Technical Information

[Canuck70Ghia]

Hello,

I am very glad I found this forum. It seems I am not lost in the dark after all!

I am reconstructing a 1970 Ghia. I have managed to acquire almost all of the 1600i parts and am heavily modifying my engine to accept the new gear. It is actually not that hard, if you know what you are doing.

I have also built my own ECU. I need to know what the stock injectors were rated at at 3 bar? (lbs per hour or cc per hour). I need this to program my system and set pulse width etc.

Appreciate some help. I cannot find this information anywhere and VW is very quiet for some reason.

[phade]

Hi there,

The stock injectors would easily be rated at 3.0 bar, but the correct fuel pressure for the fuel injection system is 2.5 bar. Here's roughly how the fuel injection (delivery) system works:-

The fuel comes from the fuel tank and is pumped at high pressure (approx 3.0 bar) from the fuel pump.

This then goes to a fuel pressure regulator, which is normally located just in front (relative to the car) the fan housing on the left hand side. It is a metal cylindrical device with four fuel hoses (Manfred may need to correct me on this) and one vacuum hose attached to it, where they are the following:-

- Fuel tank supply from fuel pump
- Fuel tank return (excess fuel pressure)
- Fuel injection rails (the metal pipe in front of the fan housing to the fuel injectors and fuel injection test port)
- Activated charcol filter (?)

If the fuel pressure regulator is working correctly (I have already documented this on the 1600i website) then the fuel pressure should be initially 3.0 bar on cold startup and drop to 2.5 bar as the engine warms up.

When you disconnect the vacuum hose from the inlet manifold end, the fuel pressure should rise to 3.0 bar.

After you have switched off the engine (and reconnected the vacuum hose afterwards) the fuel pressure should be at least 2.0 bar after approx 20 or so minutes.

Most of the technical info (if not nearly all of it) has already been covered on the 1600i website http://www.1600i.de/ but if you're still stuck then let me or Manfred know.

Cheers,

Phil

[Canuck70Ghia]

I am happy with the fuel system now, thank you for your help.

The last problem I have to solve is the Ignition Module. When I hook it up to the relay box it makes a repeated quick zapping sound. I am not sure if I have got the pin outs correct on the ignition module. I need to know what input and what kind of circuit the ignition module uses. The HAL sensor gives an upside +12v to the ECU (I can measure that!) but what does the ECU give the ignition module? I have built my own programmable ECU and I need to know if I should use a coil driver in the circuit, whether the circuit creates a ground, 5V or 12V and modify my board accordingly.

[phade]

Hi there,

I have got the circuit diagrams for the mexican beetle (I will need your email address so that I can send them).

Which language would you like them in ? English or Spanish ?

I have also got the fuel injection booklet, which also covers electrical and VAG diagnostics of the various ancillaries connected to the fuel injection system (eg. ignition module, etc).

If you don't have an ignition module, then you can use a mk3 polo one (see my parts cross reference for further details). These only cost about £25 in the U.K. brand new.

Good luck with your car.

Cheers,

Phil

[Canuck70Ghia]

kristof.langland@gmail.com

Appreciate everything you have. And Many thanks. Unfortunately the VW cars here in Canada do not match up. For instance, never any polos or lupos. I just moved back from Hampshire last year and I miss the variety and quality of European Cars. Sigh...

If you could get me the 137/138 Bosch Modules for around that price, I have a chequebook from Barclays still hanging around..

Kris

[phade]

Hiya Kris,

The ignition module fits most later VWs. From my parts cross reference list, they will fit the following vehicles (VAG part number 6N0 905 104):-

Käfer 1992-2003
Polo mk3 1991-2002
Polo (VW - Zambia) 1996-2003
Caddy 1996-2003
Sirocco mk2 and Corrado 1989-1995
Golf mk3 1992-2002
Lupo 1999-2003
Passat Mk2 and Santana 1988-1997
Transporter 4 and 5 cylinder 1991-2004
Jetta mk3 and Vento 1992-1998

Basically, it's a 3 pin connector ignition module. They are available from places such as GSF Car Parts here in the UK (they can do international orders from what I remember). If you are really stuck VW Classic Parts Center (http://www.vw-classicparts.de).

Let me know how you get on.

Phil