danglerb

Exciting news. Any guess on how this might be adapted to the 25 pin LH 2.2 cars?

I think the pins in the head shells are the same, so maybe a 25 pin harness could have a 35 pin head shell by releasing pins one at a time and moving them over?

Volla

Ok, well I am going to do everything in C, there is no need for me to go and screw around in assembly for this, the processor has enough processing power (80 MIPS). Currently the only remaining step is the programming (I will see if I can upload the rest of the stuff today)


Here is the next step.

Step 4: PCB Creation and populating

The PCB that I must make is a two layer pcb with 0.006" gaps between tracks and 0.012" vias. That is small, and I cannot do it at home. So I sent the info to specialists and received my PCB (5 of them).

All the components were ordered from Digi-Key. 34 Different components, 840 components in total for 5 boards)

After I got the PCB and components it was time to play around with solder paste and put all the components on. I baked the PCB, and then soldered on the through hole components.

There was a small delay with getting the processors, thus the last photo here is the PCB complete without processor.

Step 5: Integration

Ok, this step is a really important one. I have to check my design to see if everything works, fits and doesn't blow up.

Powering up the board, checking the power LEDS and verifying voltages was first, afterwards checking the digital inputs, and alalogue voltage levels. Here is a list of mistakes I made.

The LM317 regulator pin outs in the datasheet is numbered 1-3-2 (3 is in the middle) and in my schematics I used 1-2-3. That now means that I need to make a small wire-mod to fix that.

The LH Connector gaps between ping I measured as 5.08mm, but it is in fact 5mm. This means the connector fits a bit tight, but not a problem. (In retrospect I should have realised that it is 5mm and not 5.08, because it is german made and in the 80's the germans were already fully on the metric system.

My comparators that I use to translate from 0-battery voltage to 0-3.3v I powered from 3.3 instead of from the battery voltage. This can be fixed by cutting a track and doing a wire mod.

Those three mistakes are all that I made. After fixing those the unit's hardware works perfectly. I made a small test application that flips my outputs randomly and puts my test LEDs on when inputs are triggered and everything works perfectly.

the next step is to program the unit. The programming will be the remaining steps


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19?? VW Baja Bug (Completely custom, Golf 1.8 motor, and many, many mods) - Currently my daily drive
1988 Porsche 928 S4 Euro/ROW (Black with Ivory interior) - Under ECU surgery
1982 Porsche 924 Euro (Silver with cream interior)- Gone
1982 Porsche 928 S (Manual) Euro (Petrol Blue with Blue with black and white chequered interior) - Gone
1983 Porsche 928 S (Auto, NA spec, Red, black interior) - Gone
1994 BMW 530i Manual (Maroon, grey interior) - Gone

Dictys

Looks great so far, very interesting and I wish I had those skills. As I said before put me down for one of the five boards.

Mike Frye

This is freakin AWESOME! Please please please don't forget the S3 crowd (LH2.2).

M. Requin

Man do you work fast! And +1 on the S3's.

UncleMaz

Man, I am having major skills envy. Please don't forget plain L-Jet (in case I missed it).

Bill Ball

Wow!

supercedar

Please contact me when mine is ready. 1988 S4

Thomas

Volla

As promised, here is the update that shows where I am now.

The picture is how the board look with connector, CPU, heatsink and wire mods.

The heatsink is just a precaution and just there for testing at the moment, it wont be fitted to the other units.

Step 6: Programming phase 1

Ok, here is a video clip of the car starting and idling with my ECU (1 Minute).
I switched off the car in the end.
My idling is adjusted to idle higher, will readjust after the units works well.

http://www.youtube.com/watch?v=-JIH2r-TW0g

At the moment I have just done the idling programming. There is no safety shut off of the fuel pump, and the ECU ignores the RPM and MAF. This is just to illustrate that the unit can get inputs and switch the outputs.

The LEDs at the CPU cant be seen in the video but they are flashing in rythm to the EZK inputs and the one far right lights up at WOT.

This weekend I will spend most of my time doing the programming.

The programming phases are listed as follows:

1) Idling
2) Fuel adjustment according to RPM
3) Adding MAF readings and adjusting to fuel map
4) Add support for engine temperature, safety fuel cut off, tank venting, flappy control
5) Add exhaust feedback support and support for 2 fuel maps - normal/WOT
6) Add communication with PC via Serial, followed by USB
7) Make fuel map dynamically changeable and make windows interface software
8) Dyno the car
9)

A rough estimate will be 3-4 weeks then all the programming should be done. Hopefully I will be done earlier, so I can enjoy the car more.

I will keep everyone updated with videos and I will definitely let everyone know when I'm done and it works perfectly.

Remember I only have 4 units "in stock" at the moment, It will be a first come first serve when the project is done, afterwards I will order more PCB and components.

Afterwards I will modify the PCB and make units that will be able to work with the 25 pin LH2.2.

==================================================
19?? VW Baja Bug (Completely custom, Golf 1.8 motor, and many, many mods) - Currently my daily drive
1988 Porsche 928 S4 Euro/ROW (Black with Ivory interior) - Under ECU surgery
1982 Porsche 924 Euro (Silver with cream interior)- Gone
1982 Porsche 928 S (Manual) Euro (Petrol Blue with Blue with black and white chequered interior) - Gone
1983 Porsche 928 S (Auto, NA spec, Red, black interior) - Gone
1994 BMW 530i Manual (Maroon, grey interior) - Gone

Mongo

GENIUS!

karl ruiter

What compiler are you using with your PIC32? I used the Microchip one before and was not really very impressed. I normally kinda stick to PIC18 and below because they have reasonable horse power and I can use the Knudson Data compiler which I think is freeken awesome. Oh, but wait. You are planning on having USB connectivitity. Better use the Microchip, I guess.

Leon Speed

Volla

I use Microchip MPLab X beta 3, ICD3 and the C32 compiler from Microchip.

The PIC32 doesnt use the Microchip instruction set, they use MIPS, wich is a lot better than the PIC16/18/24/30/33 and dsPICs.

The USB for the PIC32s isnt that difficult, most of the work is already done which makes integration a lot easier.


==================================================
19?? VW Baja Bug (Completely custom, Golf 1.8 motor, and many, many mods) - Currently my daily drive
1988 Porsche 928 S4 Euro/ROW (Black with Ivory interior) - Under ECU surgery
1982 Porsche 924 Euro (Silver with cream interior)- Gone
1982 Porsche 928 S (Manual) Euro (Petrol Blue with Blue with black and white chequered interior) - Gone
1983 Porsche 928 S (Auto, NA spec, Red, black interior) - Gone
1994 BMW 530i Manual (Maroon, grey interior) - Gone

Hayk928

Just incredible how fast you're working... *Pinned*

Marc

Rick Carter

Subscribing for 85/86 updates. Good work.