E67 turbo LE5 with variable cams

[ACCLR8N]

This is my start-up tune for adding a turbocharger to a 2.4L LE5. The engine has been operated N/A without a MAF for a couple years. Besides adding turbo hardware from a 2.0, it has been fitted with 2 bar MAP and 60lb Siemens injectors. I scaled the previous tune 50% and then added 15% back for some safety.

I thought I would post it up in hopes somebody might see something horribly wrong before we try to fire it up. If it starts and idles, next step will be Swingtans OL VE tuning procedure. I see lots of warnings about variable valve timing and boost. What are people doing? There are a number of mail order tunes available for this swap so there must be a solution. Are the cams fixed in a position within the tune?

[ACCLR8N]

The car is getting way to much fuel at start-up. Have been attacking the VE tables. Wondering if I missed a table somewhere. I looked for a cranking airflow but didn't find anything.

[ACCLR8N]

Starting problem was B1832 scaled by 50% when the correct answer was 2X. Fires up instantly now hot or really cold. This table I assume is my cranking airflow I was looking for. RPM and MAP ranges have been increased to 4200RPM and 200 kPa. This car is MAFless so needed to increase the RPM as well as for boost. Currently it won't idle in OL. I created a BEN for trims and WBO2 to try and do some rough adjustments on the VVE table before trying OL again.

Waiting to see what the variable cam timing is going to do to me and how to work through that.

[joecar]

Thanks for posting your findings/results.

[ACCLR8N]

Car is running in open loop now. Had to zero the table on variable cam timing to play with the virtual VE tables. Problem we are having now is we can't go full throttle. Just about when the front end gets light and things start to get interesting, power dies and the car start spitting and popping until you back off the throttle. This corresponds with a spike in the air per cylinder. What could be causing this?


Edit: Found this thread. Going to try adding 1 to all the VVE cells and recalculate.
https://forum.efilive.com/showthread.php?8888-Weird-problem-with-airflow-spike-causing-temp-power-failure

[joecar]

Does it throw any DTC's...?

[ACCLR8N]

Does it throw any DTC's...?

Not related because of the stripped down harness: MAF circuit, Generator F. The MIL is not set.

[ACCLR8N]

Car starts easily, idles nice, works fine with minimal throttle input. Really stumped on why this car won't take any throttle. Airflow doubles in the log and car starts popping. It is in open loop, variable cams are zero, no MAF, no VSS, tune is scaled for 60lb injectors. Tried the +1 trick on the VVE tables. Codes are P0102 and P0622 MAF and Generator F-terminal because of swap harness. MIL status is no. Any suggestions?

[joecar]

Those DTC's do not cause reduced power/throttle.

Looks like IFR is not being exceeded (it looks low, so I take it that you have scaled for IFR...?).

[ACCLR8N]

Yes, the three bar 60lb injectors had to be scaled for the four bar fuel system. From the thread below I have been modifying the stomp dynamics (B2012 +20%) and haven't seen a significant change. MAFless, VVT, turbocharged, manual trans and scaled injectors. Did we forget anything to make this harder? Minor issue has been that the car wants to stall when you coast to a stop unless you blip the throttle I believe to be unrelated and not a priority.

https://forum.efilive.com/showthread.php?9417-Fuel-dynamics-mafless

[ACCLR8N]

An update for anybody following:

With Hymey and Swingtan's insite that the stomp gas was heavily dependent on the MAF we came up with a workaround. The assumption is the accelerator pump fuel at tip in is not available for modification. Whatever default value it is working from MAFless is incompatible with a scaled tune. E67 MAFless, Boosted, Manual trans, Scaled injectors=impossible.

So we picked up an adjustable, boost referenced fuel pressure regulator and dialed the pressure back to 3-bar. This got the 60lb injectors just under the table limit and I was able to unscale the tune. Like magic, you can now mash the go pedal.

Working on the coast down idle dipping too low (getting better) and re-dialing in the VE. Car owner is eager to get the cams turned back on, but I want the VE closer. Car is still in open loop with VVT set to 0.

[joecar]

3-bar referenced rail pressure and unscaled tune... good job :cheers:

( sorry for being daft (I haven't slept in a few days), so now are you running with or without MAF...? )

[ACCLR8N]

No MAF. Car didn't have one in N/A configuration for a couple years. My involvement began when the decision was made to add turbocharger and the MAF was long gone with no previsions in the truncated wiring harness. There is also no VSS or clutch switch in this swap harness.