History of MembersPage/MarcellGal/EngineSwap/Wiring

Older	Newer
		2005-09-13 15:28:54 . . . . MembersPage/MarcellGal [DSUB9 male connector]
		2005-09-11 17:30:53 . . . . MembersPage/MarcellGal [minor updates]
		2005-09-11 13:04:04 . . . . MembersPage/MarcellGal [minor updates]
		2005-03-25 19:27:12 . . . . MembersPage/MarcellGal [documented that variable intake connected]
		2005-02-20 12:08:12 . . . . MembersPage/MarcellGal [updated injector channel mdh.0 values: the h[0] is used!]

Changes by last author:

Added:

Wiring for MembersPage/MarcellGal/EngineSwap

The MembersPage/MarcellGal/EngineSwap/DaewooHarness will map readily to the GenBoard/VerThree.

Some investigation was needed to combine Opel, a Daewoo and GenBoard connections. I needed the connectors from the daewoo harness, so I decided to leave together as much of it as possible.

Time to make a spare ECM. The spare-ECM will have standard WBO2 (amplified nernst, instead of direct nernst). Therefore config will be slightly different.

TODO

* check if there are nice shielded signals in the junk daewoo harness (apparently NO!) for

** trigger

** knock

** and nernst signals

* maybe new wires to wire 4 injectors into 4 banks instead of 2 banks

Quick checklist before engine start

* TPS

* WideBand, calibrate, verify

* injector outputs:

* ignition, crimping for harness side connector

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setup

* Alubos1600

* a DB25 + DB9 endplate + DSUB stuff for the mains connectors. It was a bad decision, EC36 and EC18 is much better. But DSUB also works.

* transparent endplate

* thru-endplate cable with flying loom connector for

** PS2

** LCD

** EGT

* outside the board MAP sensor

* v3.1 board (spare might be v3.3)

* low voltage GenBoard/Manual/DDFlyback (0.7V + 0.7V)

By using the cheap DSUB connector stuff (and v3.1 board) I want to test how hard it is to make a reliable system from the lowest quality/price items that were used with GenBoard/VerThree. Actually, lower quality, using a v3.1 board that failed the quality test and needed slight repair. The Daewoo harness that is reused is also trash-grade. For EconoSealIII I would feel silicone or tefzel insulation wires would be a better match.

The reason for the v3.1 is to force myself to check some wiki pages like * GenBoard/VerThree/Installation,

* GenBoard/Manual/InitialTesting/VerThree

* GenBoard/Manual/TestingInstallation

* GenBoard/Manual/WBSensorControllerTesting,

that deal with testing and installation.

Also, using the newer v3.2 (that ships since 2004.Aug) would be much easier, and I would jump over many steps unnecessary for v3.2.

Anyway, I already regret not going with EconoSealIII connectors. While the DSUB is much better than it's reputation, making a v3 system with EC is less work, and making a nice looking v3 install with DSUB is impossible.

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Mapping decisions

Since this is a 4 cyl engine, only a few of the many v3 outputs is used. I will clamp only 2 lines of switches from the possible 3 lines. I can choose

* clamp line1 and line2: only wasted spark ignition is allowed (2 IGBT channels), but 10 high power FET outputs, 8 of which have onboard flyback. Line 3 has 2 ignition channels set up with logic-level signals (no IGBT, jsut gate connected to output)

* DROPPED: clamp line1 and line3: line3 with 4 IGBT + 2 FETs. Allowes 4 cyl sequential DIS ignition, but I have to apply flyback to the 2 FET-driven signals (using ignflyrail and onboard diode) separately

line1 and line3 would have given me some free outputs to be used later:

* 2 free inj channels: useful when going to sequential from the daewoo 2 bank setup

* 2 free ign channels: useful when going to sequential DIS ignition from the original wasted spark setup

* 1 free FET output with flyback (EC36-pin35 = I259_0) (note: the other in line3 is used for fuel pump)

* 1 free FET output without flyback: 2nd WBO2 heater channel: might be useful for something (I might apply flyback onboard or externally).

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Pin mapping

A table like this is roughly equivalent to a wiring schematic like on MartinFranck/Wiring. However

* the table has more information, like

** comments (including progress and confidence info)

** exact wire colors

** mdh.. commands for testing

** links to relevant pages

** table is easier to go through as a checklist without missing something

* and table is easier to edit and update (including help from others)

On the other hand, the schematic is more spectacular. If you have time, you can do both, of course.

||Function||Wire Color||Daewoo ECU pin||DSUB pin||VEMS ECU pin||Comments||

||Vbatt, WBO2 pin3 Heater + grey, node15|| Magenta/White || C16 || DB25-15 || EC36-25|| node15, only power when ignition_on ||

||Ground||Black||B2 (CLT GND), D8 (TPS, GND),B14 || DB25-16 ||EC36-26|| is the daewoo harness connected to engine ground or battery gnd? Do we need another ground ? ||

||Power Ground||Black|| C7, C9, D7 || DB25-24 || EC36-21 EC36-32 EC36-5|| connect these as hard as possible: inside and outside the board ||

||Trigger||Yellow/Black||A16|| DB25-17 ||EC36-27|| onboard setup for LM1815 ||

||MAP|| ? || ... || DB25-21 ||EC36-|| ... ||

||MAP and TPS +5V|| ? || D15 || DB25-18 ||EC36-28|| not through 270 Ohm, but direct +5V||

||TPS||Red/Yellow||C15|| DB25-8 || EC36-1|| ||

||Coolant temperature||Yellow||B3||DB25-19||EC36-14|| ||

||Manifold air temp||Yellow/White|| B4 || DB25-9 || EC36-2 || verify on daewoo harness||

||Fuel pump relay|| ? || ? || DB25-20 || EC36-17|| (mdh70) ||

||Injector 1,4||White/Black||C4|| DB25-10 || EC36-8|| INJFET_2 (mdh10, h[0]mask=04)||

||Injector 2,3|| Green/Black||C6|| DB25-11 || EC36-9|| INJFET_4 (mdh00, h[0]mask=10)||

||Idle stepper A||Blue/White||A1|| DB25-4 ||EC18-4|| S259_3 (mdh36) ||

||Idle stepper B||Blue/Black||A2|| DB25-5 ||EC18-10|| S259_4 (mdh46) ||

||Idle stepper C||Green/Black||A3|| DB25-6 ||EC18-5|| S259_5 (mdh56) ||

||Idle stepper D||Green/White||A4|| DB25-7 ||EC18-11|| S259_6 (mdh66) ||

||DDFlyBack || || || DB25-12 || EC36-23 || - ||

||Ignition 1,4|| ? ||C14/D14 ?|| DB25-13 || EC36-33|| I259_1, (mdh12/mdh92)||

||Ignition 2,3|| ? ||D14/C14 ?|| DB25-25 || EC36-35|| I259_0, (mdh02/mdh82)||

||WBO2 heater-||4 (Heater -) white || A15 Black/Yellow|| DB25-14 || EC18-18|| no mdh.. command ||

||WBO2 nernst|| 1 (Vs) black|| A12 Black/white || DB25-1 || EC18-13|| ||

||WBO2 pump-||5 (Vs/Ip) yellow || A14 Black/brown || DB25-2 || EC18-7|| appr. +3.96V ||

||WBO2 pump+|| 6 (Ip) red || A10 Magenta/blue || DB25-3 || EC18-9|| ||

||Variable intake|| ? || ? || DB25-22||EC36-19 || INJFET_1 (mdh40, h[0]mask=02)||

WBO2 sensor (that is mounted in the exhaust) RCal=116 Ohm

Calibration must be good, since appr 19% O2 is shown in overrun fuelcut more.

yet free:

* DB25-23, EC36-20, INJFET_3 (mdh30, h[0]mask=08)

There is a DSUB9 male "extra" connector (the DSUB9 female for RS232 moved to endplate):

* pin6, 7,9: GND5

* pin8: GND

* pin1: (TODO: maybe pin2 ? check on paper) knock signal

* pin2: (TODO: maybe pin1 ? check on paper) mcp3208 ch7 (mcp3208pin8)

* pin3: a free injector-FET output

* pin4: IGBT ignch 2 or 3

* pin5: IGBT ignch 3 or 2

Unfortunately there is not enough free outputs to implement 4 injector banks and EGR at the same time.

Done - apparently OK

* fuel pump relay

* power, including node30 => node15 (only hot when ignition_on)

* fuses (after I change the ECM main fuse that was blown when I shorted 2 signals with the probe during measuring)

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PS2 cable

Right through the endplate, using a PS2 extension cable (from shop). Flying loom minidin-6 connector, that is.

LCD cable

Right through the endplate, and flying-loom DSUB connector. DSUB15 will be applied instead of former DSUB9. In the DSUB9 used earleir, -3V was connected instead of the R/W signal (R/W was constant grounded at the LCD). But LCD without busypoll had to be reset (with mli) manually quite often, especially with new firmware, where mainloop got faster (the LCD couldn't keep up). Especially in cold, when LCD (internal RC clock) is even slower.

EGT compensational cable

Standard.

MAP supply

I connected the TPS supply so that growing throttle orifice gives increasing voltage.

We found out the hard way that we accidentally a "fake-TPS connector" (air-conditiner connector that looked like the TPS conenctor, but +5V and GND was swapped!!) and MAP supply was connected to the TPS supply inside the Daewoo harness.

Since than I verified the GM MAP sensor pinout:

* A: GND (this is the rightmost pin, when looking at it natural orienation - as mounted on the firewall; not leftmost)

* B: MAP signal

* C: +5V (from EC36-28, or EC36-29 but onboard "270 Ohm" resistor shorted)

The grounds and supplies need to be verified as well.

At least the fuel-pump relay is good though. (let me note that the Bosch relay I found in the Opel had incompatible pinout compared to the standard automotive relays).

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For Later

When it's working OK, some features will be added.

* knock sensor

* DONE: variable intake actuator

* vehicle speed input (map to 2nd VR input)

* CEL (check engine light - possibly as shiftlight)

* connect to (preferrably more than one: 3) nintendo gameboy, see OtherTuningSoftware/NintendoGameBoy

* I will connect the 1-wire I-Button as well

* some gagues

** including round LED-bar

** RPM, AFR and MAP gauge would be nice