MY big turbo S2 with VEMS

[GazzaG60]

thought id take the time to introduce myself and my car adn the mods so far. i dont have any pics to post yet or sure how its done here. im sure there will be a thread on it.

My name is Gary, im 30 years old and i am group IT manager for Salton Europe. we manufacture and sell George Forman, Russell hobbs and Carmen to name a few.

MY car history has been VW scirocco, VW corrado G60 then the S2. always enjoyed a mod. did a full carb to injection swap on the rocco. full loom engine tank etc. played with boost on the G60 with bigger injectors regs etc. that was a fast car. 300hp subaru tackle. i was building a 16vt for it aiming for 500whp. car got hit by a woman doing a u-turn in the road and that has lead me to the S2.

since buying the car i put together a list of bits i wanted to comliment what i already had that was usable from the 16vt project.

bits i had were

SC6152 turbo
Greddy E-boost 2
Defi setup
LC-1 wideband.

i then went and bought.

17" bbs RS702
tubular manifold.
VEMS ECU
Vems Gauge to replace LC-1 and defi multi-meter.
Brembo porsche GT2 caliper set.
993 TT discs
Quattronics fitting stuff (bells, brackets)

very much the start of the project.

Last week Corey did the honours with a 3" system to match the turbo and manifold he fitted the week before. i collected last wednesday. all i can say is the man is very busy so patience is the key there. very nice work too.

I collected the car and run it home to sunny manchester on the MAF and std ECU. it ran ok. got me home anyway.

i had a few issues and eventually got the car running on friday.

I will over time fill out the post with more info but for now i cannot add pictures as i dont have any or know how to post.

VEMS

the vems i bought was from VEMS .HU. good serivce. i bought the plug and play version for AAN

PLUG and PLAY

first thing to realise is it isn't true plug and play. the plug and play part stops at the harness. it needs to be configured to run on an audi and have some basic wiring mods.

HARNESS MODS

depending on config there are 2 ignition wires that are in different spots shown on the AAN and ABY pinouts. these either need physically swapping or it can be done in software, which is the best place. i cut and connectored the wires before i knew about the SW differences. The other mod is the polarity of the secondary VR sensor. these 2 wires need swapping over. once done leave as they are as the standard ECU seems BETTER with the wires swapped.

ECU BLUES

i plug in start the flash of firmware and halfway through the cable drops out of the laptop. ******** i think as it refuses a flash after that. an hour later and thanks to vems.co.uk i have a paperclip between pins 2 and 3 and the force firware is performed.

STARTING THE CAR

firstly thanks to Teppo Kalske. the help recieved was great. i was struggling with firing order. People like Teppo make you realise the worth of a community. no thanks to a certain "european supplier" who wont give away anything unless silver is passed.

once the error of my map was addressed then i could try to start. first couple of times i flooded her. basically had the wrong REQfuel which is the injector pulsewidth MS required for 14.7AFR and my crank cold and hot were way out along with a multiplier for cold afterstart. plugs out cylinders cleared and ready to go again. after an hours research of megamanual i was ready.

3 attempted cranks later and small changes to the crank settings and afterstart and she fires up.

i make a few minor changes to the VE tables and spark tables and create a lambda reference chart and off i go for a drive. ultra smooth from the start. pulls along great.

FURTHER TUNING MODS

not many really so far. i have a reasonable idea of spark and VE for big turbos with my past subaru tuning so this has been good. the AUTOTUNE feature of megatune/VEMS seems to work well. i use it all the time at present.

IDLE CONTROL AND CATCHING WHEN LIFTING OFF

here is my only real issue. standard idle is great. itll hold idea really steady. proble is when i lift off the throttle it stalls say 2/5. some mods have beem made the the PWM duty cycle for a minor improvement. i think im gonna try adjusting the base point of the throttle body and recalibrating the TPS. i had a few goes at this for an hour or so and it helped but its making my cranking change.

COLD STARTS

i have had to plug in every moring so far (3 times) and adjust the crank and afterstart for the cold start. i expected this as the coldstart is the least accessible area of a map due to time when cold. you get literally 2 minutes then its out of the cold area.
Once the happy medium is found it should be good. it takes around 3-4 cranks before a rumble at present. i can live with it but will look into tightening up the starting.

BOOST RUNNING

CAR is good in boost. feels quite strong. currently running 0.85BAR so only. the butt dyno tells me 300hp. starts to boost at 3K and by 4k we are well on the way. boost never drops off. ive done 6.5k so far and its still getting stronger.

THIS WEEK

plans for the week.

1. brace the turbo
2. Wrap the downpipe and blanket the turbo.
3. fit a proper airfilter.
4. continue with coldstart work
5. hit 1 bar boost.
6. book a Dyno run.

[Acidburn]

Sounds like a good project going, be interesting to hear what the dyno says about it. Some good information there which will help anyone doing a vems conversion.

[Greg_S]

Looks like your project is ticking along nicely, look forward to hearing more about it

[Corey]

3. fit a proper airfilter.

As I am sure my wife would like her stocking back , space was somewhat limited due to you not getting the VEM's fitted prior to dropping the car off and we had to sqeeze the MAF in to get you home

The exhaust I am especially proud of as it is one of our new products, designed and manufactured in the UK for us (We are doing an Avant also if people are interested? ), my only regret was I didn't get any images of it as time was tight. So I look forward to your images Gary

[GazzaG60]

thanks for the work Corey. how are the brakes going. i need them as soon as you can please.

ill be sure to send back the stocking. still working well. to be honest fitting the filter is near enough impossible with no MAF. gonna make one from a HKS element and a velocity stack me thinks.

exhaust is very well made. only issue so far is a little boomy at 1400-1600rpm. im hoping to tune that out. i managed to tune out 400rpm of it so far. above 2k its a dream and 4k onwards its like a bike or something.

my mate who was with me used to own Jap-innovations, a subaru specialists commented on good work quality. designed no his own car he used to have systems supplied to him by a renowned exhaust company in macclesfield. they were recognised as being so good the Robinsons subaru used to supply them as an option on a new car. Coreys systems are of better quality and welding.

took a couple of my workmates out for a M60 blast this lunch- both impressed.

[GazzaG60]

quick update on the car

must really start by thanking mates. even though they guys have hung up their spanners so to speak they cant leave a performance car alone and i get plenty of offers of help.

Well i have managed to meet a few of my goals so far.

got myself some rosejoints and with the help of a mate made up a brace for the turbo. currently looking into front mounts so nothing too special yet.

my mate did me the honours fitting a cold air intake by uni-filter to my car. the part was originally a subaru item designed to fit in the inner wing. item fits down the front below the turbo fine. need some samco to match now as curently consists of a red bit a blue bit and alloy along with the green filter.
as a side note anybody need a hks green filter. the foam ones with piping. open to offers. an item used only for a week till it went to coreys

with the stockings removed along with the maf new found airflow was apparent. cold start became an issue again as did boost settings. I was running around 0.85 bar before for maybe 300hp. now up to around 1.1bar. have crept to 1.2 but wound that out. its pretty fast at that point. you can feel the extra boost is combined with greater compressor efficiency. at 1.1bar the speedo moves fast. the only comparison i can use so far is that on a given point to point a mates old subaru with 380hp was around 20mph slower. i cant see this having 400hp. time to hit the rollers.
think that will be it till i do a headgasket, IC and rods job.

yesaterday was the first proper run on the VEMS. i travelled to our warehouse in wolverhampton bout a 205 mile round trip. used 30 quid for the trip. was quite happy with that bout 1/2 tank. car cruised well.

still working on the idle. looks like the most complex part of the setup. where lots of logging and tweaks and tests need to be performed.

not expecting the boom of the exhaust at 1600 to be easy to remove. think im looking at a box in the middle to help it. the resonance is so much power is effected at that point as are my fillings.

[Acidburn]

Sounds good and would be interesting to see some pics if you can get them working and hear what a rolling road dyno's it at?