MembersPage/BasilDaham/CordobaSX (2006-12-29 15:19:49)

Overview

Trying to get VEMS to run in a plug and play fashion on a 1997 Seat Cordoba SX, with a 2.0-16V engine (engine code ABF). The current engine hardware:


Sensors


Standard actuators

Extra actuators


Wiring

Proposed wiring for ABF to VEMS plug and play loom:

DescriptionABF ECU pinoutVEMS Econoseal pinoutVEMS channel
Main groundsT68/1EC36-5,21,32,22
Sensor groundsT68/33EC36-26
Air temp sensorT68/36EC36-2
Coolant sensorT68/14EC36-14
TPS signalT68/40EC36-1
Crank sensor powerT68/68EC36-28 (for 5V) or T68/38-EC36-25 (for 12V)
Crank sensor signalT68/67EC36-27
Camshaft sensor powerT68/46EC36-28 (for 5V) or T68/38-EC36-25 (for 12V)
Camshaft sensor signalT68/44EC36-13
Switched 12v powerT68/38EC36-25
TPS reference voltageT68/41EC36-29
Ignition coil output 1T68/8EC36-35I259_0
Ignition coil output 2External wiringEC36-33I259_1
Idle control valveT68/27EC36-18INJFET_7
Injector 1T68/24EC36-7INJFET_0
Injector 2T68/25EC36-19INJFET_1
Injector 3T68/26EC36-8INJFET_2
Injector 4T68/2EC36-20INJFET_3
Injector 12V commonExternal wiringEC36-23
Fuel pump relayT68/6EC36-15P259_5
Tachometer signal to clusterT68/22EC36-10I259_7
Knock sensor 1 signalT68/34EC18-3
Knock sensor 1 groundT68/32,10EC18-2
Knock sensor 2 signalT68/57EC18-3
Knock sensor 2 groundT68/55,56EC18-2
Boost controlT68/31 (Charcoal canister)EC36-6INJFET_6
Shift light 1External wiring (350mA)EC36-4P259_0
Shift light 2External wiring (350mA)EC36-16P259_1
Coolant fanExternal wiring (350mA)EC36-31P259_6
ALS kicker solenoidExternal wiring (Needs external flyback diode)EC18-12SPECFET_0
Water injection HSV solenoid (PWM)External wiringEC36-24I259_6
Intecooler water spray solenoid (on-off)External wiring (350mA + 5 pole relay for override)EC36-30P259_7

Unused outputs:


Input trigger

Proposed Primary trigger settings:

Proposed secondary trigger settings (not very well documented in the manual, but I might not end up using this trigger):


Fueling

Req fuel = 6.49 * (D / N / I) = 6.49 * (1998/4/506) = 6.4ms (42lb injectors)

Req fuel = 6.49 * (D / N / I) = 6.49 * (1998/4/862) = 3.8ms (72lb injectors)

It's recommended to halve this req-fuel, so the max VE entries will be (instead of 100) around 200 (or even up to 255) for better precision. Thanks for this suggestion, hence new req_fuel will be 3.2ms and 1.9ms for the two injector sizes respectively.


Ignition

For single coil setup (coil=>00):

ignchmax=00

h[2]=00 00 00 00 00 00 00 00

For wastespark setup (1+4=>00 and 2+3=>01 paired up):

ignchmax=01

h[2]=01 00 01 00 01 00 01 00

If COP used, then wire up coils to IGBT's as follows (assuming 1-3-4-2 firing order): 1=>00 4=>01 3=>02 2=>03

For COP running in normal COP mode:

ignchmax=03

h[2]=03 01 02 00 03 01 02 00

For COP running in wastespark mode (1+4=>00 and 2+3=>01 paired up):

IGN_DUALOUT=Enabled

ignchmax=01

h[2]=01 00 01 00 01 00 01 00


Idle valve settings

ISV details...


Boost control

Boost control settings...


ALS

on how to wire up a switch to turn this function on, along with launch control.

Mapped water injection

Looking for the best hardware solution to (PWM) drive the water injection solenoid according to a 3D map, or at least in scaled proportion to the fuel injectors' pulsewidth (i.e. VE map).

The staging code should work for this.


Installation problems

I made two mistakes in the rush to install the VEMS on the vehicle:

First I connected the coil to channel0 as I was following Phatbob's writeup. I got no spark. Turns out channel0 is configured as a logic output. I transferred the coil to channel1, and now i have spark. I'm just wondering if I damaged the channel0 output, and whether I will be able to use it for other purposes in the future.

After getting no fuel out the injectors, I tested them with an LED on the connector. Nothing. CHecked the software settings. They seemed fine. Turns out I made the big error. The bigger problem was forgetting to connect pin 23 to injector +12V common. I know it's a silly mistake. I know it's mentioned 100000 times in the manual. I know. Too late now. I guess this is one of the problems of plug-and-play looms. No excuses though. I connected pin23, tested injectors again and they're still not being actuated so I guess I damaged something.


Testing Injector outputs

5..60W 12V lightbulb is best for testing. Connect as if it was an injector.

See TerminalProgram

http://www.vems.hu/wiki/index.php?page=GenBoard%2FManual%2FDigitalOut

Note that it is essential that h[0] is set up for injector outputs to be actuated (even if used for other outputs)

The standard injgroup h[0] table is:

h[0]=01 02 04 08 10 20 40 80

(that is 1,2,4,8,16,32,64,128 in MegaTune)

With this injgroup (h[0] table):

When output is turned on (activated), output is pulled towards ground (GND5 to be precise, but you have all GND5 connected to GND anyway).

Measure across the lightbulb, that is between +12V and the tested output. Document what you measure.


Salvaging the Genboard!

After the initial panic, I did the above tests. Turns out I only damaged INJFET_0 and INJFET_1 (which were hooked up when I forgot pin23 flyback). I have 6 more INJFET's to play with. I hooked them up and the car starts. Good stuff. I dismantled the Genboard to replace the damaged FET's, but it seemed like more trouble than it's worth with all that silicon around the flyback board. R.I.P. INJFET_0 and INJFET_1.

Couple more questions for my install if I may:

Q1. What is the current rating on the I259_0, I259_3, I259_5, and I259_7 (logic outputs inthe 4+4 configuration I ordered)? I'm thinking of using one for driving a modern tachometer with a 1k pullup.

Q2. How do I wire in a switch for the ALS or a pushbutton for the launch control? I can't figure it out from reading the wiki. Shouldn't there be a digital input to the Genboard to activate these modes or am I missing something obvious? There's no mention of analog inputs (except for MAP sensor) on the webstore page as mentioned above. I'm confused.

Q3. Can I use the OEM idle control valve instead of a throttle kicker for the ALS? I was tempted to trick the genboard by using the idle valve output instead of the throttle kicker solenoid output in the megatune menu. But I thought I'd check first because it sounds like an output conflict since the same valve would be used for idle control AND as ALS 'throttle kicker'.

Q4. I'm wanting to wire in the water injection valve (aquamist HSV), but I can't figure out if I need a free INJFET or something else? Also do i need to recompile to make my own firmware or will I be fine the way the genboard was sent? I don't see the option of defining which output is the secondary injector, or any way to use a different req FUEL for this secondary injector (water injector).

Q5. I tried using P259_0 to drive the tachometer. I initially used a 2.2k pullup to 12V, but there was a noticeable lag between the actual revs and those displayed on the tacho. I then tried a 1k pullup but there was no improvement. Is this a problem with the P259 response?

Thanks!