Cold start tuning for big injectors without glow plugs

kidturbo

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Ok reviewed the pw and tq table settings, then implemented much of the advice above. As Dave mentioned, the PW values in lower mm3 rows/columns needed trimmed back a bit. I compared % subtracted from stock in Marks latest adjustment at higher mm3/MPa, and tapered up to it. Except in the low MPa / high mm3, range, and those I slashed 300% or so. That cleaned things up good bit on cranking, and she starts to light off nicely now at any fuel pressure, then stumbles. Argh..

Which brings my main observance so far, torque, torque, and torque tables.

These things live and breath on torque values. No matter what you change in FP, PW, ect, it always tries to maintain whatever torque value it's seeking by raising or lowering the Main Injection Flow Rate mm3 to get there. So if you undercut the PW value at say 50mm3 / 60MPa, it will just jack the mm3 up enough to satisfy the torque value it's targeting. Or cut it to reach what it "perceives" is the matching Nm value at FW..

That said, there is certainly some missing tables in our current LMM OS bag of tricks. Like boost PSI to torque limits, load based values, and crank to start transitions that Mark first mentioned last year. And there in lies the issue in any stand alone / engine dyno setting without BCM. I know how, and have full intentions of rectifying that problem for everyone soon as this builds done. But not today.

The E35x ECM experiences issues transferring between "Cranking" and "Running" modes whenever "it's" not in control of the starter relay. IE, if your truck misfires on cranking, the ECM kicks out the starter relay automatically, and then you turn key again, and tell the BCM to tell the ECM to start again. In this setup I can crank it till the starter falls off, but once it fires off and fails to start once, it won't refire until I let off the key and RPM falls to 0.. Even-though the data logs shows it still fueling... Go Figure.

So I've logged enough data now to understand why it's stumbling right after firing, but still can't trick it into just grabbing ahold and kicking enough fuel in soon as it lights off. Can do this by adding some throttle. But at 0%TPS, ECM's killing the mm3 value soon as it detects firing or a load value on engine. Exact same time it transfers between cranking torque table B1127 and Pedal Position Mode A B1161. Possible we can use some IAT and ECT multiplier combo trick to let it know it's a cold start.

If ya pull up the tables above, you'll notice that while B1127 goes up to 1400Rpm, by default GM only places torque values up to 1000Rpm. While B1161 starts at 600Rpm, and row [TPS-D 0%] must always = 0.0 Nm across the board. Next row [TPS-D 10%] has stock valves of like 40Nm at 600Rpm. Which I've push up to 180Nm with little change.

So, soon as it fires off with a requested cranking TQ of say 700Nm@500Rpm, the ecm detects a load, switches to running table B1161 and seeks the torque value in the TPS-D% matching 600Rpm cell. IE 180Nm and Bang you've overshot new torque value, cut the mm3 fuel. Then it says oh shit, I lost my mojo and attempts to recover set idle Rpm by jacking mm3 back up. If it misses that one shot, then it says F-it, lets start over again at 0Rpm.

If I set a cranking TQ table with rounded off edges so it starts pulling requested Nm at say 350-500Rpm, she spins up nice and smooth even cold as ice, and acts like its gonna take off. Then when tables switch, it stumbles to adjust mm3, and then stops fueling. If i jack the cranking torque tables up, it pushes FP and mm3 way up, and she hits off hard, but typically overshoots set idle [820Rpm currently] and once again pulls fuel completely out half sec, and can't recover..

So that's where I'm at today. Sorry for the novel, but have a look at the log pics below from same key on set.

Feel free to toss up any suggestions. As mentioned Mark has experienced / fought this issue a good bit on the engine dyno. Fix has been push up the cranking torque up to get over the hump from waterbrake drag. Now they have zero drag on em at cranking / idle.
 

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JoshH

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What is your desired idle speed? Is it possible it is overshooting the desired idle speed, an that is what is causing it to cut fuel? Maybe you could try raising that at low ECTs?
 

2004LB7

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I know you stated that you have to leave the TPS table 0% at 0 but I've read of a few that have used in a DSP5 tune to create high idle switch positions. Maybe you can try putting a torque valve in the 0% and low rpms to see it it helps. As you stated earlier you can get it to start by giving it some throttle. I know it is more of a bandaid but if you can't find any other way...
 
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DAVe3283

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You said Mark had made some major changes to the cranking torque table to fight the water brake. Since you're now hooked to a transmission just like stock, have you tried the stock cranking torque tables? Then control any excess PW exclusively through the main PW table. Theoretically that will have cranking torque transition to idle torque perfectly, since they're both stock tables then.

I do think we're missing some tables, and could probably work this out that way, but rather than go digging for missing tables, it might be pretty quick to swap a stock cranking torque table back in and fiddle the low MPa PW to get the light off as soft or hard as you desire.

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I pulled up my tune, and with my "tiny" SAC75 injectors, I pulled main PW all the way up to 140 MPa. The main reduction is 20+ mm³ and 0-70 MPa, and I taper it out on the higher mm³ up to 140 MPa. I can post the tune+stock files if you want to see, but I am not sure how directly this will correlate to a LMM.

I opened up the sample LMM tune included with EFILive, and no kidding is it missing a ton of idle tables compared to the LB7. The one I think would be most helpful in your situation is the LB7's "{B1201} Idle/Run Mode", which sets the RPM at which the engine switches from crank mode to run mode. You move this closer or farther from the desired idle RPM at a given temperature to help it transition smoothly. I wouldn't be surprised if this table exists on the LMM but just isn't mapped.

I still think you might have good luck going to stock idle speed and cranking torque tables, and just massage the injector PW tables in the cranking range until everything is happy. If you get the PW values close, when the ECU asks for 50 mm³, it gets 50 mm³, where now it may be getting 60 or 70 or who knows what. If we can get the stock fuel amount into the cylinder when the ECU wants it, it should start just like stock.
 
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kidturbo

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What is your desired idle speed? Is it possible it is overshooting the desired idle speed, an that is what is causing it to cut fuel? Maybe you could try raising that at low ECTs?

One of the first adjustments after FP was bump low ECT idle to 820 room temp. Didn't seem to help as expected. That crank to run transfer seems to take place around 600 no matter what else changes. So not an idle overshoot issue, that would be to easy.

Today I dropped it back to 760.
 

kidturbo

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I know you stated that you have to leave the TPS table 0% at 0 but I've read of a few that have used in a DSP5 tune to create high idle switch positions. Maybe you can try putting a torque valve in the 0% and low rpms to see it it helps. As you stated earlier you can get it to start by giving it some throttle. I know it is more of a bandaid but if you can't find any other way...

I started logging APP_D% along with APP% and remembered it reads about 17% higher than actual throttle. So that moves us up a couple rows in running torque table B1161. Where I pushed the 600RPM torque values up to 400Nm. See pic below. Then I rolled the cranking torque down to 400Nm and did a few starts. Things started to improved.

Next I dropped fuel pressure back down to 40-50mpa at cranking because it was having a FP overshoot issue. Hate to think a regulator is sticking, but sure acting like it cold. Would overshoot by 60mpa sometimes before it fired. Which jacks all the fueling calc way outa shape.

So I get that sorted, plus those torque reductions, now it spins up like a turbine then starts firing off around 400r, and will catch itself at the 600r switch over. In log pic below you can see the torque spikes when it fires, along with oil pressure fall and recovery. While there is still a drop in mm3 on the the transfer, its now less drastic on the PW, mm3, and timing values.

Did several back to back cranks with good starts. But there was a little heat in it by then. I noticed that by firing off so smoothly, the ECM won't jump the RPM to idle for a sec or two. So on the right track I believe. Will try it dead cold tomorrow.
 

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TheBac

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This is one of those times I wish I would've learned tuning theory, because I have no idea what you all are talking about. :rofl:
Good luck, Kid. If anyone can figure it out its you, and with some help from the guys, Im sure of it! :thumb:
 

kidturbo

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I still think you might have good luck going to stock idle speed and cranking torque tables, and just massage the injector PW tables in the cranking range until everything is happy. If you get the PW values close, when the ECU asks for 50 mm³, it gets 50 mm³, where now it may be getting 60 or 70 or who knows what. If we can get the stock fuel amount into the cylinder when the ECU wants it, it should start just like stock.

Yeah getting the PW mapped out and playing with torque values seems to be the key here. I'm gonna review all these recent changes compared to the base file and start fresh with what I've learned so far.
 

kidturbo

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Well it's one step fwd, two steps back.

Set most of the table values back to stock, adjusted PW values to better match the 200 over sticks. Which according to the flow bench data I have is roughly a 49% pulse reduction at 180 MPA.

Cranks smooth, and produced little less smoke than the cigarette in my hand at the moment.. Never even attempted to fire off at 4c ECT. Punched the cranking torque back up to 750Nm and made some smoke, but still no fire until I brought the throttle up. Data shows Main1Q_DMA needs to be reading around 65mm3 to fire off with current pw values. Which then cause it to stumble worse on the switch to running mode.. Argh...

The ECT and IAT modifier tables control how it adds or subtract fuel and timing based on temps. So I'm gonna do some bench testing at home and see if these IAT tables are reading IAT2 intake, or IAT1 at MAF which I currently don't have available. If I can bring those IAT tables back into play, think it will allow better control at cold start up without impacting warm starts.

Beyond that, I could sure use a spreadsheet that adjusts the PW cells across the mm3 @ MPa map based off the known injector flow bench number I have. Anyone, like Josh,, who's good with excel formulas, we did a full spread on the Bosch bench to flow these new tips for comparison. So I have some flow data from stock LMM tips, the SS LBZ tips dyno'd, along with the new 200's that could be mapped out better to get a closer to actual flow table. I just best guessed the numbers for the cranking tests.
 

DAVe3283

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Beyond that, I could sure use a spreadsheet that adjusts the PW cells across the mm3 @ MPa map based off the known injector flow bench number I have. Anyone, like Josh,, who's good with excel formulas, we did a full spread on the Bosch bench to flow these new tips for comparison. So I have some flow data from stock LMM tips, the SS LBZ tips dyno'd, along with the new 200's that could be mapped out better to get a closer to actual flow table. I just best guessed the numbers for the cranking tests.
I'd be willing to take a crack at making a spreadsheet tomorrow. Can you share the actual flow data? If not, can you just 0 out the data and share that so I can see the row and column layout?

I'm surprised it's taking that much pulse to start. I'll have to go back and look at your log screenshots and see if anything jumps out at me. What is the compression ratio on these motors again?
 

kidturbo

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Here is the 200s at 180Mpa.
96d848b0e38fc0a8cd6bf5e8ee07ebcb.jpg
8cc710fdcac52a5d4ddec277fd3c1a93.jpg


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kidturbo

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Here is one of the 200% or 270 PPH vs a 175% over nozzle at 1350us and couple lower MPa values. "Set Value" is what a stock LBZ should test at. You can see both of the larger nozzles look to flow less than stock at lower pressure. Id have to ask about that, but they are not linear in flow rate I recall.



35662f669063d0feb01fc2944f32a2dd.jpg


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DAVe3283

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There aren't really enough data points at low pressure to make a useful calculator, IMO. It would just be guesswork.

It looks to me that short pulse widths don't flow as much, as well as low pressure doesn't flow as much. But it is possible it is just low PW. Hard to tell from so little data. So one possibility is they flow 3x stock at all pressures, but take a while to get going. Say for the first 200μs they flow 0.25x, then for the next 100μs they flow 0.5x, then 0.75x, then 1x, then 2x, then 3x. A different flow ramp curve than stock.

So they may need more PW in the low mm³ range, and a lot less in the high mm³ range, then blend them together. They may also need more PW in the lower pressures, but I can't tell if that is more or less of a factor than the slower ramp rate. Sorry, I was hoping there would be more data and I could interpolate the rest of the table meaningfully, but looks like I can't.
 

2004LB7

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Like Dave said, there isn't much data to put together an accurate flow chart across all of the Mpa range.

the difference may be in the injector latency or opening time. lower pressure = slower to open but once open it flows more

with that being said, I did put together a sheet that may calculate the equivalent values if the above is true and you know the latency of the injector at the various Mpa points.

It's not really based off of you data, just a simple sheet that I threw together. I'm not sure how helpful it will be. Obviously with more information it can be modified to be more accurate
 

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kidturbo

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Yeah would be nice to have a full spread of known values. I'll take a look at those calcs compared to what I have loaded in ECM now.

I believe Mark has full map of the SS 100's and maybe a set of his 250's that Exergy flow benched for us to run on that M-Sport ECM. Know we sent Phil one of my sticks at least to map out. I'll ask if he can check email for it tomorrow.

Besides that, I have typical bench test off a stock LMM stick [below], which is how I realized these 200's actually flow less at 30 and 140MPa than stock. According to that machine..
 

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monster50iii

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I was pretty disappointed in the flow sheets DDP provided me with my 60s. It gave me zero information to help with tuning. It told me CC flowed, but nothing else. Anyways, I've been tuning by feel this whole time, and I noticed the same thing as you; 120-140mpa seems to be the cross over where I start to flow more fuel. Its going to take you time testing to get it close to what you like.


If I were you I'd log what happens when you give it throttle. What the numbers are that make it fire, and make it match those numbers without the throttle input. Maybe easier said than done for starting, but there's got to be a way.
 

kidturbo

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That's been my approach so far. Crank it then add some throttle till she lights and check the PW / mm3 then adjust. Issue is, once she fires off and puts some heat in the cyl, next try it's easy start.. Maybe just make a note, cold stats add 50% throttle.... :thumb:
 

2004LB7

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Have you tried putting a value in the 0 TPS and 600 RPM cell on your throttle table?

Also, what have you done with tables B1180 & B1181? stock or ???
 
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