[rusEfi] 2004 Mazda MX5 1.8 VVT #50

What engine are you torturing? Is it inside some car?
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2004 Mazda MX5 1.8 VVT #50

Post by Crazy Striker » Sat Apr 06, 2019 1:05 pm

Hi everyone !

I'm on the early beginning of my project to install RUSEFI on my 2004 Mazda MX5 equiupped with the 1.8 VVT.
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I received the Frankenso board last week as well as the ECU connector and nearly (fully ?) completed the board assembly, power supply works fine and so far no short circuits found.
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I just flashed the board and it seems to run fine when plugged on Frankenso, now need to test the crank and cam input before building the harness and the enclosure (probably 3D printed with aditional metal shielding).
I'm running SLC Free 2 lambda controller for Wideband and want to keep the possibility to put back the stock ECU to pass emissions (intendented for offroad use isn't it ?). I will make a dedicated harness for non stock functions like MAP sensor and WB02, and maybe one day e85 sensor (it is on the mail for now, as I designed an arduino based e85 flexfuel box).
I have a custom gauge made from an Arduino Mega and a small 1" oled screen to display WB02 but looking to implement CAN communication with RUSEFI in order to switch to a nano and not have to read analog signal through arduino.

For the base tune I was tempted to use the one posted on this thread viewtopic.php?f=3&t=1076&start=60, and to "soften" it a little bit by making it richer and putting a bit more ignition retard.

Will post my progression here and hopefully my car will run on RUSEFI soon enough.

EDIT :

Working :
- ECU power
- Fuel pump power
- Trigger
- Ignition
- Injectors
- MAP
- Wideband
- IAT
- CLT
- TPS
- VBatt
- Warm cranking
- Running engine in real conditions
- Alternator control
- Idle (still need some work on automatic idle)
- VVT
- Cold Start

TODO :
Mapping the ECU
Making a case


Gwendal
Last edited by Crazy Striker on Mon May 27, 2019 3:14 pm, edited 4 times in total.

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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Sat Apr 06, 2019 2:15 pm

Jut tested suppliying the board from 12V and STM32 boots up, with the ability to communicate to tunerstudio.
It draws about .1 Amp at 12V supply. Threfore i can't get the screen to light up or to display anything

Edit : it would probably work if I place the JP1 jumper ;)

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Re: 2004 Mazda MX5 1.8 VVT

Post by kb1gtt » Sun Apr 07, 2019 12:35 am

Picture of top side of board?

Did you populate the STM32, or are you using the discovery?

Take note that the DIY installs might have some problems with the contrast resistor. That commonly changes from MFG to MFG depending on where you got your LCD from. So if it seems to work, but does not show text, just FYI you might need to adjust R99 resistor. I put in an optional POT, such that if you install that POT you can simply adjust it. Normally this has a fixed resistor.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Sun Apr 07, 2019 10:22 am

Here is the top side
IMG_20190406_143630.jpg
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;)

I use the discovery so I don't know which one exactly I should populate and which one I shouldn't.
I will post a picture of the board without the discovery installed soon.
I think I should also start to populate the jumpers on top of the board, the cam and crank pullup ones for the hall sensors for example. I still do not really know if I should populate every jumpers.
For R99 I've got a pot with the board and the screen was also sourced with it (I ordered the parts from the Tindie store along with the board).
For the auxiliary harness with non stock functions, are molex 4 pin connectors any good ? I think it's the cheapest and most easily sourceable connectors for me.

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Re: 2004 Mazda MX5 1.8 VVT

Post by kb1gtt » Sun Apr 07, 2019 12:58 pm

Are you referencing MatNLok connector? I do not know your noted Molex connector. Generally crimp tools are the key problem with the connectors when used in low quantity.

About CAM / CRANK jumpers, what is your setup? VR, hall, other? Are you planning to use the MAX chip?
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Re: 2004 Mazda MX5 1.8 VVT

Post by russian » Sun Apr 07, 2019 1:03 pm

kb1gtt wrote:
Sun Apr 07, 2019 12:58 pm
About CAM / CRANK jumpers, what is your setup? VR, hall
mazda MX5 = Hall, we still use MAX because why not.
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Re: 2004 Mazda MX5 1.8 VVT

Post by kb1gtt » Sun Apr 07, 2019 1:16 pm

Do you understand JP04 and JP05?

Do you understand the jumpers note on the top of schematic page 9?
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Sun Apr 07, 2019 1:33 pm

I understand I have to populate the page 9 jumpers for pull-up on Hall sensor input, as well as using 1K pull-up resistors and no pull-down.
JP 04 and JP 05 provide the crank and cam signal to the STM32 so they sould be populated.
I hope i'm not doing a mistake :roll:
And for the connectors i meant Molex Mini or Microfit, through an auxiliary connection board
Image

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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Sun Apr 07, 2019 4:49 pm

Here are a few more pics of what I assembled so far
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Re: 2004 Mazda MX5 1.8 VVT

Post by kb1gtt » Sun Apr 07, 2019 7:24 pm

Nice job. Also remember to check your 5V before installing the W23. The slug on the U1001 is a bugger to heat with a hand held iron, when this fails your output goes to 12V instead of 5V. So only install W23 after you have verified that you have a proper 5V.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Sun Apr 07, 2019 8:01 pm

Thank you ! It was my first time soldering SMD so i'm pretty happy with the result. I've been pretty heavy handed with solder so it's not perfect though.
I already tested the 5V (got 5.08V) and it's supplying the board fine. Discovery powers up and communicate well when powered through BAT SW.
Is it really necessary to solder the slug ? Is it for thermal considerations ? I think for no its not connected to the pad but I can solve that.

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Re: 2004 Mazda MX5 1.8 VVT

Post by kb1gtt » Sun Apr 07, 2019 11:46 pm

Slug is a good idea. Most people do not use this to the full capability so the thermal can be less of a concern.

I recall the solder issue was with the feedback. When that fails the transistor never gets turned off and you get the 12 instead of 5v. If you have a proper 5v then this should be good.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Abricos » Mon Apr 08, 2019 12:16 am

check twice here !!!
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Re: 2004 Mazda MX5 1.8 VVT

Post by Abricos » Mon Apr 08, 2019 12:18 am

or not all 4 legs is one side ...

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Re: 2004 Mazda MX5 1.8 VVT

Post by kb1gtt » Mon Apr 08, 2019 12:25 am

While that solder joint is a bit less than elegant, the pads are all connected, so this bridge is not a concern. As long as it has flowed well and is not a cold solder joint, I do not expect any real problems from this joint.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Mon Apr 08, 2019 7:31 am

Thank you for the review. I tried to tidy up that solder but figured out all the pins were connected so I gave up. My phone is pretty handy to check solder joints. I've checked every joint by putting it under load and they seem okay.
Maybe I will use solder wick to remove some of the excess but it no n°1 priority

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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Mon Apr 08, 2019 5:11 pm

I've tested the LCD and menu displays well. I can also navigate through it.
I have finished populating the board and started the wiring of the connector. When reading documentation on the 2003 Miata, flybackdiodes are mentioned for powering VVT ans IAC due to their inductive characteristics. What diode should I use for them and should I put them on the board (don't think it's possible) or directly in the harness ?
I now have to find the ECU to try just sniffing the crank and cam signal while cranking. All the power terminals are wired on the connector so I cans let it run in standolone mode for this phase. Is it located under passenger feet or under dashboard on driver side ? (LHD car)?
Thanks and have a nice day.
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Re: 2004 Mazda MX5 1.8 VVT

Post by russian » Mon Apr 08, 2019 6:24 pm

You should have 1N4007 in the kit, two of them. It's technically possible to solder them on the back of the board behind the connector.

On my US 2003 the ECU is under the steering wheel.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Mon Apr 08, 2019 6:29 pm

Yes there were two of them in the kit. I didn't know if they were specifically designed for that.
Will look at my footwell tomorrow to locate the ECU. Are the cables easily reachable pour a first test ?

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Re: 2004 Mazda MX5 1.8 VVT

Post by russian » Mon Apr 08, 2019 7:01 pm

ECU placement is a bit annoying. You would have to bend to disconnect and rusEfi you be hitting your knees :( I have 10ft wires on my rusEfi for that reason.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Mon Apr 08, 2019 7:21 pm

:lol:
Maybe should I build a long harness in order to place Rusefi near the glovebox. Are they consideration to take in account when designing a long harness ? Things like twisting wires

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Re: 2004 Mazda MX5 1.8 VVT

Post by russian » Mon Apr 08, 2019 9:33 pm

Crazy Striker wrote:
Mon Apr 08, 2019 7:21 pm
Maybe should I build a long harness in order to place Rusefi near the glovebox. Are they consideration to take in account when designing a long harness ? Things like twisting wires
Mine just works, without any considerations. The fact that we have Hall sensor and do not use knock sensor yet probably helps.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Tue Apr 09, 2019 5:05 am

Okay so I will build a long harness and run knock sensor cables separately maybe on a shielded twisted pair
The maximum cable diameter for board holes seems to be suited for m0.75^2. what AWG are you running ?

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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Tue Apr 09, 2019 4:08 pm

I "stole" 7x1.2 meters (4 feet for our fellow Americans) of 4 core 0.5mm2 (20 AWG) industrial cable. Fire retardant and 80°c rating.
I will try to find 7 meters of lower gauge (18 1/2 or 0.75mm2) for power rails and ground.
I will solder the harness on Thursday afternoon and try it out after.
I'm pretty confident, maybe a bit too much, I'm too impatient 😁

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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Tue Apr 09, 2019 6:49 pm

I've just tested the low impedance outputs with my multimeter.
I have no problem getting a beep on the fan relay command but i'm unable to get continuity with the injectors output.
Maybe I was wrong on my test points but seems weird to me.
Do you have any advice to solve this issue ?
Thanks

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Re: 2004 Mazda MX5 1.8 VVT

Post by russian » Tue Apr 09, 2019 9:08 pm

Crazy Striker wrote:
Tue Apr 09, 2019 6:49 pm
I've just tested the low impedance outputs with my multimeter.
I have no problem getting a beep on the fan relay command but i'm unable to get continuity with the injectors output.
Maybe I was wrong on my test points but seems weird to me.
Do you have any advice to solve this issue ?
Thanks
"bench test" commands on TS or console should give you three beeps / LED blinks, have you tried those?
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Tue Apr 09, 2019 9:42 pm

I did not populate
LEDs, should I ? My multimeter is quite slow to react it may just be that and not a real problem

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Re: 2004 Mazda MX5 1.8 VVT

Post by russian » Tue Apr 09, 2019 10:40 pm

Crazy Striker wrote:
Tue Apr 09, 2019 9:42 pm
I did not populate
LEDs, should I ? My multimeter is quite slow to react it may just be that and not a real problem
It's really your call. You engine would run without LEDs :) You could be overthinking it? :) Wait till you can click real injectors.
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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Wed Apr 10, 2019 8:03 am

Yes you're right, it's one of my bad habits X)
Do you have a safe base tune to start my engine. I have found one in the forum for the VVT engine but I'm not sure about the good health of my motor.

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Re: 2004 Mazda MX5 1.8 VVT

Post by Crazy Striker » Wed Apr 10, 2019 5:49 pm

I don't know why but my ECU is located under my passenger side footwell, behind a metal plate. I'm pretty happy with that since there is a lot of extra room there for any kind of electronics and for an adapter board.
My stock install should be pretty similar to this. It's a picture taken on a 2003 VVT.
MX5SC009.jpg
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I will be able to shorten the harness to 50cm so that I have every wire needed

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