Wiring for MembersPage/MarcellGal/EngineSwap
The MembersPage/MarcellGal/EngineSwap/DaewooHarness will map readily to the GenBoard/VerThree.
We have the mechanical parts ready, the loom is on the way. It's harder to combine Opel, a Daewoo and a GenBoard connections than build a wiring system from scratch. But I needed the connectors from the daewoo harness, so I decided to leave together as much of it as possible.
TODO
- check if there are nice shielded signals in the junk daewoo harness for trigger, knock and nernst signals
- WideBand, calibrate, verify
- ignition, crimping for harness side connector
- GND: the ECM's GND seemed to go 1.5V above chassis GND when ignition was on. Good? no
- TPS: consider using the other connector (exactly same type as the fake-TPS that I earlier thought was the TPS conn; this new conn I just discovered behind some duct tape)
- injector switches and wiring: check/test
- verify: apparently GM MAP sensor was ruined when it got reverse supply due to an unaware situation of the MAP and the fake-TPS supplies being connected (in inconsistent manner) inside the daewoo harness
Strategy
I plan to use
- Alubos1600
- a DB25 + DB9 endplate + DSUB stuff for the mains connectors
- transparent endplate
- thru-endplate cable for PS2 and LCD with flying loom connector
- outside the board MAP sensor
- v3.1 board
- 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,
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.
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. Although I wanted line1 and line3, Fero started soldering this way so ... I think this is called "historical reason".
- 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).
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 Colour | 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- | ... |
| TPS +5V | ? | D15 | DB25-18 | EC36-29 | put 270R and 220nF filter onboard |
| 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 | EC36-36 | I259_3, (mdh32) |
| Ignition 2,3 | ? | D14/C14 ? | DB25-25 | EC36-33 | I259_2, (mdh22) |
| 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 |
WBO2 sensor (that is mounted in the exhaust) RCal=116 Ohm
yet free:
- DB25-23, EC36-20, INJFET_3 (mdh30, h[0]mask=08)
- DB25-22, EC36-19, INJFET_1 (mdh40, h[0]mask=02)
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)
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. Flying-loom DSUB connector. I think DB9 will not be enough because of the -3V necessary for the used type of LCD.
MAP supply
I connected the TPS supply so that growing throttle orifice gives increasing voltage.
I didn't know that the MAP supply was connected to the TPS supply inside the Daewoo harness. Fortunately there was a 270 Ohm in series, so the reverse supply was current limited to about 20mA instead of 100 mA (of 78L05) so MAP sensor should have survived, but apparently it did not.
The way we noticed: when MAP was connected, the TPS showed 0. Without MAP connection, TPS was OK in direction and amplitude.
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)
So I reversed the TPS supply so it's good for the MAP sensor. I'll have to add a firmware feature so that tps_low > tps_high is accepted.
And than I discovered another (same type) connector (at similar location) that was hiding before: it was the real TPS sensor connector.
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).
For Later
When it's working OK, some features will be added.
- knock sensor
- variable intake actuator
- vehicle speed input (map to 2nd VR input)
- CEL (check engine light)
- 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
See also
- MembersPage/MarcellGal/EngineSwap - project index
- thanx to MembersPage/RichardBarrington - I stole the initial table that I started from from his page
When editing, I continously verify (2 monitors and printer helps) to
- GenBoard/VerThree/PinOut and GenBoard/Manual/DigitalOut/Table
- GenBoard/VerThree/Schematic
- also looking at the board traces
- MembersPage/MarcellGal/EngineSwap/DaewooHarness