ZS Controller Install Issues

[les666]

So I am having a few issues with installing my ZS Controller. All of the wiring is done, I have checked and checked and it\'s correct as per the the manual but for some reason when I power up the unit I get cel\'s 62 Exhaust valve solenoid (vacuum) & 65 Differential pressure sensor. The check engine light turns off when I power down the controller. Also, I don\'t know whats going on but the exhaust control valve opens when I turn the controller on which I think is the reason why I\'m getting these codes. Does anyone know why this might happen? Oh yeah car is a 94 BG5A auto. ECU is a T5. Any help would be appreciated!

[Rosssub]

Have you got the dip switches set correctly?

http://download.robson-brown.co.uk/uklegacy/zerosport/01switch.jpg

http://download.robson-brown.co.uk/uklegacy/zerosport/index.html

[les666]

Yeah dip switches all set properly. Have even reset the controller. I think next step will be to refurb the BBoD and find a replacement pressure sensor...

[Rosssub]

Was everything working fine before the controller install?

[les666]

Yeah was working sweet before hand maybe vod was a bit long. Everything runs normal with controller switched off.

[Rosssub]

Can only be a wiring fault then, Do you have the right ECU pinout guide? Double check which pin is for the ECV negative pressure solenoid?

Going off My BH5 info, about to do install my self.

Wire numbers from Z/S controller:

Wire 6 (grey wires) = Differential pressure sensor

Wire 7 (blue wires) = Intake valve solenoid

Wire 8 (brown wires)= ECV negative pressure solenoid

Wire 9 (yellow wires)= ECV positive pressure solenoid

You must have womething wrong or backwards where these wires are.

[les666]

Yeah I have checked all of the wires multiple times. I have been using this https://dl.dropboxusercontent.com/u/15954835/ECU_Pinouts_BC5-BG5a-WRX_4plug.pdf to check the pins and this was emailed to me earlier from a UK Legacy dude https://dl.dropboxusercontent.com/u/15954835/Zero%20sports%20translation.doc plus I have the original japanese install manual. Maybe the controller is bung?

[Rosssub]

Those diagrams dont match up at all. ZSC wire 6 (grey wires) are going to ecu pin 7 which is \'RxD\', ZSC wires 7 (blue wires) are going to ecu pin 14 which is \'Brake switch\', ZSC wires 8 (brown wires) are going to ecu pin 13 which is \'Static test mode\', ZSC wire 9 (yellow wires) are going to ecu pin 12 which is \'Lead/read memory connector\'.

So you must have the wrong ECU pinout diagram.

The way you have it wired ZSC wires 7 (blue) that want to control your Intake Air control valve are hooked up to your brake lights...

[les666]

12 pin plug is in the third column... I think you are looking at the 16 pin plug...

[Rosssub]

No, pin 12 in second colomn. ecu pin 12 is lead/read memory

[Rosssub]

Ah one of the diagrams is completely backwards and needs to be reversed.

The ZSC diagram is looking at the loom plug face

The ECU pinout diagram is looking at the ecu pin face not at the ecu loom plugs face.

So you need to mirror image the ecu diagram for it to all work.

[les666]

Yeah I figured that out. So the wiring seems to be correct and no cel\'s until I turn the power on to the controller. So I kind guessing faulty controller? as I have reset the controller via the wee button behind the face plate. Maybe if the controller is on when I turn the car off, leave car battery disconnected for the day to reset ecu and maybe the ecu will see the readings as normal or within range and adapt? Or does anyone in Timaru have a controller I test this with?

[Rosssub]

Which ecu pin have you got the brown wires connected to? ECU pin 10 in third colomn?

Also where you cut ecu loom wire from pin 10, did you connect the brown/white wire to ecu side of cut and the solid brown wire to the loom side of cut?

[les666]

Yip all wires with white stripes are heading to ecu. Brown wire is connected to pin 10 on the 12 pin plug so both exhaust valve solenoid wires are wired in correctly. I just tried resetting the controller via the black button behind the face plate and to check that it was resetting I adjusted the crossover points and nothing changed. Anyone know if there\'s more to doing the reset than merely pushing that button?

[Rosssub]

Maybe it\'s like a modem reset and needs to be held in for 5 seconds +???

[Marky]

http://www.uklegacy.com/forums/index.php?showtopic=115371

This fulla reckons its normal for early bg to just have a permanent cel with as controller?

That said he also suggests shorting the battery to reset the ecu as well

F knows

The code makes sense at least - that\'s one of the signals it\'s messing with

I can offer no help whatsoever other than either it\'s wired wrong or the thing is busted

Give up now, just give it to me, I\'ll give it a good home in a loving environment

[les666]

Yeah alot of the UK guys reckon they have the cel all the time but a few of them say that the light turns off and that their cars don\'t go into limp mode. I dunno? I\'m quite determined to figure this out though!

[Marky]

http://www.uklegacy.com/forums/index.php?showtopic=8561&st=80

Try fiddling the dip switches to or from auto/manual maybe

Lots of the guys on there saying they just sporadically get a cel but the code is permanent even if the light isn\'t there

Seen it written about a second earth needed on autos too

[les666]

Yeah I could try adding a second earth. I thought that was just for the B\'s & C\'s autos but I\'ll give anything a bash but probably not till tomorrow though.

Oh and will take a more organised approach to the dip switches as I have only switched them up and down in no real order.

[les666]

So I\'m still yet to sort out the code 62... Oh well... I\'ll get to it at some stage. Have checked all of the wiring over and over and still at a loss. Have read that it may be a short in the wiring but wouldn\'t that mean that the cel comes on when the controller isn\'t running? I\'m not in any real hurry to sort it cos this was waiting for me when I got home from work today...

[Rosssub]

When you spliced wires 1-5 into the ecu loom did you solder or use easy splicers?

[les666]

Yeah I soldered lines 1-5 in but used bullet crimps between the soldered splice and controller. Will check their connections to make sure. Hopefully the issue lies there...

[Rosssub]

Have you got a good multi tester? Check for resistance (ohms) between soldered join and the main Z/S loom plug, should be 0 resistance. any resistance indicates a brake in continuity or broken circuit.

[les666]

So yesterday I busted out my multimeter and checked all wires and continuity was sweet. No breaks at all in any of them. So I\'m guessing something is up with the controller itself... It would be good if someone in Timaru, or even between Ashburton and Oamaru had one I could plug in to make sure though...

On the up side though, I got around to putting in the Prova 8C and so far it seems like a small upgrade. Haven\'t really given it heaps yet, will give it a couple of days but first impressions seem to have a little more torque before coming on to boost and preparatory mode seems to have shifted about 200 revs higher. I haven\'t put it through to full twin mode yet so still yet to see how vod is affected.

[Daaliso]

I installed my ZS controller last month on my 02 BE5D with no issues, and 2 days ago the car wouldnt start. Let it rest for few seconds, started the car and got a CEL. When the CEL was on, the controller wouldnt turn on. I had to manually turn the ZS controller off by switching car off shutting down the ZS Controller when the key is on the ON position. car is running sweet with no codes for the time being for the time being.. I\'ve got a Prova ECU aswel, not sure if its fighting the controller :-\