Luftmasse-Hitzdraht 2.2 ECU

For those of you not faint of heart, who believe the Volvo 480 should have more torque and horsepower, find all you need to know in here.

Moderators: jifflemon, coyote1980, Rachel

Post Reply
User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Fri Aug 02, 2013 1:50 pm

I’ve decided to start a thread on the Jetronic ECU found on the right-hand side of the driver’s footwell (in RHD cars anyway). That’s the one that controls fuel mapping.

The Jetronic that that lives in Pollution has a serial number 0 280 000 959.

edit: pictures of green label Jetronic ECU added below

Image

Image

The reason for starting this thread is…………Robou has done some fantastic work on the EZ210K ECU that lives in the centre console, among other things making the boost run higher and come in earlier as this unit controls boost for the B18FT, BUT I want to read the fuel map mainly to gain experience in how to do this and also to see if any useful changes can be made. EZ210K ECU from Ray le Otter is with a red label, serial number 0 227 400 194.

edit: picture of blue label EZ210K added below

Image

I have an S70 also with Motronic 4.4 management system modified by TME but that is a little advanced for me at the moment. If I gain some skills looking at the Jetronic I will hopefully be confident enough give Motronic Suite or Turbo Tuner a go for the 70-series engine management. Anyway I like DIY stuff here goes….warning: progress may be slow I’m just learning and don’t have lots of free time anyway....

First off a little info on Jetronic:

http://en.wikipedia.org/wiki/Jetronic

Volvo 700/900 series cars had similar systems although later cars were went up to 2.4 managment. Also some of the Porsche 928's had the same so we are in good company :hopping:

As stated in the link above "the most common variants are LH 2.2, which uses an Intel 8049 (MCS-48) microcontroller, and usually a 4 kB programme memory". This 4 kb memory is the bit I am interested in....an EPROM.
Last edited by jamesy12345 on Sun Aug 04, 2013 5:10 am, edited 2 times in total.
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

Robou
Knows an Aerodeck isn't a 480
Posts: 270
Joined: Sun Jul 08, 2007 11:34 pm

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by Robou » Sat Aug 03, 2013 12:00 am

Dream away......

Like you quote from the Wiki, the LH2.2 "usually" uses a 4K eprom, not all of them. And when you look inside, you will be very disapointed by only finding a few bytes, probably an address, but most certainly not a map. The eprom used happens to be 4K because at the time of manufacturing this could have been the cheapest solution, like in the EZ210K a 8K was used where less than 4 K were needed. For my mod I use a 16K, because a 8K is hard to get at.

The LH has practically no intelligence inside, most work is done by the MAF, the lambda sonde and the EZ210K, which sends the rpm signal and, via the bidirectional signaling between the two, indications decisive for he fuel mixture. The latter I used to develop the "eco" variant of my mod.

Most of the job is done in hardware by using the output voltage of the MAF, convert this to a frequency which is gated to the rpm signal and then pulses in relation to the airflow are made once per revolution. The only existing maps are in ROM and, as far as I could make out, only meant to correct some specific items in the engine design.

The title of your thread already indicates that most work is done by the MAF, especialy from 3000 rpm on. So manipulating its output may give you some experimental joy, but also louses up the design as such is not advised.
Too old to bother
480 Turbo midst '91

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Sat Aug 03, 2013 5:08 am

Hi Robou, thanks for info. Remember when I sent you photos of my Jetronic ECU by mistake…this got me thinking “what changes can made on the fuel side”. According to my information (from Google rather than first-hand), the LH2.2 ECU in some Saabs has an EPROM chip inside….not EEPROM but EPROM:

http://saabworld.net/f5/lh2-2-tweaking-diary-403/
http://www.futurlec.com/Memory/2732A-200.shtml
http://en.wikipedia.org/wiki/EPROM

Interesting to see that the last hexadecimal address in the 2732 is FFF. I’m sure the Motronic 4.4 has part of it that only goes to FF or 255 km/h. One for another day. Disappointing that there is nothing much to play with here. My plan was to attempt desoldering of the 2732 chip:

http://www.batronix.com/shop/soldering/ ... T852D.html
[according to Batronix, a A1259 hot air nozzle should be okay for DIP 24 chip]

read and maybe adjust whatever map was inside via some kind of programmer:

http://www.batronix.com/shop/programmer ... ammer.html
or
http://www.c-u-s.co.uk/willem-programme ... od_47.html cheaper, not USB

Then replace the chip in the board using a socket in case I get it wrong. Which is likely 

https://www.sparkfun.com/products/9095

Anyway, I am getting ahead of myself here, regardless of what is inside the box I have no idea whether any useful changes can be made. Do I need to go richer, leaner or like the small bear’s porridge, is it just right……

So I have a car that is pretty quick for a 400, 16 seconds quarter mile in Ray, Pollution is probably a little faster due to lighter weight. Thanks to the EZ210K ECU modified by Robou, over on the the VPC forum I am 15th in the quarter mile league table. OK there are not so many people in the ‘league’ but hey the competition in most cases consists of Volvo white blocks with large turbos i.e. stiff competition, so just to be placed I am happy and 0.6 seconds quicker than when the car was new 21 years ago!

Spare parts I have collected – a T25G turbo from a Nissan SR20DET, an M24 supercharger from a VW TSI engine, an M45 from a Mercedes something or other and a Nitrous kit from WON. What happens if I stick one of those onto a B18FT, I need to know if it will melt……I don’t have loads time for testing or a big budget for mods. Maybe even the fuel can be adjusted to get a little more out of the car without any adding any hardware…which is a nice thought but as above probably I am dreaming.

Unlike the S70 I have no OBD capability here to plug in a laptop and play Space Invaders. The Air/Fuel Ratio gauges for sale are worth about as much as the car, and the standalone engine management systems…$$$$..if I wanted to get a real fast quarter mile time I could just buy a GSXR1100 motorbike, get a longer swinging arm and install the nitrous on that, for less money. Not very practical where would the supermarket shopping go?

In the spirit of finding stuff out the hard way, DIY it is then:

http://www.scirocco.org/tech/misc/afgauge/af.html
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Sat Aug 03, 2013 7:28 am

As you guys know, the lambda sensor in the exhaust measures the oxygen content of the gases leaving the engine so a good way to tell is it running lean or otherwise. I’ve read bits and bobs about wideband oxygen sensors etc but we’re not talking about a Swiss watch here. Ideal ratio for emissions is around 14.7:1, but ratio for good power with forced induction or nitrous should be in the 12’s maybe up to 13. I have knock sensors I’m not scared….yet. The above link gives a guidance on how to make an Air/Fuel Ratio gauge, which I think is a good starting point to see if any useful adjustments can be made. According to the link for 12:1 I should be heading for 0.97 volts at wide open throttle WOT although that is on a VW so the values given may not be applicable at all here.

So those are my goals of sorts – what is the fuel ratio now at WOT, can it be usefully adjusted and if so, how. I know that disconnecting the oxygen sensor will enrich the mixture and that is about the extent of my knowledge :). Thinking about it, it would probably be a good idea to get a new sensor just in case.

https://en.wikipedia.org/wiki/Oxygen_sensor

For the AFR gauge some of those part numbers I couldn’t find, so I looked for the equivalent on RS Components who are pretty well known and have a UK website…shopping list and wiring diagram…

Image

http://uk.rs-online.com/web/p/linear-vo ... 424F544826

http://uk.rs-online.com/web/p/led-displ ... 424F544826

http://uk.rs-online.com/web/p/led-displ ... -_-2473107

http://uk.rs-online.com/web/p/through-h ... s/7549026/

http://uk.rs-online.com/web/p/through-h ... s/7077701/

http://uk.rs-online.com/web/p/matrix-boards/1004340/

http://uk.rs-online.com/web/p/trimmer-r ... s/3746917/

http://uk.rs-online.com/web/p/trimmer-r ... s/3747083/

(the last variable resistor above is for changing the rpm limit on my S70 auto box……:)……another one for the future)

http://volvospeed.com/vs_forum/topic/14 ... velopment/
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Wed Aug 07, 2013 5:29 am

Interesting post here, it expands on what Robou mentioned above. Just working my way through it....

http://www.volvo-480-europe.org/forum/v ... f=3&t=4393
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Fri Aug 09, 2013 5:36 am

I downloaded a demo of WinOLS, and found some '.bin' files from various websites....including Volvo 700/900-series, Saab 9000 and Porsche 928s.

WinOLS is an application, which is written especially to modify the memory contents of ECUs.

It makes it easier to search and find maps, which can be named, displayed in several ways and be modified. All data and maps are stored in project files. These project files contain all information, which are gathered during the modification of the ECU. Additional data like customer name, license plate and pictures can be added.

Modifications of maps can be stored as 'versions' and can be commented. Up to 200 versions of one original file are possible.

All modified projects are shown in a list, which can be filtered and sorted. So it is easy to find an already modified project again.


[from here http://www.evc.de/en/]

Info on Binary files...http://en.wikipedia.org/wiki/Binary_file

Wow this hex editor stuff is not easy to use. I am just trying to get to grips with finding maps. There is an way to automatically detect maps so I thought I better start with something that actually had a map inside like a Porsche 928 EEPROM. I found a schematic of the internals of a 928 LH ECU on the Rennlist website....it shows that LH2.2 ECU in this particular model/year had a 27C128 32 Kbit/4KB EEPROM. A little more computing power than Ray le Otter I think.

Currently looking for WinOLS tutorial (for dummies :)).....
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Wed Sep 04, 2013 8:32 am

Oh dear, I opened up the Jetronic ECU from the Orange Blossom Special (purple label) and found no EPROM inside!!

So as discussed above - no fuel map! Look at the difference between a Porsche 928 LH-Jetronic 2.2, and the Volvo 480 version - one of our chips is missing!!

A 928 board with a socket for an EPROM socket soldered in the top right corner:

Image

My board from Volvo 480:

Image

Some discussion on the differences....http://forums.rennlist.com/rennforums/9 ... ments.html

The point of my thread was to find out a little more about the LH side of the Volvo 480 engine management but also to try and make some adjustments in the event of, for example, a large turbo being fitted. It's a shame that I can't experiment futher with even just reading of a fuel map but anyway it may be possible to do something else....

What have we got then....pins are numbered below:

#1 - Engine speed signal from ignition ECU
#2 – Coolant temperature sensor
#3 - Throttle position switch (throttle closed)
#4 - Signal Drive 'D' position??
#5 – Grounds injection ECU and screening cable for oxygen sensor
#6 – Signal ground connection for mass air flow meter
#7 – Load signal from mass air flow
#8 – Sends control signal to mass air flow for burn-off
#9 - Power supply from system rely
#10 – Controls the inlet air control valve
#11 - Grounding point
#12 - Throttle position switch wide open
#13 – Grounds power supply to injectors
#14 – Receives reference signal for CO-adjustment at idle for mass air flow meter
#15 – 12 volts
#16 - Raising engine speed for AC
#17 - Pump relay (grounds master rely when engine speed higher than 45 rpm)
#18 – Battery voltage
#19 – FT engine: water pump relay
#20 - Oxygen sensor
#21 – Grounds system relay
#22 - Oxygen sensor test point
#23 - Controls the inlet air control valve
#24 – FT engine: pulse to EZ 210K for load
#25 - Grounding point, power ground

Lot's of interesting stuff there from a diagnostics point of view.

Pin number 20 stands out as an obvious choice for fiddling. If a lower voltage of say up to 0.4 volts is applied to this pin, then the ECU reacts as if the mixture is lean so adds a little fuel. If a voltage of between 0.6 and 1 volt is applied then the ECU will think that the mixture is rich, and adjusts the injection pulse accordingly via the output from pin 13.

This voltage comes from the oxygen sensor, so thinking about it there are a few different ways to vary the voltage going into pin 20. There is some risk to running lean and overheating or, less seriously, going the other way and damaging the cat.
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Wed Sep 04, 2013 1:42 pm

Meanwhile, the AFR gauge is growing....

Image

A shot showing the LED bar display & controller, voltage regulator and 2x trimmers sat on a matrix board ready to be connected up.
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

Robou
Knows an Aerodeck isn't a 480
Posts: 270
Joined: Sun Jul 08, 2007 11:34 pm

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by Robou » Sat Sep 07, 2013 12:11 pm

The disappointment about the lacking of eproms was predicted. Most of the work is done in hardware. Fiddling with the output of the lambda sonde is not a good idea. One would need a voltage follower to avoid load, moreover the zirkonium sonde is not the most trustworthy type. The best would be to disconnect it, but the green LH then sets a fault code and makes the mixture richer, stops sending the load signal to the EZ which as a result retards the ignition. A red LH would react only by enrichening the mixture by 5% which can be compensated by manipulating the MAF. Also I stated that at over 3000rpm it is mainly the MAF output which makes the engine run, a change in the output of the sonde will hardly have any effect. So if manipulating is in order, the MAF signal would be the one to use. Two opamps, one as voltage follower, the other as attenuator/amplifier and screened wire will do the job. And if one is not extremely careful melt the pistons.

The Porsche 928 system has been developed quite simultaneously with ours, hence the similarities.

About the question marks concerning pin4:
At the introduction of the red ECU's the maximum boost was changed, and as a result power and torque. At starting, shifting in reverse and in case of an automatic gearbox this change was ignored by introducing 12 V at pin 4 of the LH, which normally is connected to ground by means of a resistor in de CEMIII. Later in 1991 Volvo for some reason decided to leave it be. As some French guys brought into practice the whole idea can be restored by cutting the wire to pin 4 and connecting pin 4 to ground, which is present on pin 5. The gain will be about 3HP and 25NM at no costs with all blue/green combinations and the red/red combinations after some date in 1991. Mind, the loom was changed, not the ECU's.
Too old to bother
480 Turbo midst '91

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Sat Sep 07, 2013 1:34 pm

Much appreciated for comments Robou! Yes, you did point this out above......:D

I know very little about....lots of things....but especially not much about MAF outputs, so I will read up on this. Starting with the document below, which gives a bit of info on how the oxygen sensor and MAF work together on more modern systems. It was useful for me anyway.

http://stealth316.com/misc/obdii_fuel_trim.pdf

So, by directing pin 4 on the Jetronic to ground I can have +25 Nm for my automatic??

:D

If so, Christmas came early :hopping:
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

Robou
Knows an Aerodeck isn't a 480
Posts: 270
Joined: Sun Jul 08, 2007 11:34 pm

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by Robou » Sun Sep 08, 2013 9:12 am

Yes, you will, provided my mod is not used. I doubt if it will make any noticeable difference then. The mod was developed whith pin 4 connected to ground.
I strongly advise to cut the wire though, as I am not sure what changes were made to the loom. It could very well be that for some reason at some circomstances 12V is present on the circuit causing a short. Looms appear in all kinds and sorts and hardly any diagram can be trusted.

I am very suprised that so little people know about this modification. It is easily accomplished, for free and gives a considerable gain. Rumour says that Volvo withdraw it because of the bad quality of petrol in some markets, so a Dutchman reported. Well, things have changed in the meantime.
Too old to bother
480 Turbo midst '91

User avatar
jamesy12345
480 Veteran
Posts: 753
Joined: Tue Apr 03, 2012 5:49 am
Location: Durham, England

Re: Luftmasse-Hitzdraht 2.2 ECU

Post by jamesy12345 » Sun Sep 08, 2013 12:58 pm

Aha so this +25 Nm is within the figures for your mod rather than in addition to it. Very useful to know, thanks for confirmation and info.
Current:
Volvo S60 '04
Renault 21 '91
Subaru Legacy '05
Mazda RX-7 '93
Renault 5 '84

Previous:
440 2 litre, 440 Turbo, 460 Turbo, 480 Turbo x2, 854 T-5R, S40 T4, V40 T4, S70 T5 & R, V70 R x2, S60 R

Post Reply