My Winter Project

[Prof]

Well due to my mishap this has taken a back seat whilst the car was repaired.  It\'s all running well again now, and it\'s MOT time Friday - just getting the car sorted for that.
 
Work that I did manage to do:
 

• Painted front calipers blue, still got rears to do.
• Removed old rubber lip - ready for the aftermarket one to go on.
• Thermo switch for the upper rad hose is now in.

Emanage still not fitted, but it\'s almost ready to go.  Need to build water injection controller now.
 
 
Car will be getting a new paint job straight after Jap Show - so all the dinks, knocks, rust and other horrors are going to be gone :cheers :driving

[Prof]

Project is back on again
 
Painted rear calipers - rear drivers side had siezed so was replaced - many thanks to Tony for the spare
 
Front lip is bolted on. Paint job is delayed - pending funds and I wanted to keep the car going over the summer - wrong time to paint it really.
 
Prompted by Brett, I have included some pictures of the ARC intercooler - which I\'ve repaired - for size comparison with the stock one. It holds pressure well, but not tested in anger (only tested to 1 Bar, off the car)
 
I will also be posting some pics of the little gizmo I\'ve had to build to go between the stock ECU and the eManage, so that they play nicely - I\'ve still got a bit of work to do on it first.
 
So here are the pics of the intercoolers...

[Brett]

Thanks Prof! :wave

 And your sure you want to keep it? :Giggle

 How long do you think before your mapped and running in anger?

[BenLewisMav]

Can you give me some more details on what wires you are using coming from the emanage to control the elec fan/water spray and monitor the water pump + duty?
 I\'ve just finished soldering my ultimate up to my mini loom (made from old ecu connectors), but I didnt see anything in the manual about controlling/monitoring the stuff mentioned above, or the BAC for that matter..!
Any extra details about how you\'re setting up the elec fan relays etc would be goooood.
Ta

[Prof]

Ok - here is a word doc with table of connectors in it.
 
The water injection pump will be controlled by PWM circuit that\'s not part of the eManage, but is fed with 2 signals that originate from there.  One signal turns on the Water pump, and the other was designed to operate a high speed valve or fuel injector.  The PWM circuit combines these and controls the pump speed/pressure using those signals.  That controller will also monitor water level in the tank, and Intake temp and shut off the Water injection and kill the boost controller if it detects failure (fail safe mode)
 
When using the eManage with a rotary, you have 4 injector/relay outputs that can drive additional injectors or relays.  I use 2 of the outputs wired as warning relays (water to control the radiator fan, and intake to control water spray and shut off boost if on for prolonged periods).  One output was desinged to feed a fuel injector or high speed valve to control water injection, but is now being used to feed a PWM controller instead.  Finally, the NVCS map on the eManage is used to control a relay to operate water sprayer so it can also be mapped (so there are 2 outputs controlling water spray and a manual overide button as well).  The Water injection pump output comes from the VTEC output map, as that allows fuel trimming.
 
Finally, I intend on using the Idle Adjustment Map to monitor the BAC duty and adjust fuelling for the idle (to help get it through MOT ) - this is covered on page 43 of the Operation Manual, and page 14 of the Install Guide.  The BAC valve output is on pin 3Q of the ECU.

[BenLewisMav]

Legend. Just give me a week to understand it all

[BenLewisMav]

Does that mean by using both the water and intake temps as relays you dont have the knock sensor wired up?

[Prof]

Yep - not using knock on the eManage - I have got it wired into the stock ECU still.
 
The other 2 inputs are more useful.  It\'s a shame I can\'t have all three though :rolleyes:
 
Actually one of the reasons behind that decision was that the knock sensing wasn\'t working till later firmware versions, and that you need the water temp wired up to use the autotune feature.
 
Since Intake temps are more likely to give an early warning of possible knock, rather than knock sensor itself, which is detecting that knock is happening you can do more with it.

[mpk490p]

Nice to see it coming along again Dave, stupid question knock and knock sensor?

learning as we go!!

Mark

[Prof]

Knocking - as described by the Wikipaedia site:
 
http://en.wikipedia.org/wiki/Engine_knocking
 
And the knock sensor is basically just a sensitive microphone that\'s tuned to pickup frequencies around 5-6Khz, which are the most prominent when knocking occurs.  It usually bolts directly into the engine block.
 
In the FC, the knock sensor signals are fed back to the ECU, amplified and used to retard ignition, so it\'s questionable how effective that is if overboosting or too high an intake temp is the cause of it.

[BenLewisMav]

How did you learn how to tune the car anyway Dave, I was wondering if theres a step by step type guide to fuel and ignition timing??
 
As far as I can tell;
Fuel; Lean back the mixture to around 14 using a wideband, whilst keeping an eye on the EGT, and progressing from map to map for each scenario (i.e. temp compensation, lift off etc)
Timing; Advance the timing until knock is detected, whilst keeping an eye on the EGT\'s.
Other than that I\'m not really sure about the specifics.

[mpk490p]

Knocking - as described by the Wikipaedia site:
 
http://en.wikipedia.org/wiki/Engine_knocking
 
And the knock sensor is basically just a sensitive microphone that\'s tuned to pickup frequencies around 5-6Khz, which are the most prominent when knocking occurs.  It usually bolts directly into the engine block.
 
In the FC, the knock sensor signals are fed back to the ECU, amplified and used to retard ignition, so it\'s questionable how effective that is if overboosting or too high an intake temp is the cause of it.

thanks Dave i didn\'t think it would be a good thing!!!

Mark

[Prof]

How did you learn how to tune the car anyway Dave, I was wondering if theres a step by step type guide to fuel and ignition timing??
 
As far as I can tell;
Fuel; Lean back the mixture to around 14 using a wideband, whilst keeping an eye on the EGT, and progressing from map to map for each scenario (i.e. temp compensation, lift off etc)
Timing; Advance the timing until knock is detected, whilst keeping an eye on the EGT\'s.
Other than that I\'m not really sure about the specifics.

I think learning is more the way it is
 
I\'ve been following some threads on rx7club and Fc3spro over in the states, and also the innovate motorsports and emanage forums.  From what I\'ve read, most people don\'t lean out beyond about mid 12\'s on the AFR - you can go higher nearer the bottom, but you want to watch leaning it out too much at the top end, unless your damn sure of your ignition timing and charge temps.  You don\'t get a 2nd chance with a rotary engine
 
I was working on the basis that I only have to tune in 3 areas with the emanage, as the stock ECU is going to do the rest for me.
 
1)  MOT \'map\' - basically set aside a dip switch with selectable maps to allow the car to pass the emissions test (idle adjust, AFM, Injector and Ignition maps).  Going to use the wideband to tune these, with a bit of time on a gas analyser.
 
2)  WOT \'map\' - tuning for the upper part of the RPM/BOOST curves - again switch selectable - these will use the GM 3 BAR map sensor which will track boost levels beyond the stock sensor.  I plan to use the Analog in/analog out to provide an \'FCD\', and the emanage will look after all the upper part of the map beyond that, since the stock ECU will no longer be changing the map.  I plan on using the autotune feature to populate this map on the dyno and drving the car.
 
3) WI \'map\' - this will use the last dip switch - fine tuning of the Injector and Ignition maps for the water injection, and water temp and intake temp compensation.  These will be tweaked by hand using the wideband gauge.

[htkingswood]

Hey Prof,
 
Any updates? Interested in your final power figure. Also wanted to know how you went fitted the ARC intercooler and how it performs. Anyways, interesting thread.

[Prof]

Been a bit lazy of late - not done much on the car since firing it up on the eManage and then taking it straight off again due to overfuelling.
 
I\'ve pretty much finished the little mod I was working on - but too much working on the house has meant that\'s been delayed
 
I\'ve 2 days off coming soon - so hope to get quite a bit further with this.  Not tested the ARC intercooler yet, aside from a static pressure test to sound out my repair on it.
 
Keep watching... :cheers