ZR VVC- MEMS Mapping - MG-Rover.org Forums
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post #1 of 22 (permalink) Old 28-03-2015, 23:12 Thread Starter
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ZR VVC- MEMS Mapping

Haven't been on here for quite some time as started hanging out more on the facebook groups but fancy having a place to write up the development of this project.

Before this I had a Mk1 160, loved the car despite it's flaws. It was a beautiful trophy blue and the pre project drive build quality was very nice. I had learnt much with this car such as headgasket, timing belts, suspension etc. The car had been taken on track sessions quite few times however sadly since it was run on a student budget it could never quite match for my friends




Unfortunately all good things come to an end and with "Bluey" it was a mixture of a cracked windscreen, a hole in the roof around the aerial base and a hole by the side skirt where it feel off the jack and only a badly placed axle stand. So took the chance to move onto a Mk2 as I had been wanting one for sometime.

Hunting around gumtree,ebay and sales groups I came across a 04 plate 160 for 500. Unfortunately it had a scratch on the side and had been sat for 18 months on a driveway. A challenge! The first being getting it off the drive with a dead battery and alternator. Luckily had a friend who had just gotten a trailer




Skip forward to a MOT, oil chance and new tyres (old ones were bald) and the little rover got it's first taste of track abuse with my friends ZS with VVC conversion



https://www.youtube.com/watch?v=otQp9d6Jp94

Now the history is out the way here's the ultimate goal. to reach 170hp , considering most VVCs only pull 150 about as stock this is going to be a interesting task. combined with the rebuilt coilovers Ive got to put on that should make it a nice track wagon.

How will this be done I hear you ask? Well I've got a spare vvc exhaust cam i've sent off to get reground to Piper spec. Also have dowels to advance the timing to get the most out of it.

But the interesting part is that during my free time at university and lunch breaks at work I've been learning how to remap these cars. It's taken over a year and alot of nights awake thinking about this and that. But I got a prototype tested out the other week before the track session.

https://www.youtube.com/watch?v=VV9n745FtlA

Rolling road place was not brilliant as he couldn't do print outs and just had to write down the numbers are various rpm locations. Also forgot to mention the exhaust was blowing pre cat before hand and the remap file was tested first. So think the results were a bit flawed as the ecu would have been messing with the fuel trim because of the blow. Anyway first results being a 3-4hp increase across the rev range, bit disappointed but will be looking for another place to get rolled.
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post #2 of 22 (permalink) Old 02-04-2015, 19:29 Thread Starter
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Got my spare exhaust camshaft reground to a sportier specification ready to fit this weekend along with doing the headgasket and belts as the engine has no history.
As it's a 4 day weekend will also hopefully be refurbishing the tappets as well to reduce the classic k series tappet noises
Would have liked to get the head ported and polished but lack of funds (thanks to $$$ insurance) stops me from doing so but if the engine performs well at the track events this summer perhaps I'll treat it to a good polish

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post #3 of 22 (permalink) Old 04-05-2015, 10:36 Thread Starter
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Update:
Alot has happened although not all of it good.

Thermostat was fixed thanks to a friend who noticed that the rubber o ring on the ECP one I installed was MUCH smaller than the original one, quick swapping out and the coolant issue was resolved. Once done we started the car up and ran for 20 mins at 2k rpm to bed in the new cam while bleeding system etc
Once done it was running although very lumpy and had flickering headlights, dash lights with no time to fix I had to drive around like this for a while.
Castle combe action day came about and still hadnt fixed the lights, instead we fixed the janspeed manifold and a ***** cat pipe with a coke can gasket haha which unsurprisingly blows like a motherfker

Castle combe action day was upsetting as I'd been hoping to have the coilovers on and the mapping/engine sorted ready to kick ass. Instead I got a battery light on the dash 10 seconds onto the track and when I pulled off smoke started belowing out the front end as the inner cv boot split and dumped a load of grease onto the cat pipe. Brilliant.
To cheer me up my friend let me take his ZS VVC out on track as he was interested in seeing how it could be driven (although I still need a lot of practise). The car did well and pulled 100 on the long straight with it being only a stock 120 engine with a vvc head slapped on and a stock 160 manifold with the internal welds removed. However this too kicked up a battery light and getting off the track we found the alternator belt had chewed itself up. *sigh*

Driving 40 minutes on just the battery we reached ECP just in time before they closed and fitted the belt in the car park with the staff watching

I then went to visit the parents and their local scrap yard where I got a new voltage regulator and nabbed a couple of the washers I needed to assemble the coilovers. Upon trying to swap out the alternator I noticed a nut had come off it and was the cause of the problems. One nut later and the engine was running much smoother although still a little lumpy from the cam/blowing exhaust.

Coilovers are now assembled and ready to go on after the cv boot gets fixed. Then going to order a decat pipe and sort the mapping out hopefully in time for another castle combe adventure in June

Footage of the ZRs short time out
https://www.youtube.com/watch?v=XcnpySLJ-RQ

Footage of the ZS (was a bit busy on track for my liking)
https://www.youtube.com/watch?v=8fO5tsZYMss

And here is some of the quality driving that was on show that day haha
https://www.youtube.com/watch?v=ftEYlrP4Q3w
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post #4 of 22 (permalink) Old 09-01-2016, 23:56 Thread Starter
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New year, new ambition to keep this updated

Had alot of mapping progress since last, even took it to a dyno to do back to back testing to see the improvements made on the prototype. Sadly the dyno place got the rpm scaling wrong (apparently a stock car running up to 7.8k rpm)
So the peak values arnt worth much but doing the back to back rolling at least showed a 7-10hp gain across the range which for a first attempt isn't bad, since then improvements have been made so should hopefully have gotten even more especially since we found the car to be running a bit on the leaner side of things which could be down to the exhaust cam and advanced timing so a little bit of work to the fuelling and things should be sweet again


Hp figures are at the wheels

Some good times on track as well.
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post #5 of 22 (permalink) Old 29-03-2016, 07:05 Thread Starter
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More track abuse (even let the other half have a go)

Some more tweaks and slightly improved driving (was pretty poor before) has gotten my lap times down a little more

Skip to 5:07 to show what happens when you don't get trail braking right

Also with the piper exhaust cam and offset dowels i've always had a bit of a lumpy idle which I never enjoyed, so this weekend I finally got around to raising the idle to smooth it out a bit.

SAWS Tuning - MGR Remaps
Facebook- https://www.facebook.com/SAWStuning/
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post #6 of 22 (permalink) Old 24-04-2016, 20:31 Thread Starter
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Came across a nice quiet country road so decided to get a video of the pop and bang feature where I could rev the engine without feeling like a tit.


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post #7 of 22 (permalink) Old 05-06-2016, 19:49 Thread Starter
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Dyno results, wooooooooooo

Quite happy with the results, will be going back for fine tuning soon as the owners had just got ahold of the dyno the week before and hadn't yet setup the wideband system although this has been rectified

Will also be moving this from a track/daily to a pure track car especially as I want bucket seats after sitting in a friends track 306 rallyee this weekend and realising how bad the ZR seating is



SAWS Tuning - MGR Remaps
Facebook- https://www.facebook.com/SAWStuning/
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post #8 of 22 (permalink) Old 05-06-2016, 20:03
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post #9 of 22 (permalink) Old 08-06-2016, 11:54 Thread Starter
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Thanks Stu, should be some more in it and will hopefully do some back/after testing with decats soon.

It's also nice to have access to a dyno I can trust, more so than the previous results from earlier in the year which frankly dont seem to be worth the paper theyre printed on.

Also fitted a rear anti roll bar recently, often very much a skeptic with stuff but this really does seem to have reduced the understeer massively.
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post #10 of 22 (permalink) Old 13-06-2016, 00:12
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You and Catteral1 should meet up sometime, he has a Mk1 converted to VVC
too that gets tracked, he is North West based too.

Any info on the mapping you did to it ?
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post #11 of 22 (permalink) Old 14-06-2016, 12:00 Thread Starter
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Funny you should mention him as we met at the last 3 sisters track day, although didn't realize it was him at the time. He left the show with a little more than he came with

What kind of info are you after?

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post #12 of 22 (permalink) Old 16-06-2016, 03:20
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I was just interested on how you did it, silly question really, "Plugged a lap
top into it and reprogrammed the ECU" lol, just interested in what you used,
I think another question is "how much ?", not letting Catteral1 get mods and
I don't lol.
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post #13 of 22 (permalink) Old 16-06-2016, 07:25 Thread Starter
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Sorry if I came across rude, I meant it more in that I could talk for days so wanted to narrow it down a bit

In essence yes, but it's more than just pressing a button to say "make more power" . You have to adjust ignition timing & air fuel ratios to let the engine reach its sweet spot while fighting a battle against stuff like emissions and knock, which can quickly damage the internals.

How much as in power gains or $?

Mk1 vs Mk2 side by side. Notice the arch rust differences


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post #14 of 22 (permalink) Old 19-06-2016, 12:53
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Nice comparison photo, shame really but still masses of fun to be had from the car.

Might hit you up for a chat as i'm p#####g about with my 25 this year, see
how much we can get from a 1.4.
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post #15 of 22 (permalink) Old 19-06-2016, 18:01 Thread Starter
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Sure just drop me a message whenever, got easy access to a dyno and will be working on a 1.4 with cams tomorrow so should be interesting to see what can be had from that

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post #16 of 22 (permalink) Old 22-06-2016, 07:33 Thread Starter
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Well the weekend was interesting.
The cammed 1.4 had apparently been mapped before although the main ignition table had been left alone and the differences seemed to be randomly done.

Running the car up on the dyno with a wideband saw the AFR at 15:1 for low rpms before plummetting to 10.5:1 at 5k onwards!
This would explain the puffs of smoke at the top end as it was running the kind of fueling you'd see on a high level turbo engine.

So rather than going for outright power I spent the time fixing the fueling. End result was an extra few lb-ft on the midrange and a much happier engine. Will be going back to add more grunt but time was limited and dyno niggles (first time operating it on my own) ate up some time

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post #17 of 22 (permalink) Old 22-06-2016, 20:49
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Excellent read that mate, will keep you updated on our progress, car is
getting SORN'd at the end of the month but it may just be a temporary
measure as we may need the car but if not t will be getting stripped.
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post #18 of 22 (permalink) Old 06-07-2016, 07:28 Thread Starter
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Check out the supercharged VVC ZS build

Project- VVC-S

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post #19 of 22 (permalink) Old 09-07-2016, 12:33
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On my ways !
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post #20 of 22 (permalink) Old 09-07-2016, 18:33 Thread Starter
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Get on over!

As a side project for a member on here I've been working on a way to disable the immobiliser. This will be handy for the member who is not able to get to me since the English channel is in the way and would rather not be without his car while the post service does its thing.
Also benefits me as I can prepare backup ecus in case I ever brick one for one reason or another.

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