T4 : Battle Across Time (2010 to present)

[TommyP]

Always useful TP, by-the-way, where the chuff do all these numbers come from?
I'm assuming the hammer mod and Thoras' have magic powers ..... you install big nozzled injectors into an AJT mapped nay, defined AJT ECU, then "tap" (any magic words or piroetting required - Kev does this anyway) then it magically modifys all that it touches? Can the hammer do and wield other such wonders on other animate and inanimate objects?

Who'd have thought Just-T4s has become the Hogwarts for van tuning, .... does the "hammer" choose you when you enter the Motor Factors? Do the Lei flowers hanging on the rear view invisibly cloak the van from high speed touring. Does Kev have a second face at the back of his head and speaks in a strange tongue and dialect?

I dunno where they come from, some silly sensor masquerading as something useful when in fact it’s sole purpose is to keep the parts department busy and we’ll funded.


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[regcheeseman]

Always useful TP, by-the-way, where the chuff do all these numbers come from?

Thought you had all the numbers?

Block 15

Should be between 3-5, 4 is the target.

Engine running, laptop montoring, four pump lid bolts just cracked off from tight, tap, tap, tap, gentle taps and watch the number on the laptop change, you can tell by ear as well. When the number is right, tighten bolts, double check the number hasn't wandered, turn off engine, put laptop away, have a brew and stroke your hammer.

Then map it, safe in the knowledge that the mechanicals are know in the correct place for the brain to know that what it wants is what it will get - did I ever mention there's no feedback on a TDI control system, imagine a control system with no feedback, what kind of idiot..

So the hammer mod - Too far one way and the pick up off the pedal is lazy, too far the other way and the pick up becomes very eager, the idle starts to lift and it's prone to hanging up when you come off the throttle - EXACTLY the same symptoms as adjusting the fuel screw ...who would have thought it

[Activ8]

Thought you had all the numbers?

Block 15

Should be between 3-5, 4 is the target.

Engine running, laptop montoring, four pump lid bolts just cracked off from tight, tap, tap, tap, gentle taps and watch the number on the laptop change, you can tell by ear as well. When the number is right, tighten bolts, double check the number hasn't wandered, turn off engine, put laptop away, have a brew and stroke your hammer.

Then map it, safe in the knowledge that the mechanicals are know in the correct place for the brain to know that what it wants is what it will get - did I ever mention there's no feedback on a TDI control system, imagine a control system with no feedback, what kind of idiot..

So the hammer mod - Too far one way and the pick up off the pedal is lazy, too far the other way and the pick up becomes very eager, the idle starts to lift and it's prone to hanging up when you come off the throttle - EXACTLY the same symptoms as adjusting the fuel screw ...who would have thought it

I get that you're trying to mechanically correct the fuelling but surely the numbers are written into the ECU's maps.

The figure 3-5mg/s is derived from the needle lift sensor and the conversions the ECU makes based on the prepared Bosch derived maps relative to that sensor. Theres no true metering of the actual fuel its all prepared. Then all the relative numbers obtained by the sensor as the revs increase are a conversion but still based on a mapped instruction.

[regcheeseman]

I get that you're trying to mechanically correct the fuelling but surely the numbers are written into the ECU's maps.

Surely not. You'll see.

The figure 3-5mg/s is derived from the needle lift sensor and the conversions the ECU makes based on the prepared Bosch derived maps relative to that sensor. Theres no true metering of the actual fuel its all prepared. Then all the relative numbers obtained by the sensor as the revs increase are a conversion but still based on a mapped instruction.

How is it derived from needle lift sensor? that only has a binary output from which the ecu knows how long the injector is open for, doesn't know the flow rate though.

But it must be getting this number from somewhere...

[Activ8]

Surely not. You'll see.

I've seen it a lot but been able to correct rough idling / over fuelling with larger nozzles with mapping the QA.

How is it derived from needle lift sensor? that only has a binary output from which the ecu knows how long the injector is open for, doesn't know the flow rate though.

The flow rates will be preprogrammed.
Its all preprogrammed

But it must be getting this number from somewhere...

Exactly.

[TommyP]

Get a manual pump it and stay off the laptop.


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[regcheeseman]

Perhaps you could build him a pump Tommy.

I'll hammer mod it.

[Activ8]

Perhaps you could build him a pump Tommy.

I'll hammer mod it.

Lol
At least what ever TP built would be sold on the basis of raping a 1.0L Corsa.

[Fruitbat]

Lol
At least what ever TP built would be sold on the basis of raping a 1.0L Corsa.

That’s about all he rapes haha

[Activ8]

Started on the injectors today.
Found a couple of sets of Bosch donors to test and get my eye & hand in with.
Testo alfresco was the order of the afternoon, this morning the lad and I had our first flying lessons. The lad lapped it up - great to see.

[Activ8]

Tested two oem Volvo 5 pot sets.
Both sets came out of running engines a few years ago and one set all passed at 220bar 1st break, the second set 3/5 passed at 230 bar, the needle lift injector failed to open at all even at the 2nd break pressure+ (christ that was tough getting the unit to that pressure) and another injector opened at 210bar. Not a fail but I need all to be matched.

[TommyP]

That’s about all he rapes haha

It’s the little wins you have to take


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[Fruitbat]

It’s the little wins you have to take


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Hahahahaha hahahahaha

[Activ8]

Rebuilt the hydraulic ram for the engine crane/lift/hoist this morning. The O ring sizes I had already. It was missing one seal and three were perished. Just need some hydraulic fluid from down the shed. Chuffed. Just need to locate two matched heavy duty castor wheels to replace two on the base, then give it a clean.

This afternoon after.preparing some lamb for the bbq tonight I stripped the seized / faulty needle lift injector tested yesterday. The nozzle I've left to soak in a diesel cleaning additive but not before jotting down the nozzle DSLA150P838 which turns out to be a Volvo 4 cylinder 190-220bar 5x 0.205 holed nozzle (internet search). I'll check the other 4 shortly. All 5 will be rebuilt with larger nozzles that I bought in Italy last year.

Brew time.

[Activ8]

Measured the single 1st break initial shim to ask Kev for a quote and tested the sensor on the Bosch needle lift injector.
For reference this 140k injector used a 1.5mm thick shim so bang on the middle of the available shim sizes (1.00 - 2.00mm I think). There are two shims in the TDI injector but I'm not touching the 2nd stage. The KBEL two spring njector shim OD was 6.8mm & bore 3.2mm.

Made contact with a few diesel specialist suppliers, 1st "trade account only", 2nd wanted all the info to get back to me, 3rd offered a minimum order of 500pcs for nearly £200+VAT, plus I'd need to open an account. None would give me part numbers or any further info to aid my search.

Anyway , it came in within tolerance (80-100Ohm) of 97/98/98 (Checked 3x). Being the Volvo injector its fitted with a shorter cable and two pin plug that has to be extended or you borrow the Volvo system with an intermediate cable and socket & bracket to the IP housing which the injector plugs into so saves dropping the tray to get at the sensor engine connections.

The needle which is machined matched (as a pair) to the nozzle body was still pretty seized despite 24 hours in Rockoils Diesel Fuel additive. I'll do one nozzle change at a time and I keep all the injectors separate and marked up for reference.