My 1992 GTI

[DocWalt]

All of the parts are ordered except for injectors and I need to figure out what I want to do for the intake. I think I'll get it running then worry about doing a fancy intake. I'm still trying to find a set of G60 injectors...

[DocWalt]

At this point I'm only waiting for the ABD Intake, and waiting on injectors to ship. Everything else is on the way. Two weeks off of work, and not much else to do so I'm happy to have something useful to do. I hope everything arrives in time to allow me the time to get it done and with a drivable tune by the time I get back to work.

[DocWalt]

I'm about two-thirds of the way through the harness installation. Hall sensor, coolant temp sensor, idle valve, injector power/signal wires to weather pack connectors, all power wiring, and new fuse block installed. I only need to wire up the TPS, wideband power & signal, and intake temp, as well as building the fuel injector harness. The fuel injector harness is the most complicated part, weatherpack connectors are a bit annoying.

ECU firmware flashed, and my circuit mods are tested. The ignition setup works perfectly including tach. I calibrated the idle valve and it works perfectly too. I'm not 100% sure about the coolant temp sensor calibration, but that's not a big deal to tweak down the line. I'm super excited that everything is working out!

[DocWalt]

Current engine status:


Megasquirt harness is completed. I need to buy some smaller wire loom to finish tidying it up after I get the car started, but it's looking great so far. All of the sensors are looking good so far, and all of the control hardware checks out. Now it's just software setup which has been well documented, so I'm expecting everything to go relatively smoothly from this point on.

Also, my ported & polished head arrived with the stainless header. Looks fantastic, but I need to clean a lot of glass blasting beads out of the ports and coolant passages.


As of today:


Megasquirt is fully installed. Just waiting on a throttle body. Don't worry, the CIS stuff was just for mockup It won't fit with the big bore intake and my strut bar anyway.

New head intake port:


Exhaust port:


Assembled with the TT cams and the lightweight lifters. What a pain in the ass.

[DocWalt]

More progress on the new engine, ARP undercut headstuds installed, head dropped on and torqued down. I set the timing and torqued everything down except for the main crank sprocket bolt. That will have to wait until it's in the car, I think.

[DocWalt]

Megasquirt installed and I'm about 75% of the way done tuning. Runs great at WOT, and runs well pretty much everywhere except idle. I had the idle tuned very well but I decided to try using the stock VW idle valve to bump up the idle when I'd need it using MegaSquirt's closed loop idle control. What a PITA, haha. Sounds kinda silly in the video cause of that, but oh well.

[Alex3000gt]

Nice Kenny! You sure have put a lot of work into that Volkswagen!

[Jimvr4]

Nice job!

[DocWalt]

Thanks guys! I've spent some more time on the idle and it idles perfectly at ~1000 RPM when warm. I need to tweak the warmup stuff, but I'm getting closer! Pulls like a train at WOT. WOT tuning is cake in comparison to idle. No wonder why the flashable ECUs are selling like hotcakes compared to standalones, tuning all of this cold start and idle stuff sucks.

[DocWalt]

I've got MegaSquirt working very well! A little bit richer than I'd like at idle, but I need to do that to stave off the heat soak of the IAT sensor. I don't really want to mess with the IAT correction to make it less sensitive t heatsoak over 100* but I think it will be worth trying so I can save a bit on gas and have less worries about emissions testing. I definitely need to spend more time fine tuning, it's correcting the mixture quite a bit sometimes at cruise, but still great at WOT, and transitions smoothly between on/off throttle almost everywhere. Below 2k is still a little bit jerky because of the dashpot tuning, but my BRZ does the same stuff.

Random picture of how I connected to the stock CIS lines since I had the intake out to epoxy the bung to the tube temporarily.



I definitely need to find a good solution to the intake, maybe run the stock plastic pipe to a Digi2 airbox with a cone filter adapter and a silicone coupler. I doubt that the ABD intake will line up and fit under the strut bar using the Digi2 airbox.