Fiat Punto GT

Document your project with images, pictures, etc., and share with others.
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Fiat Punto GT

Post by Page »

Hi,

Many of you you may not know or ignore the existence of this little car.
it is this ...
Image

Not much with compared today's cars but back on '94 was quite good . It is spacious inside and average upholstery and plastics. (but lasts longer than today's cars )
Today looks ok but for me it's ....
What can somebody say for his son !
I like it !
o k a y .... LoL

5 speed manual tranmission and 1.4L, 8v, 1 overhead cam , little turbo and 133-136Hp with about 20+ Nm of torque .
Not so terrible to turn around corners (compared to Uno Turbo or Corsas) but was the exploded torque that wasn't helping to target the corner .

My little car was sitting between garages and tripods, almost for 8 years while
i was fooling around with classic minis, renaults and peugeots .
It was an experiment of drag racing propose which reached the astonishing 418 hp@11.200 rpm with all the internals (and externals) parts changed and tuned for the max.

But that was at the past ... Happy days are over and there is no Car at my disposal to go around the town except of this little car. Spend my last money trying to raise it back to road again . And this means that have to be road legal .

so let me take you around a funny story .

(My apologies for any language mistakes that will do, i'm a self learner of english and trying hard to keep your interest and not to be bored.
*and with a little help of Google translate too )


This is a picture of the car after of finding many parts that was missing and placed back. Looks more like a car now . And immediately after a good wash took the picture. to look fresh ... LoL
Image

Here it's me
Image

trying to do from this
Image

to this
Image

( let me make a short break here )
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

With this
Image

made the clutch from mechanical to hydraulic all the way to the pedal
Image
Image
Image
Image

Few changes to engine mounts
Image
Image

crankshaft pulley with A/C position
Image

full weight of a NEW Used flywheel
Image

Helix clutch
Image

New water pump
Image

Most of A/C is in here ...
Image

and the rest of it is here
Image

Not starting from this yet ...
Image

Stripped the the dashboard in order to place the new wiring and the Half of a/c
Image
until there is nothing
Image

Everything went smoth, the dashboard is placed back after 5hrs
Image

electro-hydraulic pump of Peugeot PAS, steering system
Image

Few new things coming knocking on my door ...
Image

And a new BMW 325 Hall cam sensor
Image

I created this in order to accommodate the BMW cam sensor
Image

at the back end of the inlet camshaft
Image

Image

Image

Image

New billet crankshaft and connecting Rods and oil pump
Image

New alternator
Image

All this happened on Fiat's, Bravo-Brava 1.6L 16v twin cam engine.
Image
Last edited by Page on Mon Dec 23, 2013 5:22 pm, edited 2 times in total.
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

engine on the Car
Image

In this photo you see the materials for the construction of the exhaust manifold
Image

Image

the upper half of the billet 316L inox of the exhaust manifold
Image

the bottom half of ...
Image

bolted together
Image

and then welded with pipes
Image

A rehearsal with the turbo placed on
Image

turbo with fittings placed on
Image

The turbo is a twin scroll Mitsubishi TD04/19T
Here is behind (lol) of the Garrett 3071
Image
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

cleaned the fuel rail and placed back with new fuel pressure
Image

Attached with New Renault's Megane 225 injectors
Image

Image

NEW sparkplug wires from ...
Image

Image

Image

made this to suit renault 75°C thermostat and thermostat housing
Image

Image

made the inlet manifold as short as could be ...
Image

Image

oil cooler Lines
Image

and oil cooler
Image

Narrow band bosch 4 wire lambda
Image

Euro 4 emissions metallic catalytic converter
Image

down pipe with a hole for wide band lambda and a hole for pyrometer
Image
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

NEW 3 pin bosch idle valve .
Image

Starting of Electric wiring ...
Image

almost ending the Project which looks like this
Image

petrol tank cleaned outside / inside and placed back with new 255L/min / 6bar larger fuel pump and Lancia integrale fuel filter, new fuel pipes
Image

Image

Image

Image

Image
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

:lol:

i made it ....
I need a break before continuing the story .

the thing is that right know the car is propper working Car apart from mapping .
It is i belive a ten days old ...

:D
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

The Car must work emission legal like new cars.
This means that first need to make the engine working AFR of clean burn 14.7:1 at idle and at 2000-2500rpm and then find a gas analyzer for trimming and optimizing in order to pass MOT tests
and be a nice smooth light turbo engine .

But first let's see the configuration of the ecu.

Air & water copensation
Image

engine config.
Image

fuel map
Image

ingition map
Image

injector angle
Image

seqential parameters
Image

lambda parameters
Image

idle parameters
Image

idle map
Image

start fuel
Image

over-run
Image

manifold compensation
Image

manifold pressure scale
Image

rpm , air, water scale
Image

do i miss something ?
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

Engine is new therefore the First 1000-1500 km must be worked as light load is possible
Settings on fuel and ignition you see, more than 100 kpa are guess work, just to fill up the cells from my experience.

Air & water compensations are based from my experience and are good starting point for the warm weather of Greece. although when engine is cold AFR is a lot richer than it should be.
It is easy for me to configure the right settings, just run out of time.
This will take a while

engine configuration are well done except rpm limits (for the moment)

fuel map is currently done mostly round idle as a warmed engine and of course with transients off for mapping.
Needs of some optimization but when it's warmed up at idle , afr fluctuate between 14,7 to 15,5 with out lambda close loop.
I haven't enable the close loop yet in order to optimize fuel as possible to make less work for lambda .
When engine idles is targeting the 40/800 cell and actually fluctuate in slow rate between 780 to 850 rpm range .


ingnition map is good for the moment maybe needs little trimming round idle and light load and is guessing above 100kpa


On sequential parameters
injector angle means that starts spraying form 45 deg ATDC
And cam sensor position means 78 deg ATDC of First cyl ? Altho you see this i haven't applied to ECU yet.
i will post an oscilloscope with spark plug on the First cyl and help me write the correct number in the cam position cell .

lambda is off (for now)

start fuel map is ok, engine when it warms up starts without assistance of throttle although is little weak, sometimes, due to low idle rpm .

manifold compensation, really can't understand it and haven't apply anything ! haven't touched it .

__________________________________________

the problem is that I need to raise idle to 900 rpm target and idle valve aren't helping .
Today i went for a long jorney of about 40 km (lol) and find out that even though set the max rpm idle control to 1700 rpm this was stayed open as i could hear compressed air leaking from the pipe of the valve back to atmosphere when i was at 3000 rpm
This means that possibly is not working at all and probably explains why PWM idle map not working .
My idle setting are wrong . Could you spot why isn't working ?
I all ready made an on bench test with idle valve and fast (aux3) is properly connected .
MarcoV6T
Posts: 101
Joined: Tue Jul 26, 2011 12:20 pm
ECU Model: S80 Pro
Firmware Version: 58

Re: Fiat Punto GT

Post by MarcoV6T »

You should zero out the manifold compensations, as your main load is MAP, although then you’ll have to recalculate(interpolate) the fuel map cell’s.

For your idle valve, when I was using the Bosch two wire, any frequency above 80Hz was useless, you’re having it at 200Hz. Try values between 30-80Hz, and you’ll see that it will have a larger dynamic range(the relation between PWM duty and valve movement, a lower Hz will give more movement for the same PWM duty).

Now I’ve never used a 3 wire valve, so the frequency may be higher, althoug, it’s still a relative big valve, thus try different frequencys and see what happens.

I could easely hit 3000rpm or more at idle with that big valve, so it’s not the limiting factor.
Page
Posts: 44
Joined: Thu Mar 07, 2013 12:06 pm
ECU Model: S60 Pro
Distributor: Local Dealer GR
Firmware Version: 62

Re: Fiat Punto GT

Post by Page »

Yep, this valve looks like the 2 pin valve.Your're right

I found some settings related with 2 pin valve here in forum.

For start i'll set as 100HZ , P-60, I-5, D-2, 0.4 delay,
Max Pid adj 7, min Duty cycle 20.0, mAx Pid delay after over-run 3.0 .

I'll start with these figures and make the hole idle map full of 45s


although i haven't try it yet , Stevie notice that my min tps is set to 5% and Idle valve stop working after 3% ....
So it never worked !
This seems to be the cause of the problem
Post Reply