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Summary of change:
Adapting VEMS 3.2 ecu to turbocharged 2.5 liter BMW inline 6 'M20B25' engine which is standard ie. without internal mechanical modifications. Instrumentation, sensors and operational devices. * Crankshaft Speed/Angular Position Sensor (CS) ** Standard BMW/Bosch 60-2 trigger wheel with variable reluctance (magnetic type) sensor. Standard BMW item manufactured by Febi-Bilstein - AB Technik. * Manifold Absolute Pressure sensor (MAP) ** Genboard mounted (VEMS internal) Motorola (MPX4250AP) (2.5 kg/cm2) absolute pressure sensor. * Coolant temperature sensor. (CLT) ** Standard Bosch item: 0 280 130 026 * Inlet Air Temperature sensor (IAT) ** FAE 33180 * Throttle Position Sensor (TPS) ** Standard OEM spare part 'SE04-M'. 2.6 - 0.88 kOhm angular potentiometer, without idle and full throttle microswitch. * Idle Air/Speed Control Valve (IAS) ** Standard BMW/Bosch item 0 280 140 509 (rotary valve type). * Lambda Sensor (LS) ** Wide-Band Lambda Sensor (Bosch LSU4). 5 wire special connector, ordered this with the wiring loom connector from VEMS shop. ** LSU4 Bosch item 0 258 007 057. * Ignition Coil ** Standard spark delivery via distributor with original BMW/Bosch 'TZI' coil. * Ignition module ** Using 'IGN 00' channel to drive 'dummy' Bosch '0 227 100 124' ignition module. * Boost control ** Standard wastegate actuator control 'so called' 'N75' valve, VW/Audi origin; turbo control valve VW part code: '0589 062 83F' * Turbo Control ** Turbocharger Holset HX30 center core with custom compressor and turbine, without variable nozzle turbine. Hence not needing control device. * Injectors ** Bigger injectors than in standard naturally aspirated BMW engine are needed to cope with increased power level (from 170 PS to around 250-300 PS). ** For maximum fuel vaporisation modern 2 to 6 hole injectors are preferable. ** Bosch: B 280 431 824/20 item. Has four spray holes with wire splitter, four 'atomization helper' air channels, high impedance (~ 16 ohm). 261 g/min approx. 351 cc/min (N-Heptane). ECU '#188' wiring diagram. - main relay - fuel pump relay - fusebox - sensors (CLT, IAT, TPS etc.) groundings (GND) - ohjaustransistorien maadoitukset (GND5) - RS-232 ECU programming cable - wideband oxygen sensor. - injectors - injectors flyback rail - coolant and inlet air temp sensors - crank angle / engine rotating speed sensor - engine phase / 'camshaft position' sensor - throttle 'angular' position sensor - idle air speed solenoid valve - wastegate actuator solenoid 'N75' valve. - knock sensor - ignition module - ignition coil - coolant radiator fan motor(s) (not implemented -> BMW original/mechanical wiscous coupled fan used.) - Econoseal 36 pin 'EC36' ECU connector - Econoseal 18 pin 'EC18' ECU connector ------------------------------------------------------------------ main relay (1) (= physically rightmost) / +12V feed to ECU fusebox. Pin 30 Vbatt +12V via fuse 1. 86 +12V feed via ignition key (taken from original BMW 'motorstecker'connector). 85 GND 87 +12V feed to VEMS ECU fusebox (ie. to fuses 2,3,4,5,6,7,8,9). ------------------------------------------------------------------ Fuel pump relay (2) (=left relay) / +12 V feed to fuel pump. Pin 30 Red Vbatt +12V feed via (fuse 2). 86 Red +12V relay coil feed via (fuse 1). 85 Red EC36-15 pin / fuel pump relay coil drive to GND. 87 Green +12V feed to fuel pump. ------------------------------------------------------------------ Fusebox, +12 V feed to relay coils and devices. Fuse 1 / 20 A Main power to main and fuel pump relay and other fuses. Fuse 2 / 10 A Fuel pump. Fuse 3 / 2 A VEMS ECU. Fuse 4 / 5 A WBO2 heater. Fuse 5 / 10 A Fuel rail / injectors. Fuse 6 / 3 A Idle Air Speed valve. Wastegate control valve. Fuse 7 / 10 A Ignition coil. Fuse 8 / 10 A Iginiton module. ------------------------------------------------------------------ *** Fuse 3 / 2A *** ECU +12V power feed. Pin Color EC36-25 Red -------------------- *** Fuse 4 / 5A *** Wideband lambda sensor heater to (7057) wireloom 'end connector'. Pin Color 3 brown Vbatt/relay 1 (fused +12V) sensor heater voltage (+) -------------------- *** Fuse 5 / 10A *** Fuel rail injectors Injector Color Pins 1 Red VBatt/relay 1 (fused +12 V) Note ! injector flyback rail wire after fuse to EC36-23 pin. -------------------- *** Fuse 6 / 10A *** Idle Air Speed valve (IAS) Pin Color 2 red-white Vbatt/relay 1 fused +12V Wastegate valve, ('N75 valve') Pin Color 1 yellow Vbatt fused +12V feed -------------------- *** Fuse 7 / 10A *** Ignition module Pin Color 4 red Vbatt +12V fused -------------------- *** Fuse 8 / 10A *** Ignition coil Pin Color + green Vbatt +12V shielded / fused feed. ------------------------------------------------------------------ Grounds (GND and GND5) Power ground 'GND5'. -------------------- used for the power-switchers, such as injectors, ignition and Wideband lambda sensor heater driver(s). At least two 'GND5' ground wires must be connected to ECU side. pins EC36-5, EC36-21, EC36-32 connected with yellow/green 2.5 mm2 wire. IT IS ESSENTIAL THAT ALL GND5 OUTPUTS BE USED TO ENSURE CURRENT DEMANDS CAN BE PROPERLY HANDLED WITHOUT DAMAGE. Sensor and digital ground 'GND'. ----------------------- pins EC36-26, EC18-2 connected with yellow/green 1.5 mm2 wire. At least two GND ground wires must be connected to ECU side. ------------------------------------------------------------------ Sensors, actuators and other harness groundings. Coolant temperature sensor (CLT) Pin Color 2 Yellow/green EC36-26 (GND) RS-232 cable DSUB 9-pin RS-232 female connector (to PC serial port) pin color connection and function 5 black EC36-26. RS-232 signal ground (Sensor and digital ground: GND) shielding EC36-26 Signals protection against radio frequence interference. Inlet air temperature sensor (IAT) Pin Color 2 black EC36-26 (GND) Crankshaft speed/angular position sensor (CRAS), VR sensor 60-2 pulse wheel Pin Color 1 black EC36-26 (GND) 3 transparent (shield) grounded from same physical point as EC36-26 is in ground. Throttle position sensor (TPS) Pin Color 2 gray EC36-26 (GND) Knock sensor (Knock) Pin Color 2 black EC18-2 knock GND (same as EC36-26) shielded wire grounded from same physical point as EC36-26 is in ground. ------------------------------------------------------------------ Harness connections. -------------------- RS-232 cable DSUB 9-pin RS-232 female connector (to PC serial port) pin color connection and function 2 white EC18-14. Receive data (RxD), data received by PC, transmitted by ECU (to PC). 3 blue EC18-15. Transmit data (TxD), data transmitted by PC, received by ECU (from PC). 5 black EC36-26. RS-232 signal ground (Sensor and digital ground: GND) shielding EC36-26 Signals protection against radio frequence interference. Note ! Shield is grounded at ECU end. ------------------------------------------------------------------ Wideband lambda sensor (7057) wireloom end connector Pin Color Connection 1 black EC18-13 (ie. EC 18 pin 13) (Vs / nernst cell) 2 yellow/green Not connected (xxx RCal) 3 brown Vbatt (+12V fused) sensor heater voltage (+) 4 white EC18-18 (EC 18 pin 18) (sensor heater -) 5 grey EC18-7 (ie.EC 18 pin 7) (Vs/Ip pump -) 6 red EC18-9 (EC 18 pin 9) (Ip pump +) Shielding (around pin1) EC36-26 Signals protection against radio frequence interference. ------------------------------------------------------------------ Fuelrail injectors and coolant temperature sensor (CLT) modified original BMW 'cassette'. Fuelrail injectors (fully sequential wiring). Injector Color Pins 1 Red (VBatt, fused +12 V) (Flyback rail wire connected to EC36-23.) flyback wire must be taken after fuse ie. protects against back emf if fuse blows. (flyrail johtosarjasta heti sulakkeen jälkeen). Pin 2 Inj 1 black EC36-7 Inj 2 white EC36-19 Inj 3 begins 'dark grey' ends 'light grey/blue stripe'EC36-8 Inj 4 brown EC36-20 Inj 5 blue EC36-9 Inj 6 begins light grey ends 'light grey' EC36-18 Note ! injector 3 and 6 wires has been extended (crimp connector with solder) to reach ECU. Coolant temperature sensor (CLT) -------------------------------- Pin Color 1 Red EC36-14 2 Yellow/green EC36-26 (GND) ------------------------------------------------------------------ Inlet air temperature sensor (IAT) Pin Color 1 white EC36-2 2 black EC36-26 (GND) ------------------------------------------------------------------ Crankshaft speed/angular position sensor (CRAS), 60-2 pulse wheel VR sensor. Pin Color 1 black (sensor +) EC36-27 (primary trigger) 2 yellow (sensor -) EC36-26 (GND) 3 transparent (shield) grounded to same physical point as EC36-26 is grounded. see the. BMW (E30) - Motronic - Zusammenfassung von Drehzahl- und Bezugsmarkensensor.jpg 510 Ohm +/- 5 % (measured: 531 ohm) ------------------------------------------------------------------ Engine phase / camshaft reference sensor (CAMS), Pick up from cylinder 6 spark plug wire Pin Color 1 black CAMS sensor (pin order is similar to CRAS) not connected to VEMS ECU. 2 yellow GND 3 transparent (shield) grounded to same physical point as EC36-26. Note ! Not connected to ECU. ------------------------------------------------------------------ Throttle position sensor (TPS) Pin Color 1 yellow EC36-29 (+5V TPS supply) 2 gray EC36-26 (GND) 3 green EC36-01 (TPS signal Input) ------------------------------------------------------------------ Idle Air Speed valve (IAS) 'Bosch 0 280 140 509' Pin Color 1 green-white (blue) EC18-4 (Step A) 2 red-white (red) fused +12V feed 3 yellow-white (brown) EC18-10 (Step B) Note ! Original wires extended (crimp connector with solder) to reach fusebox and ECU connector. Extended wire colors in parenthesis. ------------------------------------------------------------------ Wastegate 'N75' valve Pin Color 1 yellow fused +12V feed. 2 gray EC36-10 ('I259_7' 'Drive 07') ------------------------------------------------------------------ Knock sensor (Knock) Pin Color 1 blue EC18-3 knock signal 2 black EC18-2 knock GND (same as EC36-26) shielded wire grounded to same physical point as EC36-26. Note ! Shield is grounded at ECU end. ------------------------------------------------------------------ Ignition module (Ign Mod) Pin Color 1 shielded RG58 c/u wire (connected to Ignition Coil negative) 2 yellow-green (Ignition module Ground) 3 yellow-green (Pulse Generator Ground) 4 red Ignition Positive (+12V) 5 blue Pulse Generator / Input Signal from ECU (EC36-35 / IGN 00) 6 Not connected 7 Not connected Shielding connected to same point as other groundings. ------------------------------------------------------------------ Ignition coil (Coil1) Pin Color - shielded RG58 c/u wire from ignition module. + green (shielded) from +12V fused feed. ------------------------------------------------------------------ Econoseal 36 pin 'EC36' ECU connector 1. Blue TPS signal 2. white IAT 3. 4. 5. yellow/green 'GND5', power ground. 6. 7. black (INJ A) (Cyl. 1 injector) 8. light grey blue stripe (INJ C) (Cyl. 3 injector) 9. blue (INJ E) (Cyl. 5 injector) 10. gray Wastegate 'N75' valve. I259_7 -> 'Drive 07'. 11. 12. ----------- 13. 14. red CLT 15. red Fuel Pump Relay control 16. Green (Drive 9) 17. Red (ING H) 18. Light grey (INJ F) (Cyl. 6 injector) 19. White (INJ B) (Cyl. 2 injector) 20. Brown (INJ D) (Cyl. 4 injector) 21. yellow/green 'GND5', power ground. 22. 23. red Injectors Flyrail. 24. ----------- 25. red ECU main power 26. black GND, sensor and digital ground. 27. black 'crankshaft' speed/position 'primary' trigger signal. 28. 29. yellow TPS +5V SUPPLY 30. Green (Drive 11) 31. Green (Drive 10) 32. yellow/green 'GND5', power ground. 33. Green (Drive 1) 34. Green (Drive 2) 35. Green (Drive 0) 36. Green (Drive 3) ------------------------------------------------------------------ Econoseal 18 pin 'EC18' ECU connector 1. 2. black knock sensor '-' signal, 'GND'. 3. blue Knock sensor '+' signal. 4. blue IAS (Step A) 5. 6. ----------- 7. grey WBO sensor1 'Vs/Ip Pump -' 8. 9. red WBO sensor1 'Ip Pump +' 10. brown IAS (Step B) 11. 12. ----------- 13. black WBO sensor1 / Nernst Cell 14. white RS232, receive data (RxD) to PC. 15. blue RS232, transmit data (TxD) from PC. 16. 17. 18. white WBO sensor1 'Heater -' ------------------------------------------------------------------ ** TODO: Firmware, VE, igniton advance and other tables. A bit of a problem - genboard does not communicate properly ie. transmits 'garbage'. Startup serial settings cannot be changed in ecu config ( fixed 9600,n,8,1 no flow control at compile time). Bootstrap mode (at 19200 baud) works (ie. responds with AVREF1 etc.) as expected, so it seems the ECM stays in BootLoader mode because firmware is invalid. Maybe after an unsuccessful firmware upgrade? Try to update firmware, it should work. Todo: Need to organize wiring diagram, etc. * MembersPage/BengtR/GenBoardAssembled * ... ** TODO: Other information will be updated within few weeks.
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