Hope I'm posting this in the right place.
Long-time lurker, almost-first-time poster who's been slowly figuring things out .. I think. I'm trying to get this setup dialed in, but I'm not sure I'm looking at the right things in TunerPro or heading in the right direction in adjusting things. Maybe someone can give me some guidance in what to look at or suggest something I'm doing wrong? Long post to try and give as much information up front as I can.
The engine is an AEB from a 1998 Passat, rebuilt to run counter-clockwise and installed in a high-roof 1975 VW camper with the Passat 012 gearbox. Other than the reverse-rotation it's mechanically stock -- pistons, cams, head, intake manifold, turbo, intercooler, compression ratio -- aside from an aluminum diverter valve, and the only change to the AEB's wiring was an ICM delete and the use of newer 4-pin coils (bolt-down type). It's been running well for a couple of years, there's no issue from the reverse-rotation setup -- I've had several multi-day trips into Canada and down into California since the original conversion along with a lot of daily-driving use. The pipe between the MAF and turbo is a hair longer than stock, also the hose between intercooler and TB is a little longer than stock, but that's it. I've swapped the ECM, harness, TB, VVT chain tensioner and MAF for the system from an '02 Passat AWM engine (ME7.5 wideband with DBW, ECM 4B0906018CM), re-pinned the crank and knock sensor connectors to use the AEB parts. Using things I learned here, I've successfully reflashed the ECM to a 4B0906018CH bin with IMMO off, turned off LDP and SAI (AEB head, no port) and have it running generally pretty nicely with the new electronics. N75, N80 and N249 are all enabled and connected like they should be (N112 went away with SAI), the MAP sensor is in an adapter in the pipe between the intercooler and TB -- the AEB intercooler didn't have a spot for it.
I think I'm having issues with the fueling and possibly the injectors, and I'm second-guessing myself because this is all new to me .. though I am learning and am apparently not as dumb as I thought I was.
I'm running the AEB's 4bar FPR because I have it. From the charts I've seen, AEB injectors (0280150447) are 210cc/min, AWM injectors (0280156065) are 282cc/min, both measured @ 3bar. The AWM injectors are too short so I didn't use them. Initially I ran the stock AEB injectors and bumped KRKTE to 0.13493 from the stock 0.10478, which is what MasterJ's "ME7 TUNER WIZZARD" Excel program calculated for 210cc/min injectors. That seemed much better than it was with those injectors before I changed KRKTE, but I still got lean DTC's sometimes .. and I'm also concerned I might be maxing out those injectors, but I just don't know. I also have a set of longer EV6-style injectors that physically fit, flow tested as 367cc/min @ 3bar. No idea what P/N is because it was ground off, they were supposed to replace 0280150450 which are (EDIT, typo) 378cc/min. I put them in the other day, changed KRKTE to the calculated 0.07721 and from watching VCDS it was running rich, with pre-cat O2 sensor control (measuring block 33) in the 23-28% range at idle. Adjusting KRKTE lower into the 0.072xx range made it worse, adjusting it the other way improved things, and I most recently bumped KRKTE to 0.08458 which got the block 32 LTFTs to 5.8% at idle and 0.0% at partial throttle, with reasonable-seeming pre-cat O2 sensor control values at idle (3-7% range), but I'm back to getting some lean DTC's, and while driving the pre-cat O2 control values go into the negative by like -12% to -18%, which worries me.
Am I overthinking things about block 33 being high at idle? Am I on the right track with using these injectors and adjusting KRKTE? Should I go back to the AEB injectors and put KRKTE where it was working well and adjust from that point? Are there other injectors that would fit the AEB manifold/fuel rail that would be better to use? I'm not looking to tune this thing for major HP or torque -- it's a slab-sided box on wheels, the handling gets pretty hairy above 80MPH, and even the AEB's 150HP is about twice what it came with.
I've got some logs in CSV format generated by VCDS I could dump if they'd be helpful. I haven't gotten ME7 Logger working on my laptop yet, and I didn't realize until literally just now that there's a logging function in NefMoto. Maybe I AM as dumb as I thought I was.
At least I don't have to rely on this car as my daily.
Any guidance or suggestions would be appreciated. Thanks!