[help needed] W201 M111 Conversion (Hellen 128)

[AndreyB]

Just to recap:
problem: injectors do not click with bench test
GND path is a bit unclear
not rusEFI controls main relay

Usually there is a more clear wire at least for sensors ground. Is all your ECU ground via vehicle body?

I think we need a working reference point. Would you be able to temporary simplify the setup?

Simplest case would be if you can power ECU directly and wire one injector for test also directly to ECU if that's something you are comfortable doing. Once you have a working state and a not working step it would be time to start replacing fuses with jumper wires temporary?

[ML190E]

Yes all ECU grounds are to the vehicle body as the only thing connected to the negative terminal on battery is a ground directly to chassis.

I will wire ECU direct and then wire one injector directly also. Just so I'm clear do you want me to wire the ECU directly to the battery for power? Can I connect the constant 12v wire and the ignition 12v to the battery at the same time or will that cause an issue?

And then once ECU is powered hard wire the injector, am I right in thinking that the injector should have constant 12v to one pin and then the earth is supplied by ECU?

[AndreyB]

Yes all sounds right

[ML190E]

OK so hard wired ECU to both positive and negative supply From battery.

Hard wired injector 1 and gave it direct feed from batterynto one side and connected other side to ECU output.

Carried out bench test but injector did not fire, gave the injector negative feed from battery and it fires straight away.

Seems like ECU is unable to switch out the ground to injectors

[ML190E]

UPDATE - we have injectors firing the settings were incorrect in injection hardware settings.

Wrong outputs were assigned so once we corrected this we are now able to fire injectors using bench test function.

I have also now calibrated the pedal position sensor bit I keep getting a TPS error which I can't seem to figure out

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[AndreyB]

What does Jimmy have in his tunes https://rusefi.com/forum/memberlist.php?mode=viewprofile&u=1115 ?

[AndreyB]

Maybe minor improvement in default tune and maybe pin names should not mention injector numbers at all only ECU pin numbers like https://github.com/rusefi/rusefi/commit/b98eff38696d0da6e44bfac6395c2e7e2bfba66f

overall root cause: default tune is non existent, at some point once we have a reference vehicle more stuff would need to be hard coded. until then it's manually picking parts of Jimmy's tune

[ML190E]

So I reviewed a few of Jimmy's tunes and managed to use the settings to calibrate the TPS and also the trigger

Car fired up but only on 2 cylinders but we figured out the ignition settings and now have it on 4 cylinders. It's running and revving but not very well which is to be expected at this stage.

Next step is to start tuning the idle bit I definitely been to fit a wideband 02 sensor now to help with this. Is there a particular brand of sensor that you would recommend?

Thanks for all the help so far I'm delighted to now hear the engine run again on the rusefi

[AndreyB]

I am sorry that you are having a horrible support experience with rusEFI. Until a dealer steps in I should probably halt retails sales of these units.

I've just modified https://github.com/rusefi/rusefi/wiki/Hellen-128-Mercedes to mention that this board has on-board WBO controlled but again that would mean more of limited support pain. Maybe AEM?

https://github.com/rusefi/rusefi/wiki/Support#q-matt-and-andrey-are-on-facebook-shall-i-message-matt-or-andrey-directly

[ML190E]

Thanks Andrey

I'm certainly not having a horrible experience, I am enjoying the learning curve to be honest.

At the end of the day car modification isn't always easy and the advice both yourself and Jimmy have given so far has been brilliant.

If I buy the AEM sensor (which seem to be just Bosch sensors) should I wire it directly to the board or should I run a separate AEM gauge? I assume wiring it to the board will be better?

[AndreyB]

If I buy the AEM sensor (which seem to be just Bosch sensors) should I wire it directly to the board or should I run a separate AEM gauge? I assume wiring it to the board will be better?

I am sorry I do not understand this question. Please elaborate on what exactly do you mean by "wire to the board".

[ML190E]

The Hellen 128 has a plug on the board marked WBO which I assume is for Wideband

If I purchase a Bosch wideband sensor can I wire it directly to this plug and then use tunerstudio to see the Air/Fuel Ratio gauge or should I purchase a separate gauge and wire it to this?

[blundar]

https://github.com/rusefi/rusefi/wiki/Hellen-128-Mercedes

Hellen128 includes zero, one or two wideband controller modules onboard. You can tell if your board has zero, one or two modules populated by looking at the PCB. Looking at the picture above on Jan2-2021, only the right wideband section (WBO0) is fully populated. (the PCB section under WBO0 has all parts, the section under WBO1 does NOT)

It is much harder than "I can just wire a sensor to the white plug" but easier than "I need to buy a new controller and use it to run the sensor." In order to get this working, you're going to need to read the docs considerably more. While the Hellen128 is designed to take a lot of pain and suffering out of wiring, you're still going to need to use your head and read documentation to get it set up fully.

[ML190E]

https://github.com/rusefi/rusefi/wiki/Hellen-128-Mercedes

Hellen128 includes zero, one or two wideband controller modules onboard. You can tell if your board has zero, one or two modules populated by looking at the PCB. Looking at the picture above on Jan2-2021, only the right wideband section (WBO0) is fully populated. (the PCB section under WBO0 has all parts, the section under WBO1 does NOT)

It is much harder than "I can just wire a sensor to the white plug" but easier than "I need to buy a new controller and use it to run the sensor." In order to get this working, you're going to need to read the docs considerably more. While the Hellen128 is designed to take a lot of pain and suffering out of wiring, you're still going to need to use your head and read documentation to get it set up fully.

Thank you for your advice, my apologies for my lack of knowledge on thisas it is the first time I have ever attempted to wire up, configure and run a standalone ECU. I'm more accustomed to nuts and bolts than electrical wiring and circuit boards etc. I am willing to learn and generally capable of taking good instruction so I really appreciate everyone's help so far.

Seems like I've been a bit nieve as the ECU came with a small pigtail harness for the white plugs on the PCB for the wideband so I thought I could fit a sensor and wire it to this pigtail harness and plug it in.

I have a friend who is an electrical engineer who has been helping me along the way also so I will get him to review the documentation and see what he thinks.

Regards

Marc

[duhafnusa4]

any updates?

[ML190E]

So latest update is I have fitted a Bosch LSU 4.9 wideband 02 sensor

I've followed the wiring diagram on the wiki to wire the sensor to the wideband output on the board, with Jimmys guidance I have enabled the rusEFI can Broadcast and I have also enabled can wideband under EGO sensor. The only wire I don't have is the RCal as my sensor only has 5 wires and not 6 but Jimmy feels I do not need this

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The air/fuel ratio gauge is still not giving me a reading so that I can start to tune

Is there something else I need to do? Or is that 6th wire the missing piece that i do need

Marc

[AndreyB]

Please post a picture of the sensor. I would expect six wires.

[ML190E]

Part number I purchased is

0258017025

[AndreyB]

Feel free to not provide requested info. Feel free not to post picture of how you wired things. Feel free not to clarify how you dealt with sensor male plug and harness plug.

[AndreyB]

At the moment i wonder if calibration resistor from plug was cut or else.

[ML190E]

Feel free to not provide requested info. Feel free not to post picture of how you wired things. Feel free not to clarify how you dealt with sensor male plug and harness plug.

Originally I did cut plug off and wired my own male and female plug but was advised I needed the original Bosch connector so I wired it back on. I purchased a female connector for the Bosch plug and then wired it exactly as per the diagram above from the wiki. Only wire I don't have is the green one.

[AndreyB]

Six wires are required between ECU and female plug.

You are responsible for the green wire from ECU to female plug. Until I see a picture of your green wire between ECU and female plug there would be nothing else for me to do here.

Calibration resistor is inside the male plug on the sensor assembly. Because calibration resistor is inside the male plug there are only five wires between male plug and actual sensor.

[ML190E]

I've now wired the 6th wire (green wire on diagram but yellow on the actual loom/plug)

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[md_sanci]

Next to the wbo connector there should be a mosfet bts3028 that would enable sensor heater circuit.

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[md_sanci]

Next to the wbo connector there should be a mosfet bts3028 that would enable sensor heater circuit.

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Like this

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[AndreyB]

Ooooops that's my mistake

We need to either ship you the chip or ship your board for modification. I believe you are in Ireland? I would need Alex to help he is in EU as well.

[md_sanci]

Ooooops that's my mistake

We need to either ship you the chip or ship your board for modification. I believe you are in Ireland? I would need Alex to help he is in EU as well.

Yes, i can help, but we need feedback how should we do it, i send it out or i can rework the board.

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[ML190E]

Sorry just catching up with this now

Thanks for the input lads, I think I will get myself an AEM gauge and hook it up rather than sending the board away etc.

[ML190E]

If I run an AEM gauge can it input into the ECU to help with tuning etc?

[md_sanci]

If I run an AEM gauge can it input into the ECU to help with tuning etc?

If you plan to use as analog input, i can share how to modify the board. If it is can connection then it just config.

For board mods i need the board revision.

Maybe this will also help you
https://github.com/rusefi/rusefi/wiki/Hellen-128-Mercedes

Section add extra io

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