MembersPage/MarcellGal/EngineSwap/Wiring (2005-03-25 19:27:12)

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


Strategy

I plan to use

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,

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.


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

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


Pin mapping

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

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

FunctionWire ColourDaewoo ECU pinDSUB pinVEMS ECU pinComments
Vbatt, WBO2 pin3 Heater + grey, node15 Magenta/White C16 DB25-15 EC36-25 node15, only power when ignition_on
GroundBlackB2 (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 GroundBlack C7, C9, D7 DB25-24 EC36-21 EC36-32 EC36-5 connect these as hard as possible: inside and outside the board
TriggerYellow/BlackA16 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
TPSRed/YellowC15 DB25-8 EC36-1 
Coolant temperatureYellowB3DB25-19EC36-14 
Manifold air tempYellow/White B4 DB25-9 EC36-2 verify on daewoo harness
Fuel pump relay ? ? DB25-20 EC36-17 (mdh70)
Injector 1,4White/BlackC4 DB25-10 EC36-8 INJFET_2 (mdh10, h[0]mask=04)
Injector 2,3 Green/BlackC6 DB25-11 EC36-9 INJFET_4 (mdh00, h[0]mask=10)
Idle stepper ABlue/WhiteA1 DB25-4 EC18-4 S259_3 (mdh36)
Idle stepper BBlue/BlackA2 DB25-5 EC18-10 S259_4 (mdh46)
Idle stepper CGreen/BlackA3 DB25-6 EC18-5 S259_5 (mdh56)
Idle stepper DGreen/WhiteA4 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 
Variable intake ? ? DB25-22EC36-19 INJFET_1 (mdh40, h[0]mask=02)

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

yet free:

Done - apparently OK


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:

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.


See also

When editing, I continously verify (2 monitors and printer helps) to