[car_restoration] 405 T16 Restoration

[B1ack_Mi16 67]

Painted it all by myself in the barn, not perfect, but good enough

[johniban 59 1 Cars]

id be happy with a paint job like that! looks top notch

[B1ack_Mi16 67]

Just added a USB connector to the bottom of the centre console which can be used to connect the laptop to the ECU.

 

Also mounted the wideband lambda display with integrated controller in the ashtray area.

[B1ack_Mi16 67]

Finally some more progress to report.

Started to work on the ECU this morning.

Started by soldering wires to all plug pins to be used, then continued by mounting orginal internal map sensor from the 2.0 8v turbo.

Soldering in progress

Finished product

[calvinhorse 870]

That's super cool, well done

[wicked 103 3 Cars]

Nice! The MS3 Pro has nice spec's but the price is bit steep too..

 

 

Started by soldering wires to all plug pins to be used, then continued by mounting orginal internal map sensor from the 2.0 8v turbo.

 

 

Don't use that one; 200kPA is not enough for you... Why not stick to the external 3bar MAP?

Probably for the OEM look? In that case you might look for on old Audi S2/S4 ECU. 250/300kPA MAP sensors can be found in those...

[B1ack_Mi16 67]

Ok, I didn't write it just now. But the internal MAP sensor is only used as barometric sensor, so should suffice just fine for that.

I have a proper 3bar MAP sensor mounted at standard position in the 306 GTI inlet manifold

 

You see it here (still got the OEM look on the MAP sensor). Considering to shorten the fuel rail so I can remove the injector spacers/adaptors.

Edited November 23, 2015 by B1ack_Mi16

[wicked 103 3 Cars]

Makes sense... Keep up the good work!

[petert 588]

Why do you need to know barometric pressure as well as manifold pressure?

[B1ack_Mi16 67]

Probably won't need it, but if one are to run engine on TPS in some situations it can be used to minor adjust the fuelling/ign.

 

Haven't really got a clue about mapping the MS3, so have no idea of how it works yet.

 

I already had the sensor, so chose just to put it in there in case it might prove to have a function

Edited November 23, 2015 by B1ack_Mi16

[johniban 59 1 Cars]

Thats a bloody awesome idea with the ecu casing,

[B1ack_Mi16 67]

It's win-win as the loom looks stock also as orginal 2.0 Mi16 loom is used as base, with some added wires

[wicked 103 3 Cars]

Why do you need to know barometric pressure as well as manifold pressure?

 

The Atmospheric Pressure Sensor is used by the ECU to determine the air pressure of the ambient air in or around the vehicle. The ECU uses this input to adjust air/fuel ratio and ignition timing for changing altitude conditions (and thus density of the air entering the engine).

 

 

So for altitude compensation. On higher altitude the air contains also less oxygen. I know that the Audi S2/S4's run more boost at higher altitude to be able to deliver the same power as on low altitude. Kind of comfort thing, you don't require on a racer.

[B1ack_Mi16 67]

Air filter and 4" 90 deg silicone bend arrived today.

 

Working on adapting the cooling fan and lightning harness as the routing is a bit modified compared to orginal.

Some cut and splice of wiring required.

 

[johniban 59 1 Cars]

Looks like its going to go some by the size of that turbo!

[B1ack_Mi16 67]

It's a Holset though, they are large for their capacity.

Don't think it'll provide to more than 400bhp max.

 

Some slow progress going on, nothing too interesting though.

 

Mounted 5 channel amplifier.

 

Making battery box, still unfinished, moving battery to under the boot.

 

 

 

Mounting rear speakers

 

And need to make a bracket for the USB / Minijack input for the CD-Player next to the wideband gauge.

[B1ack_Mi16 67]

Welded on outputs to idle valve and dump valve on the 3" pipe to the throttlebody.

 

Dummyfitted piping to idle valve.

 

 

Also got an adjustable wastegate actuator for the Holset, hopefully this can control the boost pressure. If not I will have to change to an external wastegate solution.

 

 

Sadly the carpet clips are NFP, so had to sandblast some rusty ones, quite bad condition some of them, have sprayed them in acid here, will add zink primer and paint afterwards.

 

 

Here's a small vid of testing of the stepper motor from the Megasquirt 3 Pro.

 

http://vid428.photobucket.com/albums/qq3/B1ackMi16/405T16/Wiring/VID_20160208_225616_zpsmzsynggq.mp4

 

I've also managed to get MAP and Baro sensors configured ok, and air and coolant temp and TPS works as they should.

 

Now I'm just struggling a bit with getting response from the flex fuel sensor. Might have wired it wrong... have to do some investigation.

Edited February 9, 2016 by B1ack_Mi16

[B1ack_Mi16 67]

Got the stainless 45 deg bends and a straight section so mocked up the turbo outlet pipe today.

 

Need to get it to my mate for welding next.

 

 

 

Will also try to glue in the rear windscreen this weekend. Not sure how hard it can be...

[wicked 103 3 Cars]

Are your hands that tiny or is that turbo so big...??

[B1ack_Mi16 67]

4" / 10cm inlet for the turbo. It is a bit big.

 

However I don't have particulary large hands.. rather small so might be a combination of both

[B1ack_Mi16 67]

Managed to glue the rear windscreen into place this weekend. Now I just can pray it has a proper seal all way round, I got a bit short on the glue in the end :/

 

[B1ack_Mi16 67]

Mounted the oil-filler / breather tank yesterday, bottom left close to radiator.

 

 

Also put the rear seats in to clear some floor space, still missing plastic part around central arm rest, couldn't find it....

 

[B1ack_Mi16 67]

Managed to get the volume control stick working today as some resistors arrived in my mailbox

Finished with phono jack outlet.

Does anyone know if there exists more variants of this style radio remote stick? I would really like one with 1 extra function, to change source when pressing the stick in, like on the newer Peugeots.

[imaS 0]

That looks quite similar than I have in 406. The functions are: volume = up/down, track change/radio search = front/back and lastly source/radio memory/CD change = twisting motions. Could you utilize that switch?

Edited February 26, 2016 by imaS

[B1ack_Mi16 67]

Hm. Haven't tried to twist it. Maybe it activates two wires at the same time then?