VW 1.8 16V KR ITB - Starts only on brake cleaner / Rough idle / Wasted Spark

EMU BLACK / CLASSIC
1

Hi everyone,

I have been working on my project for quite some time now and I’m running out of ideas. I hope someone can point me in the right direction.

Engine setup

  • Volkswagen 1.8 16V KR
  • Honda CBR1000RR (SC57) throttle bodies
  • OEM VW 60-2 crank trigger
  • ECUMaster EMU Classic
  • R8 coil-on-plugs
  • No camshaft position sensor (wasted spark)
  • Toyota 1ZZ-FE 250 cc injectors
  • Alpha-N
  • Fuel pressure: 3.0 bar (stable)

The engine ran perfectly before the conversion on carburettors. The only major change is the conversion to EFI.

Symptoms

The engine only starts when I use brake cleaner. Without brake cleaner it cranks but refuses to start.

Once it starts, it keeps running around 1050 rpm, but it runs very rough, almost like it has a large camshaft, although the engine is completely stock internally. It seems like not all cilinders are participating, but they are.

Idle AFR is approximately 14.2-14.5 and fairly stable.

Occasionally I get small pops back through the intake when the RPM drops.

Things I have already checked

  • Base ignition timing checked with a timing light and matches the commanded timing.
  • No sync errors or unexpected tooth errors.
  • Fuel pressure remains stable at 3.0 bar.
  • Injectors are wired individually and every injector is tested individually through the ECU.
  • Injectors have been ultrasonically cleaned and fitted with new filters and O-rings.
  • R8 COPs are wired individually (prepared for sequential ignition in the future when a cam sensor is added).
  • Every coil is tested individually through the ECU.
  • Cylinder head and engine grounds have been checked.
  • SC57 Throttles can not be synced

Wasted spark settings

My ignition outputs are wired as follows:

  • Ignition Event 1 → Cylinders 1 & 4
  • Ignition Event 2 → Cylinders 2 & 3

image
image807×515 161 KB

Injector phases are configured as:

  • Injector 1 → Ignition Event 1
  • Injector 2 → Ignition Event 2
  • Injector 3 → Ignition Event 2
  • Injector 4 → Ignition Event 1

Injection mode:

  • Start at Ignition Event
  • Injection Offset = 0°
  • Squirt Twice Per Cycle = OFF

image
image1491×882 194 KB

My question

Can someone confirm that these injector phase settings are correct for a wasted spark setup without a camshaft sensor?

Some documentation suggests 1-2-2-1, while intuitively I would expect 1-2-1-2 because the engine firing order is 1-3-4-2.

I am not sure whether I am misunderstanding how ECUMaster assigns ignition events, or whether my configuration is incorrect.

Besides that, does anyone see anything obvious in my setup or symptoms that I may have overlooked?

My goal is simply to get the engine running correctly up to around 3500 RPM without load, after which it will be professionally tuned.

Any advice would be greatly appreciated.

Thanks in advance!

Ramon Kelderman

2

You need squirt twice on for batch firing injectors (no cam sensor)