I will be installing a MoTeC M150 in my GC. My goal is to eventually remove the stock ECU completely and replace all OEM functionality with the M150. Yes I will be reverse engineering the CAN bus on this car. I also have an M1 Build license so i can write my own software into the M150. Generally I'll be figuring it out as I go. I hope to document my efforts here and share with all of you. I'll take pics and hopefully vids as well describing the things I am doing along the way. When this integration effort is done I hope to have a plug-and-play (PnP) stand alone engine management solution available as an option for anyone interested in really flexing their GC's muscles.
This will be the first time i post a project on a forum so bare with me. Thanks.
I decided that i really didn't want to cut the factory harness in order to wire in the M150. So, I have decided to build a "y-harness" of sorts that will serve as an interface between the stock harness and the ECUs. Shown below within the dotted red box is a diagram of what I will build to accomplish this. I will refer to it as a PnP (plug and play) box from now on.
A big part to the success of the PnP box was going to be my ability to source the OEM ECU connectors. I spent some time working with several resources to try and source the OEM connectors, but a feasible option was not found. Basically I was going to have to commit to buy a large quantity (1000+) in order to be heard. The connectors are a Delphi Micro 64 type (100 pin) connector which has been locked by the OEM. If you look at the center of the connecter, between the top and bottom two rows of pins, you will notice there are 3 different "fins" of various lengths. Evidently the size and spacing of these fins are unique to our platform. That's what I mean when I say "locked by the OEM". Below depicts what I am talking about.
So, I bought an extra ECU and harness from a salvage yard and harvested the connectors for my PnP box.
I also picked up an enclosure and blank PCB to build on.
What do you mean by slowly outgrowing the Haltech? I thought Haltech did everything and more? I'm still learning about tuning solutions is why I'm asking.
Getting the board layout finalized took some thought. Aside from not having to cut my harness, I also wanted to be able to make changes to the ECU connections quickly and easily. To accomplish this I decided to use headers and jumpers. The pic below does a little more to explain how i will make the I/O connections to either the OEM ECU, M150, or both. Slowly I will remove all control away from the OEM ECU and give it to the M150.
This pic does well to show what the physical layout of the PCB is.
I'll likely spectate this thread as I never thought anyone would put the money into a Motec on this forum. I've seen a Motec M130 in person, including initial setup and tuning on another car, and I'm impressed!
Just a quick test fit of the board inside the enclosure.
Now back to soldering on the back side of the board. This picture hopefully does well to show you how the wiring on the back side of the board works.
And finally got all the soldering done. Great care was taken to ensure adjacent pins were not soldered together (short). Took a while and things got pretty harry quickly, but I am pleased with how it turned out.
Soon it will be time to plug it in line and try starting the car!
I haven't made as much progress over the last week as I wanted to. Anyway, I decided to try making a vid. It is pretty much a recap of what I've done so far with a test run at the end using the PnP box! I want to get better talking on cam so I think I will be doing more of these in the future.
I have some additional items on order which i hope will be arriving soon. I'll be out of town next week, so hopefully when I get back on the 19th all the rest of the stuff will be here and I can get going again!
I am waiting for some Bosch igniters to arrive along with some additional wiring supplies/connectors to make up two wide band O2 looms. Looking like there might be a chance of it showing up on my door step early/mid April hopefully.
I am also trying to see if MoTeC will characterize the stock fuel injector so that my VE table will be something meaningful (actual airflow through the motor) instead of just a number that gives me my target AFR. If MoTeC agrees to do it for me then that will mean sending an injector off to Australia. If MoTeC wont do it then I'll be getting a set of either ID1000s or 1300s depending on fuel rail fitment limitations.
In the mean time I finished up a resistor box which is designed to simulate injectors and ignition coils. First thing I'll be doing is taking over control of fuel and spark and the Delphi is obviously going to throw a fit when I try to do that. This box will hopefully keep it happy and give it the false sense it is still firing injectors and coils when in fact it is not. There are 6 each 12 ohm (12Watt) resistors and 6 each 1 ohm (20Watt) resistors on this board. Might need to integrate a cooling fan as well...
I also completely finished up the PnP box. It needed a good seal where the loom passed through the wall of the enclosure. Got the fiberglass and resin out and went at it. Here is the result.
Hang in there! Ill get this M150 integrated eventually! Just want to make sure I do this right. No short cuts!
Still waiting on the Bosch igniters to come in. They are on a pretty bad backorder it seems with Bosch. Once the order shows up I'll have a bit more wiring to finish up and then I can get on with it.
MoTeC Australia has agreed to characterize the OEM fuel injector for this car. So, I ordered an extra and shipped it off. It will be a month or two turn around time but worth the wait. What this will mean is my Volumetric Efficiency (VE) table will be an accurate representation of airflow through the motor instead of just a "number" to get me my target AFR. I think it will be nifty to look at air flow through the motor as a function of the cam position (both intake and exhaust). Maybe we can use this to define new cam lobe profiles...who knows.
Just wanted to let you all know this project is still on my front burner.
I have had a request to make another interface box. For now I just need to make sure its going to work the way I have envisioned it before I entertain making more for others.
The Bosch igniters are finally here and I have started working out more of the wiring. I also made some changes to the resistors in my resistor box and added some fans to aid in cooling. Its pretty crude...but fingers crossed that it will work out.
Also, MoTeC characterized the stock injectors for me so now I have all the proper injector data to enter into the tables in M1 Tune. This was an early surprise for sure! I didn't think I was going to get this till end of June at best!
I am also traveling to some training classes at MoTeC East coming up first part of June to accelerate my orientation to M1 Tune and M1 Build.
Will be welding in bungs for the O2 sensors soon and then I think everything will be game on for getting the M150 installed! Still lots left for me to learn and figure out. The training in June is really going to help.
Hopefully I'll have more to share more often now that all the hardware is here!
I'd like to do the same thin when I swap engines, but I prefer Stack to Motec - Motec is FAR more common, and I'm extremely experienced with that telemetry format so I'm kindof torn - Sub'd!
Fantastic work! Professional quality start to finish.
Recently I have been tied up with other commitments and this project has been pushed to the back burner. However! I am back on it once again and hope to make some progress rest of this week and through the weekend.
This evening I was able to PicoScope the car and pick off Crank, Intake Cam, Exhaust cam, and Cyl#1 pressure trace (primary bank). I have just sent this log file to MoTeC Australia so they can start making a Reff/Sync mode for this engine. Once Australia sends me the Reff/Sync Mode it will then be uploaded to the tuning software so the M150 will have a trigger pattern to compare incoming crank/cam signals against. It will then constantly compare the crank/cam signals against the known trigger pattern and calculate the rotational position of the engine.
I have also spent a fair deal of time characterizing the OEM sensors and filling in the appropriate tables in the tuning software. Still some work left to be done in this area. I think Ill do another dedicated post later describing how I have been tackling that part of the project.
More parts are going to show up this week Wednesday and Thursday. I bought a Dual Lambda to CAN module for the O2 sensors. I also have a fuel pressure transducer coming. This car does not have a fuel pressure transducer stock. The fuel model in the M150 required fuel pressure to be known so I will be installing the transducer up near the fuel rails. Most of you probably know for this car the fuel pressure is regulated back in the tank and dead headed at the fuel rails.
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