Integrated Engineering's "Project 2.5L Engine Dyno" Build Up Thread

[Pineapplegti !]

Good to see a true engine dyno. I grew up helping my grandfather play with his. When are 2.5 cams coming

[BlackRabbit2point5]

The box we are going to use is the new AEM ECU- not their old "EMS". We are just actually signing up to be an AEM WD right now because of this awesome new ecu. It can handle anything you throw at it- cam timing (qaud), dual drive by wire, even direct injection.

Being direct with them we will work with them to figure it out and more then likely have a package available with harness & basemaps. Between the engine dyno, tons of datalogging and a 'scope, we have the resources to get it done.


Pete

Poking my head back in here to try to get some more info on the new ECU... Actual name, part number, is it commercially availible. I do some contract work for an AEM electronics dealer and while I'll probably wait for a base map and harness from you guys I'd like to be familiarizing myself as much as I can. If you could kick me a users manual pdf and a link for the new tuning software provided it isn't covered by the prior tuning suites I would be hugely thankful.

Sent from my HTC Evo 4G Shift using Tapatalk

[pete@integrated]

We are still using the Vi-pec / link ecu's because they can do everything the AEM does, and I had no reason to switch. They have been extremely reliable for us so far.

The AEM I was all excited about because it "does" FSI but when you talk to their tech guys it can't drive it internally and it's all totally untested and basically not supported yet.


Anyways, did some work today:



^Digital scope hooked up, measuring the cam / crank / vvt / throttle body frequencies and wave forms.



^Forklift = mobile work bench.



Here you can just barely see the cam / crank waveforms plotted together. It's hard to photograph the laptop screen. We should have this sucker figured out here shortly. I need to tear apart my harness and change it around to wire up the e-throttle because that was a last minute decision.

[Pat @ Pitt Soundworks]

We should have this sucker figured out here shortly.

If you tilt the laptop a little more towards the camera you get a cleaner picture. There. I just figured out the hard part for you

[pete@integrated]

Nah, we played with it a little bit- it didn't want to go. Plus, there's a little bit of "only want so good of a picture" going on there as we don't really need anybody lifting our hard work right off the interwebs.

[vento 95 GL]

^Forklift = mobile work bench.

is that the new "hot" air intake

[pete@integrated]

That + exhaust leak = EGR.

Haha, no that's just called dave being lazy. He took the cover off because we put the fuel rail on and was too lazy to order an intake. Then he was also too lazy to put the cover back on, resulting in exhaust manifold cone filter mod.

He has a winter beater anyways so the car is basically sitting- which is why I had the chance to go all dr. Frankenstein on it's electronics today.

[Max_O]

Man, you guys are doing amazing things for the 2.5L.....I have already thought of spending a few $k's on pending products you have coming. Most looking forward to cams and a shiny new valve cover

[BlackRabbit2point5]

Ah crap looks like I'll be turning my interest back to putting mine on Haltech Platinum Sport 2000 then

Sent from my HTC Evo 4G Shift using Tapatalk

[pete@integrated]

If you aren't going to keep it drive by wire then why not do the Link extreme? Then I can get you a base map with everything setup etc... They are pretty reasonable... The V88 has a pretty hefty premium for the e-throttle which IMO is justified since it's a pain in the ass.

[pete@integrated]

Sorry for the *total* lack of updates on this guys. I got a little busy working on some other projects and this got pretty much shoved on the back burner.

We got the stock throttle body working on the Vi-Pec- it actually works quite well. I'll have the guys shoot a quick video of that this week. We are getting very close to getting this thing fired up on the dyno now with that hurdle crossed. We need to hook up the exhaust and do some housekeeping on some smaller items, and we'll be in business.

We are very excited to start testing some power parts I promise guys the updates will flow again starting soon.

[Anile_eight]

Very nice! good work guys!

[pete@integrated]

So, I promised an update, and here it is...



We officially have the 2.5L on our dyno, and running on Vi-pec standalone. We got it fired up late last night, and spent some of today cleaning up the mess. A few tweaks and a couple missing OEM bits and we'll be ready to start doing pulls. We have the OE Drive by wire working already, the VVT will be next once we start doing some tuning. We will be sure to build out a nice index of base maps as we go for anyone who wants to follow in our footsteps.

Really excited to start testing a few products- big and small. I'll have the guys make a little video for you in the next day or two.

[HollisJoy]

So, I promised an update, and here it is...

is that exhaust pipe 2.50" or 3"?

[TrillyPop]

Sweeeet Let me know if I can provide support in any way, I appreciate what you guys are doing

[GTACanuck]

Thats awesome Pete! Keep up the work on the 2.5's! We appreciate it

[MK5CNY]

Sub'd

[spartanrabbit09]

Sub'd

[itskohler]

When you get everything sorted out, what are the possibilities of this being marketable? Will you start doing stand alone tunes? Just wondering.

[nickbeezy]

When you get everything sorted out, what are the possibilities of this being marketable? Will you start doing stand alone tunes? Just wondering.

we need anti lag boosted 2.5l on vipec

[nunumkv]

oh my cant wait. Want that fuel rail!

[itskohler]

Definitely need it if you get a SRI.

How was the cookout Omar? I wanted to go so bad!

[pete@integrated]

Vipec anti-lag...



18psi...

[itskohler]

Nice.

[pete@integrated]

Little update on this: The junkyard motor we bought, which allegedly had 40k miles on it- has zero compression on cylinder #1. I'll post some pics of the tear down and resulting OE rebuild- we want to leave it stock for now and build up from there.

[magics5rip]

sub'd Love what I see thus far!

[killa rabbit]

keep it up looking good

[DarkSideGTI]

This thing sounds good!

[Sales@IE]

Good news guys, after a few snags the motor has perfect compression and is up and running like a champ! We put together a little teaser video of a baseline pull for you. Now we can start development of new parts and start making some power.

[itskohler]

[tay272]

Cannot wait to see the end results, you guys rock!

[vr6-kamil]

Very cool. what do you have for exhaust on video it's very loud, is it just like a straight pipe and 1 muffler?

So did the engine dyno 170hp exactly like VW claims?

[magics5rip]

[pete@integrated]

Our dyno has 2 x 4 foot long, 5" mufflers and a 5" stack out the building. Before that, we had a 3" straight through magnaflow, about 3 feet long. That stuff is all left overs from our previous testing of 800+ bhp turbo engines, they don't want any backpressure.

Currently, we're just messing around trying to get the VVT working. It made 170bhp / 195 ft-lb with out much drama, but didn't want to go a whole lot past there. We are going to play with the backpressure next, I intend to dream up some sort of mechanism where it can be adjusted- short of changing mufflers / pipe sizes.

Top end power is really, really bad- I'm excited to rectify that, it'll make it a lot easier to setup the dyno as well. You tell just from the exhaust note that it's got nothing up top.

I've got a few prototype parts that should wake it up significantly

[DerekH]

Wouldn't a simple butterfly valve serve your purpose in adjusting the back pressure?