A motronic55 install might save some time making a harness, but you must always verify the harness reasonably carefully.
This involves
- measurement of all used pins
- mostly DVM ohm-mode
- sometimes voltage mode
- visual inspection
- the injector part of the harness receives much heat. Insulation might be worn. It's better to fix ASAP, than to risk engine damage.
Documents and files to use
- [ motronic-AAN-ECxx.xls pinout spreadsheet]
- this is the most important docs, so you know pinout and function mapping. In MegaTune you will see names like EC36pin10 while you have it wired to some motronic pin. While you do the measurements, write the measured value and the pin you used, and any notes you think appropriate
- firmware 1.1.23.zip from [here]
- temperature calibration tables from EasyTherm
- coolant: NTC type 1900_256 or 2063_256 is a very good starting point
- MAT: PTC type 260_425 is a good starting point
- MegaTune (1.1.12 or later)
- latest v3gui.exe also [available here], useful for firmware upgrade and config dump. Use the latest (currently 2007-08-03)
- AAN starting config and tables
- note that better tuned fuel and ignition was made for 3B engine (and successfully applied to AAN as well), see MembersPage/MarcellGal/PowerAndTraction
- normally you have some preference at the time of order, like MembersPage/TeppoKalske (page bottom). Also consider that the crew who built and tested your device might have updated it!
Sensor measurements
Measure sensor resistance against AANpin30.
- ... Ohm between 44 and 30 (MAT)
- ... Ohm between 45 and 30 (CLT)
Injector and idle-air output measurements
Measure injector and idle air pins against AANpin37 (that is the flyback pin, same function as EC36pin23 in standard VEMS docs)
- inj cyl1
- inj cyl2
- inj cyl4
- inj cyl5
- inj cyl3
Grounds
Measure that grounds are strongly (max 0.1 Ohm) connected inside the VEMS ECU.
- AANpin10
- AANpin19
- AANpin24
- AANpin30 sensor ground
- AANpin48 trigger ground
You can measure that most are connected in the harness, but at least AANpin30 (sensor ground) and AANpin48 trigger ground are likely not connected.
Measure that all the above grounds are connected inside the ECU.
Trigger
This step assumes you successfully made all the above steps.
This needs ignition on.
The secondary trigger crankhome-VR is already reversed. Resistance=...
Trigger
Measure trigger resistance against AANpin48.
- 882... Ohm between 49 and 48 (135 cranktooth-VR primary trigger)
- 886... Ohm between 47 and 48 (crankhome-VR secondary trigger)
HALL signal
- ... V between ... and 30 (this needs ECU plugged in and ignition on)
- changes between 0 and 4..5V as the engine rotates
This step assumes you successfully made all the above steps.
WBO2 on SSC4 male standard - applies to audi AAN and 3B (also to BMW), but the SSC5 is used by default, unless SSC4 requested:
- pin1 nernst,WBO2 pin 1
- pin2 heater(-),WBO2 pin 4
- pin3 pump(-),WBO2 pin 5
- pin4 pump(+),WBO2 pin 6
- Remember that WBO2 pin 3 must get heater+ from a 5A fuse from +12V supply wire ! The WBO2 heater+ does not come from the ECU (only the WBO2 heater-)
WBO2 Rcal
Resistance between pin2 and pin6 of the 6pin WBO2 connector: 103 Ohm
http://www.vems.hu/files/MembersPage/TormasiAudiAAN/ has some msq files.
The ignition output channels are suspicios. channel 4 assigned to 2 cylinders.
TODO: upload mcd and mct dump to be sure.
Hiba: Motor nem indul.
Terminal log file
Date: 2007.08.11. - 14:45:20
Hello>
j[0]=4580 5780 5F80 6080 6780 6880 6580 6B80 6C80 7180 7580 7980
j[1]=5080 6280 6880 6780 6E80 6E80 7280 7780 7480 7880 7980 7880
j[2]=5080 6480 6A80 6B80 6C80 6F80 7280 7980 7780 7A80 7680 7880
j[3]=4F80 6380 6D80 6C80 6F80 7080 7380 7980 7780 7880 7880 7980
j[4]=4D80 5D80 6B80 6F80 6E80 7080 7580 7A80 7780 7780 7480 7880
j[5]=4E80 5C80 6A80 7180 7180 7280 7780 7D80 7B80 7B80 7B80 7980
j[6]=4D80 5B80 6780 6E80 7280 7480 7480 7D80 7E80 7A80 7A80 7980
j[7]=4D80 5A80 6380 6E80 6F80 7480 7480 7A80 7D80 7F80 7F80 7880
j[8]=4E80 5B80 6180 6B80 7080 7380 7480 7D80 7E80 8080 8080 7980
j[9]=5280 5B80 6080 6B80 7080 7780 7580 7E80 7C80 7B80 7B80 7680
j[A]=5680 6180 6580 6B80 7180 7880 7880 7D80 7B80 7C80 7B80 7780
j[B]=5C80 6580 6D80 7180 7380 7880 7880 7D80 7B80 7A80 7A80 7880
l[0]=3D 3B 37 31 2F 34 37 37 37 37 37 37
l[1]=3D 3D 37 31 34 31 34 37 37 37 37 37
l[2]=3D 3D 3B 36 31 31 31 37 37 37 37 37
l[3]=3D 3D 3B 34 34 31 37 37 37 37 37 37
l[4]=37 37 34 34 36 36 37 3B 3D 3D 3D 3D
l[5]=3B 3B 37 37 37 37 37 3B 3D 3D 3D 3D
l[6]=3D 3B 37 36 37 37 37 3D 43 43 43 43
l[7]=3D 3D 3D 3B 3B 3B 3D 3D 43 47 47 51
l[8]=4D 4D 48 47 47 47 4D 4F 51 51 55 55
l[9]=63 63 63 66 5C 5C 5C 5C 5C 5C 5C 58
l[A]=75 75 75 75 63 63 63 5C 5E 5C 5C 58
l[B]=7E 7E 7E 78 63 63 63 63 63 63 63 63
n[0]=43 4C 58 9C A0 A4 A8 A8 A8 A8 A8 A8
n[1]=41 4C 58 98 9C A0 A4 A4 A4 A4 A4 A4
n[2]=3C 4C 58 94 98 9C A0 A0 A0 A0 A0 A0
n[3]=38 48 54 7C 90 94 98 9C A0 A0 A0 A0
n[4]=38 48 54 6C 84 88 88 88 88 88 88 88
n[5]=34 44 50 60 78 7C 80 84 88 88 88 88
n[6]=30 44 50 5C 74 78 7C 84 88 88 88 88
n[7]=30 38 3C 40 5C 68 68 68 68 68 68 68
n[8]=2C 34 38 40 5C 5C 5C 5C 5C 5C 5C 5C
n[9]=2D 33 38 3F 4C 58 58 58 58 58 58 58
n[A]=24 28 2F 37 3D 3E 3E 3E 3E 3A 3A 3A
n[B]=20 21 27 30 36 38 35 34 34 36 37 38
k[0]=0F 17 1C 21 28 2B 33 3A 46 5A 6E 82
r[0]=07 0C 10 16 1C 22 29 31 37 3D 43 4A
h[0]=01 02 04 08 10 20 40 80
h[1]=00 48 36 24 12 00 00 00
h[2]=36 46 56 40 66 50 50 50
b[0]=3B 3B 37 34 34 31 31 34 37 37 3B 3D
primep=00
primep_temp_scaling=33
cwl=BE
cwh=6E
cranking_thres=03
awev=63
awev_temp_scaling=4A
awec=11
warmup_clt_range[0]=00
warmup_clt_range[1]=00
warmup_clt_range[2]=13
warmup_clt_range[3]=27
warmup_clt_range[4]=50
warmup_clt_range[5]=64
warmup_clt_range[6]=78
warmup_clt_range[7]=8C
warmup_clt_range[8]=AA
warmup_clt_range[9]=C8
warmup_clt[0]=C8
warmup_clt[1]=C8
warmup_clt[2]=AA
warmup_clt[3]=8C
warmup_clt[4]=82
warmup_clt[5]=7B
warmup_clt[6]=78
warmup_clt[7]=73
warmup_clt[8]=6E
warmup_clt[9]=64
warmup_rpm_scale=A8
req_fuel=4B
divider=01
alternate=04
injopen=00
battfac=22
kpafac=D0
kpaoffs=94
injocfuel=08
injrampup_battfac=FF
injpwm=FF
injpwmt=FF
als_launch_input=0F
rpmk[0]=09
rpmk[1]=60
tpsdot_kpadot_conf=00
tpsdotrate[0]=04
tpsdotrate[1]=07
tpsdotrate[2]=0F
tpsdotrate[3]=1A
tpsaq[0]=07
tpsaq[1]=09
tpsaq[2]=0E
tpsaq[3]=14
als_cut_mintps=FF
tpsasync=03
acmult=6E
tpsacold=14
launch_enrich=00
launch_retard=00
overrun_fuelcut=10
overrun_fuelresume=0F
rev_limit=48
airden_ignore=61
config11=41
config12=40
config13=02
batt_cal=C6
fastidle=C6
als_max_cut=00
dbaro=0A
tps_low=16
tps_high=E6
fan_temp=EA
fan_hyst=05
fan_channel=FF
iac_step_seq=D8
iac_conf=18
iac_max_steps=C8
iac_tps_thres=05
iac_cold_idle_temp=63
iac_warm_idle_temp=B4
iac_cold_rpm=6E
iac_warm_rpm=55
iac_cold_start_pos=B3
iac_warm_start_pos=6B
iac_afterstart_rpm=0A
iac_afterstart_duration=19
iac_speed=05
iac_kp=32
iac_ki=19
iac_kd=0A
launch_rpm=FF
iac_integral_limit_dec=23
iac_integral_limit_inc=78
iac_integral_deadband=14
iac_deadband=32
als_cut_maxtps=FF
iac_overclose_interval=C8
iac_ref_pos[0]=BF
iac_ref_pos[1]=BA
iac_ref_pos[2]=AD
iac_ref_pos[3]=A8
iac_ref_pos[4]=A1
iac_ref_pos[5]=91
iac_ref_pos[6]=82
iac_ref_pos[7]=7A
iac_ref_pos[8]=75
iac_ref_pos[9]=73
iac_sol_channel=60
iac_ign_slope=14
softrpm_range=32
iac_ign_advance_limit=20
iac_ign_retard_limit=18
iac_ign_threshold=18
ego_conf=06
ego_lag=04
ego_coolant=7E
ego_maxtps=E6
ego_maxmap=69
ego_minrpm=07
ego_maxrpm=46
ego_warmup=14
ego_lean_limit=1F
ego_rich_limit=0A
ego_pid_kp=1E
als_enrich=00
ego_delta=03
ego_target=19
ego_pid_window=01
wbo2_warmup_ramp=FF
als_react_tps=FF
wbo2_abs_limit=E0
wbo2_limit_maxt=F0
wbo2_fallback=70
wbo2_retry_t=06
als_retard_rpm1=FF
als_retard_rpm2=FF
wbo2_ri_target=A5
wbo2_nernstdc_target=86
wbo2_pump_pw_zero=67
wbo2_calibration=A9
wbo2_heater_pid_kp=45
wbo2_heater_pid_ki=11
wbo2_heater_pid_kd=1A
wbo2_heater_pid_ilimit=80
wbo2_pump_pid_kp=15
wbo2_pump_pid_ki=4E
wbo2_pump_pid_kd=00
wbo2_pump_pid_ilimit=FF
wbo2_ri_confidence_scale=80
knock_conf=01
knock_sampling_window=F2
knock1_frequency=29
knock1_gain=0E
knock1_integrator=14
knock2_frequency=29
knock2_gain=00
knock2_integrator=00
knock_threshold=0A
knock_noise_scale=D8
knock_max_retard=18
knock_default_retard=04
knock_retard_step=04
knock_retard_delay=30
knock_advance_step=01
knock_advance_delay=50
knock_minrpm=0A
knock_maxrpm=42
ve_learn_coolant=CF
ve_learn_max_power=64
ve_learn_rpm_scale=28
ve_learn_kpa_scale=28
ve_learn_ego_scale=50
ve_learn_min_weight=14
ve_learn_speed=32
ve_learn_limit=80
ve_learn_conf=01
lcd_c0=FE
lcd_delay=42
lcd_backlight=FF
kpa_conf=22
als_igncut_rpm2=FF
als_retard_mintps=FF
als_retard_maxtps=FF
lcd_default_view=00
primary_trigger=47
secondary_trigger=19
tooth_wheel=5A
trigger_tooth=08
another_trigger_tooth=12
crank_minper=33
tooth_wheel_twidth1=20
tooth_wheel_twidth2=00
cam_sync_r_edge_phase=00
cam_sync_f_edge_phase=00
reset_engphase_after=40
ign_tdcdelay=84
ign_dwell14=30
ign_dwell6=4A
ign_crank_advance=28
ign_out=70
ignchmax=04
engine_off_delay=02
pump_on_mintime=04
fuelpump_channel=50
inj_stage2_rate=FF
inj_stage2_start_tps=FF
inj_stage2_start_map=FF
als_igncut_rpm1=FF
als_deact_time=00
als_deact_egt=00
als_retard=CC
als_rev_limit=FF
misc1out_minrpm=FF
misc1out_maxrpm=FF
misc1out_mintps=FF
misc1out_maxtps=FF
misc1out_minmap=FF
misc1out_maxmap=FF
misc1out_channel=FF
misc2out_minrpm=FF
misc2out_maxrpm=FF
misc2out_mintps=FF
misc2out_maxtps=FF
misc2out_minmap=FF
misc2out_maxmap=FF
misc2out_channel=FF
act_wot_rpm=FF
act_wot_channel=FF
act_rpm_rpm=FF
act_rpm_channel=FF
egt1_cal=4A
als_tks_channel=FF
boost_conf=66
boost_targetoffs=00
boost_minpressure=3A
boost_pid_kp=D6
boost_pid_ki=46
boost_pid_kd=2C
boost_pid_ilimit=7D
boost_channel=62
water_pump_temp=00
hybrid_rpm_a=00
hybrid_rpm_m=00
water_pump_hyst=7E
water_pump_channel=FF
toothrel_normal=76
toothrel_missing=00
fuelcut_min_kpa=08
fuelcut_max_kpa=90
tach_channel=07
tach_div=10
shiftcut_conf=00
shiftcut_channel=FF
shiftcut_time=7F
softrpm_rpm=50
1.1.24