with max boost recall is shown

    Street mode – relevant locking level, boost pressure, oil temperature and speed

    Race mode – locking level, boost pressure, oil temperature

    Quarter mile mode – locking level

    Main menu - relevant mode, boost pressure and Haldex oil temperature

    Setup menu – speed- and quarter mile setup

    Haldex oil temperature cannot be shown with all types of vehicles, because not every rear axle differential supports this function. This depends on the year of manufacture of the differential.

    Operation:

    Configuration

    When implementing the Haldex controller for the first time, the speed signal of the gearbox can be tuned with the speedometer or GPS signal and the HC MK3 PRO Haldex controller and saved in a submenu. This is necessary for a precise tuning of functions relevant to speed. All settings remain unchanged even in case of loss of electricity, because they are saved in the processor.

    Operation/Setting

    CRC Performance HC MK3 PRO Haldex controller can be operated quickly, easily and intuitively only by rotary and pressure potentiometer (F-Drive operating device) and the large display. Setup menus are in the submenus so that they are not to be seen in operation mode. This makes a quick change of operation modes possible without maloperation.

    Optional Equipment

    Boost pressure gauge

    The Haldex controller has a very effective boost pressure gauge. By making use of premium parts /units /components and measuring instruments/vehicle sensors for control and calibration of the sensors, this boost pressure gauge surpasses all currant analog displays concerning precision and reliability/operating safety by far. Additionally, the boost pressure gauge has an max boost recall you can delete whenever you want.

    Oil temperature gauge/status display

    Depending on the year of manufacture of the rear axle differential, current Haldex oil temperature is shown in the main menu. Oil temperature gauge has an max temperature recall

    you can delete whenever you want. With rear axles that do not support oil temperature function, current status of the Haldex clutch is shown. As long as emergency operation is not being activated in the original steering of the rear axle differential, the display shows Haldex OK. In case of activating the emergency operation, e.g. in exceeding temperature limit, Haldex

    Error is shown and Haldex clutch is being opened completely.

    Things to Know

    Bauteileschutz Kennfeld

    The rear axle differential of 4- motion vehicles has various means of protection to avoid damages in the gearbox caused by strain. If temperature rises above 100 °C, e.g. by lack of oil, protection map is being activated and Haldex clutch is being opened completely. As soon as temperature drops below 100 °C, Haldex clutch operates normally. In most cases, such temperatures are not to be reached on regular streets, nevertheless, preservation of such protection functions steered by the original steering which is located at the rear axle differential is very important.

    As the Haldex controller HC MK3 PRO by CRC Performance does not mesh mechanically in the original rear axle (modification of the rear axle valve), all mechanisms of protection remain completely!

    In/Outputs

    Inputs

    Boost pressure
    Speed signal
    Emergency brake switch / stoplight switch
    power supply

    Outputs

    F-Drive control
    Display
    Haldex clutch
    K-Line diagnostic
    Last edited: Jan 22, 2014
    snowy, S3Alex, sssline and 1 other person like this.
  28. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    And I must say it's not going to come cheap but looking forward to trying it out
  29. badger5
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    badger5 RIP S3dave Site Sponsor

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    when will your beast be ready to run andrew?
  30. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    I hope May time?
  31. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Well just paid for the stand alone haldex controller. Hope to see it in a few weeks time..
    snowy, bigray and StaceyS3 like this.
  32. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Well guys the standalone haldex controller has turned up.....very fast delivery too

    [​IMG]

    i just need to make a few things to make it look nice in the cabin, not sure where to fit the screen?
    S3Alex, StaceyS3 and s3dave like this.
  33. JD09
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    JD09 I'm not modding, I'm improving

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    Andrew, I'd just like to take this opportunity to berate you, Bill, Tuffty, Westy and anyone else with a build thread on here. You lot are the reasons I've caught the modding bug again, as these threads just show what my car is capable of. Over pay the mortgage? Nah, £1,500 in orders over just one day for the car.

    If you see someone that looks like Victoria Pendleton coming your way, looking angry and wielding a metal pipe, that'll be my missus, having found the receipts and/or parts for my car.
    newbster, JudderMan, Westy and 2 others like this.
  34. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    It is an important part of modding that you learn the skills to prevent this from happening... its a life skill thats useful for anything that the missus will get upset about... which lets face it is mostly everything :)

    <tuffty/>
    Webster2001, newbster, Westy and 6 others like this.
  35. s3dave
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    s3dave TFSI Hybrid

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    should be in the stickies really "Before you start"....;)
  36. superkarl
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    superkarl MAN OF STEEL

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    Or a blue pill and a red pill.
    The blue pill being heroine
  37. audiholic ste
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    audiholic ste Member

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    Diazepam works well for my wife . 1 10mlg tablet and half an hour later she is well chilled . They are from a different planet .
    superkarl likes this.
  38. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Thanks guys

    Set up the standalone haldex controller on the bench to see how easy it is to use

    Not connected so no boost or Oil temp readings so thats why there is a error

    Filmed on a gopro hero 2 @ 720hd so as you can tell they don't like doing macro stuff when you see it.

    HaldexVid_zpsa63b2e07.mp4 Video by andylindley | Photobucket
  39. Gary_808
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    Gary_808 Member

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    Is that the controller where you can do custom setup also? In 5kph steps you can adjust the drive?
  40. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    Yes you can adjust it to what ever you want

    In off its just 2WD only.

    If i run it in "street" then its just running my Blue haldex controller

    In "race" i will run it in 50/50 split or as it says on the display 100% Haldex but as you can see i can adjust it to as low as 0%

    1/4 i can adjust it way i want
    snowy and bigray like this.

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