My PES G1 with FMIC Build

[keithwbloom]

J Fonz tuned ATQ ECU on my bench. SC and FMIC all sorted and ready to install. Porsche Boxter Brembo calipers refinished and ready to reassemble and install. Lucas rears refinished, rebuilt and ready to install. Unfortunately my bathroom is not, and I am on car day restriction until I refinish wainscoting. :p


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[swcrow17]

Keith....can't wait to see this baby get up and rolling....next GTG I suppose?

[keithwbloom]

Not waiting until garage day night before GTG to install, I am aiming for last weekend in January.

[swcrow17]

awesome. you're definitely one of the residential electrical engineers.

[TheColoradoRed]

This is taking almost as long as mrgreek's air ride install.

"My PES G1 with FMIC build (or how I took longer than anyone to put on a damn SC)."

This thread doesn't have enough SC porn

[Matt98B5]

"My PES G1 with FMIC build (or how I took longer than anyone to put on a damn SC)."

I check this thread almost every day, thinking, "Ohh, a new post, maybe it's done! ...nope, just someone else razzing Keith for taking so long..."

Great work, though. I'm very impressed by virtually all your build/diy posts on the forum for completeness and attention to detail.

[keithwbloom]

This thread doesn't have enough SC porn

Would you like a picture of my J Fonz custom tuned ATQ ECU?

[Bdubskii]

Was that book helpful in learning how to tune an ECU? I've seen it online and thought about grabbing a copy, but didn't know if it was worth it.

[keithwbloom]

Was that book helpful in learning how to tune an ECU? I've seen it online and thought about grabbing a copy, but didn't know if it was worth it.

It is heavy reading, and a lot of it is theory and background, which I found helpful to understand why homegrown ECU tuning has taken a long time to gain a foothold in consumer and hobbyist markets.

Much of the intimidation stems from ignorance, while many of the roadblocks were technological. The technology barriers are getting bridged,so if you remove the veil of ignorance, you can really start to play with your engine management and air/fuel maps.

The base tune is just the first step, and having an experienced tuner do it gave me a level of comfort. The book gave me knowledge and confidence to talk shop and request specifically where I wanted to start.




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[Bdubskii]

Nice! seems like I've have to pick that one up for a good read on the train lol.

[TheColoradoRed]

I'm all set, a picture of an ECU is like the handicap porn of superchargers.

I've been learning about ECU tuning too (granted not for a SC) so I can be prepared when it comes time to custom tune my 2871r with Eurodyne Maestro.

[JayTheSnork]

This is taking almost as long as mrgreek's air ride install.

"My PES G1 with FMIC build (or how I took longer than anyone to put on a damn SC)."

This thread doesn't have enough SC porn

I love this one, especially since I renamed mrgreek's thread that way.

[keithwbloom]

My C.O. is going to AZ at the end of this month for 5 days. T-minus 19 days 'til install window.

[keithwbloom]

I have the tuned ATQ ECU with the same part number as my OE unit, but I m assuming I am going to have to do some adaptations to get it work with the existing components in the car, e.g. keys, cluster, and IMMO-III coding. Does anyone have a laundry list of things I need to get sorted before I swap ECUs during SC install?

Install date Friday 1 February in Polidori's garage.

My gas mileage is going to suck afterwards, isn't it?


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[CotySinz]

I have the tuned ATQ ECU with the same part number as my OE unit, but I m assuming I am going to have to do some adaptations to get it work with the existing components in the car, e.g. keys, cluster, and IMMO-III coding. Does anyone have a laundry list of things I need to get sorted before I swap ECUs during SC install?

Install date Friday 1 February in Polidori's garage.

My gas mileage is going to suck afterwards, isn't it?


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Haha, I was gonna say, if you wanna drive to Ohio, I have a 3 and 1/2 car garage with a lift and all the Snap On tools you could need if you wanna make the trip, just get the thing together, need SC porn lol.

[keithwbloom]

Removed the stock air box and CAI plenum and deposited them into cold storage. Won't be needing those anymore.

Assembled the MAF to the stubby K&N using a temporary plastic adapter. I am going to make a pattern from that temporary adapter and have a permanent one fabricated from aluminum. When I had the assembly together, I mocked it up to the SC intake manifold to see how it would fit in situ, and I think I am going to order a different stubby and also a 45° or 90° elbow to put the filter element out next to the RF inner fender panel.

Lots of room for SC and FMIC plumbing goodness now:


Perils of tweaking with your daily driver... got the call my wife was stuck in traffic, had to hastily reinstall MAF with stubby filter assembly so I could go pick up kids from school. Couldn't find the little filter I have for the SAI snorkel, and clearly didn't have time to fashion the adapter I am going to need for that, so I took an old cotton knit shop rag (which actually turned out to be an ancient pair of Fruit of the the Looms) and covered the SAI intake, securing it with a couple of rubber bands.

When I drove it to pick up my kids, I could definitely hear the throttle body more clearly. I suppose that is the sound bump everyone talks about when they replace the stock air box and CAI plenum with their favorite flavor of alternative intake hardware.

That sound bump is clearly going to be drowned out by a scream from the G1 after the first of Februrary.

[Steve in Chicago]

I took an old cotton knit shop rag (which actually turned out to be an ancient pair of Fruit of the the Looms) and covered the SAI intake, securing it with a couple of rubber bands.

No time to fabricate something permanent? Then a "brief" solution will do.

[Bdubskii]

When the kids gotta get picked up, you gotta do what you gotta do.

[keithwbloom]

I kicked the Fruit of the Loom guys outta my engine bay after I found my SAIP intake filter and fashioned up a permanent snorkel extension using a piece of intake tubing I picked from a V6 a few weeks ago.



I used the band clamp to tighten the opening while I warmed it with a heat gun, the opening was a touch loose. A few minutes under gentle heat, tightening the clamp a little at a time and "voila!" tight fit on the filter adapter.

When I remove the top elbow from the existing intake tube, its flared end will connect snugly over the new extension:

[dublax44]

So much jealousy and want.

[Steve in Chicago]

I kicked the Fruit of the Loom guys outta my engine bay

So your engine bay has gone "commando".

[kevspassat]

No time to fabricate something permanent? Then a "brief" solution will do.

You're so punny Steve!

[keithwbloom]

Short list of things to check off before Friday's install at Polidori's house:

1. Program/code/adapt the 3B0 907 551 DB ECU from J. Fonz Tuning with base boost profile on it for G1 to work with cluster IMMO key, and whatever other soft coding may be needed.
2. Dry assemble SC on bench with all peripherals and new MAF to intake manifold elbow to make sure all needed fasteners and clamps are accounted for
3. Install and secure SAIC snorkel filter
4. Survey and map vacuum lines where GReddy actuator will plumb to

So today I did #3, it was warm and the air box connector elbow on the SAIC intake was easily coaxed from the plastic tube. The snorkel extension I made last week fit nicely inside, trimmed to length, and will probably fasten up securely to a mounting clamp bolted through to the wing with the 10mm bolt and fender washer used by the air box when present.

[pic of the snorkel to follow once i visit the auto parts store and get a hose mounting clamp]

And then to get #4 done while I was in there, I popped off the engine cover for a quick review of the vacuum system and the tapping points in the PES install guide, and I found this:





Now I'm no Dyson or Hoover engineer (that job title would suck), but I am guessing that this may explain my recent slump (last couple of months) in fuel economy. I thought it was a seasonal thing perhaps, and a little bit of last hurrahs playing with the sound of the throttle body through the stubby K&N filter in the cold weather. I didn't expect this.

So I have a few vac lines to replace it seems, probably a good idea to replace the lot of them if they are all potentially this brittle. I will probably try to do this part of the install tomorrow. It is supposed to be awesome weather.



Keith

[TheColoradoRed]

[John prusinski]

Now I'm no Dyson or Hoover engineer (that job title would suck)
Keith

better than being a "box engineer"

[keithwbloom]

The fmic was hung by the radiator with care… in hopes than an SC will soon there.

New power steering cooler in space behind driver's side fog light:


Aluminum support straps mount intercooler front and center, with clearance under top plumbing for air con coolant sensor.


Had to Dremel away a bit of the fascia sub frame, now the old mount point slips over fastener head, so that IC can stay supported when sub frame is removed:








More pics in a bit. Gotta go cleanup my neighbor's garage floor. I left a puddle of PS fluid when I swapped out the cooling coil. Had to go get a liter from VW dealer... $35. Ouch!

[hu vw]

Gotta go cleanup my neighbor's garage floor. I left a puddle of PS fluid when I swapped out the cooling coil. Had to go get a liter from VW dealer... $35. Ouch!

Next time clamp the lines before removing them, less mess and no financial expenditure.

[vwb5t]

my local napa has the right stuff for $20

[keithwbloom]

my local napa has the right stuff for $20

I didn't want to drive very far with the PS pump making the sucking air sound. My local VW dealer is by far the closest source of PS juice, only 2 miles or so.

[vbora01]

1 day til install! Been watching this since the first post... install all the other things too! Brakes... etc.