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what maf and map sensor are on this newer engined car? looks like maf has topped out around 3500rpm+
if the lambda sensor is true? and fuel is dropping above 3500rpm maf must be dropping also or not ?as the lambda stays pegged around 1.34- 1.36.
 

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I think i need Tribesman... On hard acceleration i see black smoke in the mirror and i'm not happy with the egt. I want a not to aggressive tune with complete no smoke. But at the moment think, no smoke is not possible with the edc15.
Are you sure the injection duration table is extrapolated correctly? According to the logs, you are injecting 76 mm3, but how much duration and railpressure are you using for that value?
 

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Discussion Starter #463
@Joel
I can't look into the mapping. This i why i need TribesMan, but i'm in contact ;)

@sussexa
Nothing is maxed out. The EDC15 has a MAF reading issue over OBD and all values over 4000rpm are the same.

MAF = Bosch 0 986 284 007 (80mm from VAG cars)
MAP = Bosch 0 281 006 059 (4 Bar from VAG cars)
RPS = Bosch 0 281 002 527 // Volvo 8631588 // Bosch replacement 0 281 002 631 (1800 bar)

Lambda values are true. The values can not go over 1,36. 0V=AFR10,0 and 5V=AFR20,0. More can't be displayed.
 

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Discussion Starter #467
EGT is not as i like it. At the weekend i will remove the oxy cat and we will see, how the EGT will drop.
 

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Acceleration is looking strong, about 18 secs from 100-200, not bad at all.
EGT seems very reasonable to me too. But I don't take the Autobahn every day. ;)
 

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Discussion Starter #469
18sec up hill ;)

Only in the 5th gear on flat road, i think its a little bit faster. In my opinion the exhaust is the bottleneck, but the power is definitly more then ok. Its over 85hp than stock and with the better VNT settings the drivability is so much better and it feels very strong in low revs.

Ah and i let TribesMan lift the idle rev from 850 to 950. This is a "must have" for all JTD 8V owners, because the idle vibrations are really bad (just only in Stilo?). With 950 all this bad vibrations are gone.

Here a short video of the display. Now i can switch through the values. I can create value-blocks and i can also log this values.

 

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Discussion Starter #471
Project is still going on! After some conversations with TribesMan, we think is can be help too use the 120hp injectors too lower the egt.

So i have ordered 6 used injectors and let them test by Bosch. 3 broken and 3 in good condition... When i get the money back from the broken injectors, i will buy again some injectors...

Then i have seen that the exhaust manifold is bend. Cylinder 4 is leaky and make whistle noises. I talked with a lot of companys and nobody can say, what the best solution is. So i use a stock exhaust manifold with only one modification in the flange and hope the best. But this time without heat protection wrap - just only the stock heat shield.

used injectors
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_923.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_924.jpg

good injectors
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_932.jpg

exhaust manifold
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_934.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_935.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_936.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_937.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_938.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_939.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_940.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_941.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_942.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_943.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_944.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_945.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_946.jpg

heat protection with thermo paint
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_947.jpg

leaky exhaust manifold
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_948.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_949.jpg

new injector removal tool
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_925.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_926.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_927.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_928.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_929.jpg
 

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I see you did the same approach as me, with the partial cuts in the exh head flange. Let's hope it will work out!
The one that warped has a completely divided flange, right?
Also a thing to consider is the diameter of the stud holes. I'm not sure how it is @ the std 8v manifold, but with the 16v one, only the holes of cyl 3 are slightly oversized, the rest is significantly bigger. (10.5mm for M8 iirc)
 

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Discussion Starter #473
Yes, i saw this in your pictures and like the idea. And yes, the warped exhaust manifold has the completely cutted flange.

But it's curious. With the old engine, the flange (without cuts) was bend at the outside and now with the new engine, the flange (with cuts) was bend inside. :ermm:

The 8v manifold has smaller stud holes on cylinder 2 and all other holes are slighly bigger. Look here http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_937.jpg

When i will change the injectors, i also change the fuel rail with the 120hp one. For the wiring loom i made an extension, because on my fuel rail is the sensor in the middle of the rail.

http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_950.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_951.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_952.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_953.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_954.jpg
http://www.danverclan.de/media/pics/stilo/turboumbau/turbo_8v_jtdm_955.jpg
 

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Wow, it was leaking quite a bit! I can understand you can feel the difference. Let's hope it stays leakfree.
What about EGT? A little bit higher now?
 

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Discussion Starter #478
I just only did a small "installation lap" and don't looked at the egt. With more exhaust gas the vnt should be wider open and the egt is lower?! But we will see...
 

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crosshot, i must say this to you.
Congrats! Very nice effort! You sound like a very nice guys, always opened to learn!

I'm also thinking in this kind of upgrades on my 147, does my gearbox must be cutted as well?
I saw that you have fitted a TMAP on yours, you don't know a 3pin MAP? I would like to keep stock view.
Also for the MAF, the 2.4 JTD 20v 175hp would not it be better?

Keep the good work mate!
 
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