SEGR/ORM Kit Builder's Thread

calcrd · **Posted:** Mon Mar 10, 2008 12:06 am

I removed the 2 screws that hold the OBDII connector when taking off the panel below the steering column. As the connector hung loose I noticed it only had two wires connected to it, one red and one white. There were several other wires attached to the connector but it appeared that they had been cut. Is this normal ? I have an 06 CRD sport

Silverdiesel · **Posted:** Mon Mar 17, 2008 12:14 am

Everthing is fine Except:
Wires #1 and #3 were crossed sending 12V to Maf sensor output. I caught the mistake (mistake in the internal box wiring -had 1 and 3 crossed) but only after connected for a short time.

Does this 12v to output sensor wire for MAF hurt or damage MAF?

My CEL lite is now off after the fix but a "PD" code comes up on my scanner (A piliminary P0102 Maf output low).

So if I can ask, did I ruin the MAF or am I OK?

Roland

UFO · **Posted:** Mon Mar 17, 2008 12:24 am

Clear the code, and make sure the MAF is plugged in. If you keep getting the code P0102, you may have overloaded it - it's not designed to take 12V in the input.

Silverdiesel · **Posted:** Mon Mar 17, 2008 12:43 am

Hey thanks ever so much for a quick response!
I will probably replace MAF soon then- but CEL is off!!

Agian this forum has given me confidence to get enhancements and improvements on to this Jeep.

BTW I have not soddered since high school projects and I graduated high school in 1972!
But had fun doing that board and all those tiny sodder connections.
I am very proud to get this all done and working- chalk up another SEGR sucess story!

Roland

05infernoCRDL · **Posted:** Sat Apr 05, 2008 12:45 am

ok started soldering the two kits today... the 13K, 22K, and 1M resistors are not marked.

what are the colors of each?

*edit* shoulda had a beer for more liberal thinking... ITS ON THE BAG.... doh!

05infernoCRDL · **Posted:** Sat Apr 05, 2008 3:33 pm

here is a some pictures of the finished kit for those of you waiting for UFO to do yours...

new soldered no wires and with wires

and a comparison of the first two and the old finished kit

hope you are drooling in anticipation now :lol:

honey_don't · **Posted:** Sat Apr 05, 2008 3:41 pm

Thanks, those pics make me feel both lazy and hungry.

05infernoCRDL · **Posted:** Sat Apr 05, 2008 7:16 pm

Okay... This sucks... When I was finishing the second one, I kinda broke a circuit. It is the ground one. Right at the spot for the #6 hole.

My question is this... Can I solder some wire to bypass the part that broke and it still work?

I am on my mobile out and this is bugging me so I can explain more later.

Thanks in advance

05infernoCRDL · **Posted:** Sun Apr 06, 2008 3:59 pm

okay so i figured since it was broken anyhow i'd try fixing it...

i soldered a "jumper" wire from the places the wire was broken
to the next piece... the resistance on the box from power pin to
all other pins are the same as the other good one... i am letting
my old one cool down from the sun then i will test all three
against each other... the long and short is i think it is fixed... and
i'll keep that one for in my car so if something goes screwy i
know what it is and i can repair it again.

and the blurry pic..

UFO · **Posted:** Mon Apr 07, 2008 1:16 am

05infernoCRDL wrote:

Okay... This sucks... When I was finishing the second one, I kinda broke a circuit. It is the ground one. Right at the spot for the #6 hole.

My question is this... Can I solder some wire to bypass the part that broke and it still work?

I am on my mobile out and this is bugging me so I can explain more later.

Thanks in advance

Shouldn't be a problem. What happened to your PCB?

05infernoCRDL · **Posted:** Mon Apr 07, 2008 1:26 am

UFO wrote:

Shouldn't be a problem. What happened to your PCB?

hahah.... ummm... in my anal retentiveness, IN the box (which no one will see),
i soldered the colored wire for pin 2 in for pin 6... when i took the wire out (cause
the colors IN the box had to match outside the box :oops:

the hole filled and in my
inexperience i could not figure how to get it uncloged...

tried puting the correct wire at the hole and heating the solder up and push the correct
wire through.. no go... tried sucking it out with the wire by heating the wire up over the
hole... no go... so i thought i could knock it out with a punch :oops:

.. i knocked
it out alright.. the whole insert... so that is my story

i think i posted the blurry pic... i measured the resistance of my first box against the
other two.. my first attempt to fix the board failed.. so i took one strand of the wire
soldered it to the green cylindrical resistor... wrapped it around the #6 wire... then
went to a resistor on the other side of the board and soldered it there... then all the
resistances were in the same region.

i am going to run them to make sure before i install them in other's vehicles... i am
going to keep the patched one for myself..

another topic... do you think right behind the drivers headlight under the fuse box
is a good place to mount it... you can actually take the fuse box off the 3 posts,
mount the segr and put the fuse box back on and it is not seen at all

UFO · **Posted:** Mon Apr 07, 2008 3:00 am

05infernoCRDL wrote:

another topic... do you think right behind the drivers headlight under the fuse box
is a good place to mount it... you can actually take the fuse box off the 3 posts,
mount the segr and put the fuse box back on and it is not seen at all

That location sounds like you might save a lot of wire length. Just make sure the box will not get wet.

UFO · **Posted:** Mon Apr 07, 2008 11:56 pm

I built up a test box to dry run the latest SEGR kits and got some output measurements a bit outside of Turbo Tim's test procedure. The 4.0V measurement for my box (with the EGR signal high and the AFC signal low) is running in the 4.4V - 4.5V range. I realize this is not out of the range of the MAF input, if it really is a 5.0V signal, I'm just curious whether anyone has run a SEGR with such a mismatch between the input and output?

I'm pretty sure the cause is the 10k resistors. I've sampled a number of them and they are varying between 9.5k and 10k.

05infernoCRDL · **Posted:** Mon Apr 07, 2008 11:58 pm

how long of a test are you wanting?

i can try the two tomorrow that i have... just tell me how to test the 10K resistor

UFO · **Posted:** Tue Apr 08, 2008 12:17 am

05infernoCRDL wrote:

how long of a test are you wanting?

i can try the two tomorrow that i have... just tell me how to test the 10K resistor

I just used a digital ohm-meter on the parts before they are soldered into the PCB. Basically I don't expect there to be any issues, I was just surprised to see such a variance in the output. It makes sense to me now.

I will test my "engineering model" SEGR box in my Jeep this weekend. If it throws a code, I'll know I need to tweek the resistance in the amplifier circuit to basically "calibrate" the output.

05infernoCRDL · **Posted:** Tue Apr 08, 2008 12:25 am

i doubt there will be a problem

LocoCRD · **Posted:** Tue Apr 08, 2008 12:34 am

UFO wrote:

I built up a test box to dry run the latest SEGR kits and got some output measurements a bit outside of Turbo Tim's test procedure. The 4.0V measurement for my box (with the EGR signal high and the AFC signal low) is running in the 4.4V - 4.5V range. I realize this is not out of the range of the MAF input, if it really is a 5.0V signal, I'm just curious whether anyone has run a SEGR with such a mismatch between the input and output?

I'm pretty sure the cause is the 10k resistors. I've sampled a number of them and they are varying between 9.5k and 10k.

They shouldn't be a problem. 9.5k although dissappointing from digikey is still in the 5% resistor tolerance, in fact the resistors are the same ones as last time. I'll see if I have any from the last batch lying around to see if they vary as much. I have built up 2 kits here for a couple local guys and will hook one up to my Jeep tommorrow. I will report any CEL's, but I don't expect any.

Edit: FYI, I just measured the 10k's left over from last batch and they vary from 9.6k to 10.1k.

UFO · **Posted:** Tue Apr 08, 2008 1:15 am

LocoCRD wrote:

UFO wrote:

I built up a test box to dry run the latest SEGR kits and got some output measurements a bit outside of Turbo Tim's test procedure. The 4.0V measurement for my box (with the EGR signal high and the AFC signal low) is running in the 4.4V - 4.5V range. I realize this is not out of the range of the MAF input, if it really is a 5.0V signal, I'm just curious whether anyone has run a SEGR with such a mismatch between the input and output?

I'm pretty sure the cause is the 10k resistors. I've sampled a number of them and they are varying between 9.5k and 10k.

They shouldn't be a problem. 9.5k although dissappointing from digikey is still in the 5% resistor tolerance, in fact the resistors are the same ones as last time. I'll see if I have any from the last batch lying around to see if they vary as much. I have built up 2 kits here for a couple local guys and will hook one up to my Jeep tommorrow. I will report any CEL's, but I don't expect any.

Edit: FYI, I just measured the 10k's left over from last batch and they vary from 9.6k to 10.1k.

I think I got the good ones, as all the previous boxes I built all tested within 0.1V of all three test points, with 4.0V input.

Turbo Tim · **Posted:** Tue Apr 08, 2008 10:20 am

If these resistors are off on the value to where it is causing a problem on the SEGR output, then probably all that will have to be done is change them all to a 1% type.
Right now they are 5% tolerance.

Let me know and I can get you the new part values…..

fastRob · **Posted:** Tue Apr 08, 2008 10:39 am

Turbo Tim wrote:

If these resistors are off on the value to where it is causing a problem on the SEGR output, then probably all that will have to be done is change them all to a 1% type.
Right now they are 5% tolerance.

Let me know and I can get you the new part values…..

Should I be testing resistors or other parts?

My favorite tool is a framing hammer. Getting ready for this board assembly is a whole new challenge to me.

In reading through the thread the wire lengths can vary greatly depending upon the box placement. On the safe side how long should they be?
Thanks,
R

SEGR/ORM Kit Builder's Thread

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