Vehicle Installation Notes

Document Number DVIN0001

Title VW Beetle RSi
Approved By
Revision Date Prepared By Change History
Draft 18/08/2003 MM

Introduction
This document outlines the installation of an M800 ECU into a 2000 VW Beetle RSi. The Beetle RSi was
a limited edition car that had a VW Bora/Golf 2.8lt narrow angle V6 and 5 speed gear box. The
engine has a 15 degree bank angle but the crank shaft is constructed in a way that it is an even
fire engine (no odd fire TDC’s required). The engine has a switched position inlet cam shaft and a
fixed exhaust cam. The intake manifold has two flow paths with a flap arrangement that is
controlled but an electric over vacuum solenoid.

The installation needs to be piggy backed due to the factory dash board being controlled by CAN.
There are six wires going from the ECU to the dash and it is unclear as to what each does (one pair
is obviously CAN Hi and Lo). It must be stressed that this installation was on a race car which had a
few road systems removed (ABS, SRS etc) so it is not entirely certain what error codes this installation
will cause on a road car.

Plans in the off season are to find out if the tacho runs off the CAN of via a separate signal wire. If
the RPM is a separate signal the tacho will be run from an output from the M800 and the factory
ECU will be removed.

Parts required
Quantity Description Part Number Notes

1 M800 ECU 13001

1 34 pin M800 connector 65044

1 26 pin M800 connector 65045

1 VW/Audi ECU header plug Supplied by customer

1 VW/Audi ECU plugs Supplied by customer

1 M800 D9 comms cable 61036

1 6 pin DTM (F) 68056 external Lambda

1 LSU 57004

M800 Start up file

Available from the Intranet – VW Beetle RSi VR6 Start up.e21

© Copyright – MoTeC Pty Ltd Page 1 of 6

Reproduction in whole or in part is prohibited without written approval from MoTeC Pty Ltd.
MoTeC Pty Ltd DVIN0001 VW Beetle RSi

ECU Wiring
M800 pin OEM Description Comments Wire Colour
A1 117 AUX 2 DBW motor cut Grey
A2 5V ENGINE
A3 102 IGN 1 Cylinder 1 and 6 cut Orange
A4 94 IGN 2 Cylinder 5 and 2 cut Yellow
A5 103 IGN 3 Cylinder 3 and 4 cut Green
A6 IGN 4
A7 IGN 5
A8 IGN 6
A9
A10 1 GROUND Splice Black
A11 2 GROUND Splice Black
A12 8V ENGINE POWER
A13 8V AUX POWER ALSO SPLICE INTO CAN PIN 8
A14 84 TPS TP1 cut Green
A15 26 AT Splice Brown
A16 92 TPS TP2 cut
A17 93 ET Splice Violet
A18 118 AUX 1 DBW motor cut White
A19 96 INJ 1 CYLINDER 1 CUT Black
A20 97 INJ 2 CYLINDER 5 CUT Yellow
A21 88 INJ 3 CYLINDER 3 CUT Green
A22 89 INJ 4 CYLINDER 6 CUT Red
A23 115 AUX 3 Cam solenoid cut Grey
A24 104 AUX 4 Intake solenoid cut Brown
A25 29 AV 5 MAF Orange
A26 3 12V POWER Red
A27 112 INJ 5 CYLINDER 2 CUT Blue
A28 113 INJ 6 CYLINDER 4 CUT Purple
A29 INJ 7
A30 INJ 8
A31 AUX 5 Lambda heater
A32 AUX 6
A33 AUX 7
A34 AUX 8

D9
M800 PIN D9 PIN DESCRIPTION OPTIONAL CAN CABLE.
B23 1 Can HI PIN 5 WHITE OR YELLOW
B17 2 RS232 TX
B18 3 RS232 Rx
B14 5 0V COMMS PIN 1 BLACK OR BROWN
B24 6 Can LO PIN 4 GREEN
A13 8 8V AUX POWER PIN 3 RED OR WHITE

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MoTeC Pty Ltd DVIN0001 VW Beetle RSi

B CONNECTOR
M800 pin OEM DESCRIPTION COMMENTS Wire Colour
B1 90 REF Splice White
B2 86 SYNC Splice Grey
B3 AT 1
B4 AT 2
B5 AT 3
B6 AT 4
B7 AT 5
B8 DIG 1
B9 DIG 2
B10 DIG 3
B11 DIG 4
B12 LA2S
B13 LA2P
B14 0V COMMS PIN 5 ON EXT CAN
B15 0V AUX POWER
B16 0V ENGINE
B17 RS232 TX
B18 RS232 Rx
B19 AT 6
B20 AV 6 External MAP Orange
B21 34 AV 7 TPD1 Blue
B22 35 AV 8 TPD2 Violet
B23 Can HI PIN 1 ON EXT CAN
B24 Can LO PIN 6 ON EXT CAN
B25 LA1S
B26 LA1P

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MoTeC Pty Ltd DVIN0001 VW Beetle RSi

Some external sensor connections may be added upon customer request. Lengths for the adaptor
loom maybe specified by the customer.

It is recommended that the DBW motor and ref /sync wires are made with shielded Tefzel as it was
noticed that in early testing the DBW motor could induce noise on the ref that was read as RPM
even when the engine was not running.

Sensor Calibration
The sensors that needed to be calibrated were the air temperature and coolant temperature. It
must be noted that the air and water sensor calibrations below are for sensors piggy-backed into
AV inputs on an M800. Resistive circuit type sensors (temperature sensors usually) cannot be spliced
into AT inputs due to the internal pull-up resistor in the M800, splicing into an AV eliminates this
problem although a custom calibration has to be made with the sensor attached to the complete
vehicle loom.

The air temp sensor is contained in the MAF sensor.

Air Temp calibration

Temp -50 -40 -30 -20 -10 0 10 20

A/D 770 730 700 660 605 552 505 467

30 40 50 60 70 80 90 100 110
411 367 308 227 178 153 138 130 122

120 130 140 150 160 170 180 190 200

114 106 98 90 82 74 66 58 50

Water Temp calibration (AV piggy-back)

Temp -50 -40 -30 -20 -10 0 10 20

A/D 1510 1420 1270 1100 900 665 505 472

30 40 50 60 70 80 90 100 110
364 282 219 180 136 98 77 68 59

120 130 140 150 160 170 180 190 200

50 41 32 23 14 5 4 3 2

The MAF sensor was not put on a flow bench to determine an exact calibration. The MAF
calibration was simply done as a linear calibration of 0-100g/s. The MAF sensor and MAP sensor will
sometimes go into error when the throttle is closed due to the engine pulling lots of vacuum and
the sensor going below the minimum A/D counts.

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MoTeC Pty Ltd DVIN0001 VW Beetle RSi

General Setup Menu

Main Setup
Name Abbreviation Value

Injector Scaling IJPU 20

Injector Current IJCU 0.0

Injector Battery Comp Ijbc 4

Efficiency Calc Method EFF 1

Load Calc Method LOAd 1

Load Sites Selection Ld S -1

Number of Cylinders CYLS 6

Ref / Sync Mode rEF 17

Crank Ref Teeth cr T 60

Tooth Ratio Tor 42

Crank Index Position criP 77

Ignition Type ign 1

Number of Coils COIL 3

Ignition Dwell Time dELL 3.0

Ignition Delay Time dLY 40

Name Value

Ref Type 2

Ref Edge 1

Ref Filter 0.5

Ref Trigger Level 1.0

Sync Type 1

Sync Edge 1

Sync Filter 2.0

Sync Trigger Level 0.0

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MoTeC Pty Ltd DVIN0001 VW Beetle RSi

Drive By Wire Motor

The VR6 motor uses a Bosch Drive By Wire throttle. The DBW motor is a Bosch 0 205 003 053 and is
characterised in drawing D01.

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