Common rail 2.0l tdi standalone

Toyotaguy

Well-known member
Joined
Dec 30, 2011
Location
Idaho Springs Colorado US
TDI
2010 2.0l swapping a toyota pickup
Thanks for the duration maps for the CBEA injectors that is huge i was going to get the injectors flow tested but now i dont need to because it i have a better base point. Thanks for the advise on the duration of the pilots. I have found that on the Cummins and duramax that the pilots are only harmfull after about 2700 rpm. because there is only so much time to get the injection done.
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
actually the pilto should be less harmfull, if used wisely, as they lower the peak dp/dalpha, so create a more stable combustion with eventually a lower peak pressure for given bmep

also you should do good by using the stock railpressure map as a starting point
 

m1ketdi

Veteran Member
Joined
May 18, 2009
Location
Leam
TDI
Leon BKD
You should try and get a copy of the original hex from this ecu.

Then learn how to identify maps using winols or similar and you will have a much better starting point for building a desktop calibration for your standalone.

Or pay someone for their assistance with this....
 

engineered2win

Veteran Member
Joined
May 24, 2011
Location
Dublin, OH
TDI
MkVI Golf TDI
Normally the pressure transducer in the glowplug measures up to 200 bar (at least the denso ones, dunno what the 2009+ us spec tdi uses), but the control is only used during part load (emission area) at fulload the timing is open loop.

basicly what you do is make a base timing map that is good and then use the feedback from the calculated 50% mass burned fraction to shift the timing a certain amount from the base map, to make up for changes in fuel quality etc etc

anyway, for what you are trying to achieve it is way over the head, as you won't be running any EU6 or equivalent emission regulation there also won't be any need for such a precise mbf50 control

better focus on making decent base maps (can be read directly from the logs, or even easier from the stock ecu file)

as for pilots, this engine uses double pilot till quite high rpm, IIRC till 4000, then it goes to single pilot..

double pilot is also something you wont need in a vehicle like that, as it will cause more harm than good. so run a single pilot, at low load around 1-1.5mg and at medium load you can go till max 2.5 or so, separation (from end of pilot till start of main) dont go under 700-800us and max about 2000 us.. if you want to run double pilot and do things right thing will get really complex as you need pressure wave correction etc etc

if you look for my posts, I posted stock duration map somewhere from this engine, so that should give you already a serious headstart to get it running right
The glow plug pressure transducers are produced by BERU, which is a subsidiary of BorgWarner. The pressure range is 0-200Bar.

I would only use the base inj timing maps as a starting point. Their concern will be emissions at #1 priority, as that is the most difficult aspect of building diesels for US emissions standards. If you can read the cylinder pressure from the glow plugs, I would tune to MFB50(mass fraction burned), which is when 50% of your fuel mass is burned. I haven't gone through all the calculations to determine the optimum MFB50, but it's generally around 8-10* ATDC. That will give you the best BSFC and power.

The main purpose of pilot injection is to reduce diesel clatter, but there are other benefits from multiple injection events, such as better cold idling/starting, and better combustion. You will get better atomization running multiple events because, when you run only 1 large event (main fuelling only) the fuel fuel mass can be thought of as a shell fired from a cannon. If you only fire very short bursts of fuel, the mass of each burst is smaller and it penetrates the compressed air less. If you fire one large burst of fuel it will penetrate farther and hit the piston. This will cause an increase in soot and will affect BSFC as well due to a less efficient burn.
 
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ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
I have the calibrated ecu in hand! Runs perfect. Multimaping available.
2.0 tdi CRKA recommended.
Greg
Hi Greg,

I'll be in Nashville In August, would love to see the Bosch Motorsport ECU's in action on the Boxer engines!!
 
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