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Post Info TOPIC: Analysing and testing the 8V Tracker, Sidekick and Vitara ECUs


Guru

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Testing the 8V Tracker, Sidekick and Vitara ECUs
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After quite a break I've been working on the 8V ECUs again and I've refitted the Ostrich into our 8V Vitara test vehicle for some further tuning work. This ECU is a later 8V with an EPROM memory as standard

The Ostrich fitted to the ECU, the header plugs into an IC socket in place of the stock EPROM, a loop of lacing cord helps to keep it in place:

 

Ostrich 2 on Vitara 8V ECU

 

There is just enough room for the cable to come out between the halves of the case:

Ostrich emulator cable

The emulator is stuck on the side of the ECU case with some double sided tape, the cable has since been replaced with a shorter cable for a tidier installation and better signal integrity.

Modified Vitara ECU

The ECU was then refitted to the Vitara:

Ostrich emulator fitted in Suzuki

The laptop was then hooked up, the Ostrich has a battery backup so the vehicle will run without the USB connection. TunerPro can be used for live tuning and one of my SDL interfaces is used to provide the live data stream.

scanning with TunerPro

 



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

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We were able to spend a few hours on this project yesterday using the Ostrich emulator, TunerPro, an SDL interface and the logic analyser to trace software execution

We were able to confirm/determine the functions of a number of the tables and also the function of a number of the processors internal registers as well as to map the temperature sensor raw data against the logged temperature.

Known table locations include:

Base Fuelling table (16x16)

Base ignition advance table (12 x 16)

Injector PW battery compensation

Injector PW additional battery compensation for low volts

Ignition timing high coolant temp retard (above 88C)

Ignition dwell time compensation for battery voltage

WTS linearisation table

IAT linearisation table

EGR temp sensor linearisation table

Taget Idle

VSS scaling constant

 

Our knowledge of this ECU is now even greater than it was before.

 



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Senior Member

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Posts: 201
Date:
Reverse Engineering the 8V Tracker, Sidekick and Vitara ECUs
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Great work James - I haven't seen that much 30ga kynar since I quit NCR back in '85.



-- Edited by fordem on Saturday 17th of December 2011 02:11:19 PM

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Guru

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Here is a picture of the board without the test equipment fitted:

MH6111 flash conversion

There is no window on the memory chip because it is a Flash memory device. The board is obviously only suited for bench testing but I'm very pleased with it, I'm sure its the first Flash based first generation Vitara ECU in the world.



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

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Posts: 1187
Date:
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The daughterboard is now up and running and tested with the Ostritch Emulator. Now I can hook it up to my test set and start to do some testing with TunerPro.

MH6111 with Ostrich emulator



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

Status: Offline
Posts: 1187
Date:
Testing the 8V Tracker, Sidekick and Vitara ECUs
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After spending a couple of hours checking the wiring we plugged in the daughterboard, added a couple of wires to the ECU for power and connected one of our SDL Interfaces.

MH6111 plug in

After a little debugging we were able to begin some thorough analysis, running the ECU while monitoring code execution and recording diagnostics

MH6111 code trace

 

MH6111 reset code

 



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

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Posts: 1187
Date:
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A prototype daughterboard was hand made with sockets for the processor, port expander and memory

MH6172 daughterboard



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

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Posts: 1187
Date:
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A few hours were spent tracing through the PCB some more to ensure that all the connections to and from the processor and the buffer IC were correct. Then it was time to begin designing a daughterboard to replace the processor and add external memory. Look what arrived in the post:

 

MH6111 riser

 

This is taller than a production board would use but this is for a rough and ready daughterboard for development so we anted to have some access to the PCB beneath to allow access to measure some signals

DSM adapter

 

 



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

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Posts: 1187
Date:
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Now was time to connect up some special engineering tools:

MH6111 hacking

 

 

The Ostrich allows me to perform code modifications directly from my PC, the Logicport logic analyser lets me watch the code execute and is invaluable for debugging and code verification. Below is a trace of some test code running:

 MH6111 hacking

 

This setup was used to determine which processor pin corresponds to which port or function by running test code that toggled each port bit or function individually while the pins were monitored with an oscilloscope



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

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Posts: 1187
Date:
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We didn't find any of the software tools available for these processors to be particularly user-friendly so we created our own. An Integrated Design Environment (IDE) incorporates a text editor, disassembler and assembler. It works well enough to produce a simple listing of the software:

 

RhinoPower IDE

Here is the initial disassembly with a few comments inserted. Once the software is reasonably well commented its time to start running tests on the ECU. These ECUs need to be modified before we can 'look' inside them.



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

Status: Offline
Posts: 1187
Date:
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The 1991-94 8V Track/Kick/Vit ECUs use the same firmware (either E034 or E900) but the ECU type is configured using four resistors, R300-R303. Knowing the functions of these resistors allows us to create the correct replacement ECU for a vehicle from any compatible 8V core

33920-56B30 config






__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

Status: Offline
Posts: 1187
Date:
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The early 8V ECUs have no external EPROM as standard, this means they cannot easily be read or reprogrammed. To be able to access the software we desoldered the processor from the PCB and fabricated an adapter to fit in our old  ROMReader PCB:

MH6111 ROM reader PCB 

 

 



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.



Guru

Status: Offline
Posts: 1187
Date:
Analysing and testing the 8V Tracker, Sidekick and Vitara ECUs
Permalink  
 


To be able to repair ECUs effectively and efficiently we often carry out a number of experiments to analyse both the hardware and software. The 8V ECUs fitted to the 8V Sidekick, Trackers and Vitaras contain a number of devices for which data is no longer available so a good deal of work has been put into properly understanding these units.

 



__________________

1984 Suzuki SJ413K pick up, 1.6 16V Baleno engine
2000 Suzuki Vitara 1.6 8V, many mods
2004 Suzuki Ignis 1.5VVT 4Grip
2006 Suzuki Jimny 1.3VVT JLX+
and many more.

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