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Adding Modules on Modular ECUs

April 08, 2018

 

This article gives instructions to people who want to upgrade their modular ECUs. This shows and documents the procedure for the M2000 and M6000 ECUs, but the same applies to all Modular ECUs.

M2000 Upgrade Procedure

The M2000 has eight (8) ignition outputs, eight (8) injector outputs and four (4) auxiliary outputs. It has one (1) slot for an upgrade and it can be any of the small expansion modules.

The small expansion modules available as of the moment are:

  • Mini Analogue Input Module (4 x 0-5V analogue inputs)
  • Mini Real-Time Input Module (2 x CAS, 1 x Flex fuel / frequency input, 3 x VSS)
  • Drive-by-wire Controller Module
  • Mini Output Module (6 x push-pull auxiliary outputs)

The main internal parts of the M2000 are shown below:

 

 

Step 1:  Tools you will need

1.1          Get a 10mm socket and a flat-head screwdriver.

 

10mm socket

Flat-head screwdriver

 

Step 2:  Remove the circuit boards from the ECU housing

2.1          Unfasten all four clips at the end of the ECU.

Note: Clips location is shown on the page above.

 

2.2          Push the circuit boards out of the housing by pushing on the serial (square) connectors through the front connector opening:

 

Step 3:  Plug the desired expansion module onto the main circuit board

 

Note: M2000 can only accommodate one small expansion slot. In this example, we have installed a mini output module (giving 6 auxiliary outputs) 

 

Step 4:  Put back the boards back inside the ECU housing.

 

4.1          Remove the MAP sensor nuts at the end of the ECU (using a 10mm socket)

 

4.2          Remove the plastic end cap

4.3          Make sure the seal is tucked underneath the flange of the Superseal connectors correctly

 

 

4.4          Slide the boards back into ECU housing.

In this step two things should be observed:

a. The edge on the side of the seal must fit in to the screw inside ECU housing.

 

b. Make  sure that the seal is firmly attached to the housing without being pinched or crushed.

4.5          Reinstall the end cap by sliding it over the MAP sensor barbs and main connectors, and clip it on to the ECU housing.

4.6          Tighten the MAP sensor nuts with a 10mm socket

 

After following all these steps, M2000 upgrade is done. As a check, you should ensure that the two MAP sensor ports still hold vacuum. If not then the MAP sensor barb may have come off the seal, or the seal may have come off the MAP sensor itself.

M6000 (and other large body Modular ECU) upgrade procedure

The main components of the M6000 are shown below:

 

 

The large wire-in or M6000 is physically a lot larger than M2000. It has three (3) large expansion slots (one of which is fitted with an output module) and four (4) small expansion slots.

Here are the steps for M6000 upgrade.

Step 1:  Prepare the tools.

1.1          Get a 10mm socket and a flat-head screwdriver.

Flat-head screwdriver

 

10mm socket

 

Step 2:  Remove the board inside the ECU housing.

2.1          Remove the MAP sensor nuts located in front of the ECU using a 10mm socket

 

 

2.2          Unfasten all six clips at the end of the ECU then remove the end cap.

 

Note: Clips location is shown on the page above.

 

2.3          Take off the metal plate.

 

 

2.4          Slide out the circuit boards by push the brass barbs located in front of the ECU. Pushing on the brass barbs prevents them from coming off the MAP sensors during disassembly.

 

Note: Be careful of the additional high current ground wire inside the ECU to ensure that circuit boards don’t snag on it as they are removed.

Step 3:  Add the expansion modules as desired.

Note: Normally upon purchasing an M6000, 1 large output module is already installed. M6000 can accommodate 4 small modules and 3 large modules. In this example, we have populated all expansion slots. Also, the same procedure for M6000 can be used to upgrade the large plug-ins.

 



Step 4:  Put back the boards inside the ECU housing.

4.1          Slide it in with the circuit board at the bottom.

Note: Normally upon purchasing an M6000, 1 large output module is already installed. M6000 can accommodate 4 small modules and 3 large modules. In this example, we have populated all expansion slots. Also, the same procedure for M6000 can be used to upgrade the large plug-ins.

 

4.2          Put back the seal all way around.

The seal on M6000 sits back a little further from the end compared to M2000 because of the metal end plate.

 

Note: Make sure that the seal is underneath the flange of the connectors, and also inserted into the groove in the end of the ECU housing.

4.3          Put back the end plate

(note, its not symmetrical)

4.4          Find the little stripe at the bottom of the end cap and at the bottom of the ECU casing. These stripes must land on each other (the end cap is not rotationally symmetrical; it has a top and a bottom. The bottom of the ECU is slightly wider than the top).

 

Correct way of putting back the end cap

 

4.5          Put back the end cap and clip on.

 

Note: If pressing the end cap using your hands does not work you can use a flat hard surface to push it until all clips engage

4.6          Tighten the MAP sensor nuts using a 10mm socket.

 

 

After following all these steps, M6000 upgrade is done. Just as with the M2000 it is good practice to ensure that the MAP sensor ports are still sealed and hold vacuum.


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