Installing universal standalone GCU requires certain
modifications to be done to the mechatronics unit inside VW DSG
DQ500 gen.1 transmission.
Actual for 1.0.9b-6 release
To modify
it You’ll need:
- Soldering station
- Dremel /w abrasive plate
- Torx
- Side cutters
- Wires (24AWG silicone/PTFE wires, oil resistant, 200C rated)
CAUTION: This modification require soldering
experience and steady hand due to very tight location of soldering
After removing unit
from valve body it is strongly recommended to degrease whole assembly
to improve ease of modification and keep your workplace clean. Universal
degreaser works just fine as well as brake cleaner or so.
- Remove solenoid connector plate and drill rivets
holding stock TCM cover.
- Remove plastic covers of flat flex cables and break welded
connections.
- Remove aluminum cover of stock TCM. Make sure to do it
carefully to avoid damaging flex cables and sensors.
Next steps will require you to solder several wires. Please
use quality wires that are designed to work in such environment.
Oil and chemical resistance as well as 200 Celsius degree rating
are strongly recommended.
Perform
following connections:
- 1. A1, B1, C1, D1, E1, F1 connect
together and then to GCU +5v_out (M1)
- A2, B2, C2, D2, E2, F2, G1 connect together and then to GCU
s_GND (L2)
- A3 connect to GCU AN_in1 (C1)
- B3 connect to GCU AN_in2 (C2)
- C3 connect to GCU AN_in3 (C3)
- D3 connect to GCU AN_in4 (C4)
- E3 connect to GCU FREQ_in1 (A3)
- E4 leave unconnected.
- F3 connect to GCU FREQ_in2 (A4)
- F4 leave unconnected.
- G2 connect to GCU FREQ_in3 (B3)
- G3 connect to GCU +5v_out (M1)
- G4 connect to GCU AN_in9 (E1)
IMPORTANT: Add 2k2 pull-up to +5v_out (M1)
on GCU end of loom.
- 1. Solenoid +12V SUPPLY
- 2. GCU PWR_out1 (H1)
- 3. GCU PWR_out2 (H2)
- 4. GCU PWR_out3 (H3)
- 5. GCU PWR_out4 (H4)
- 6. GCU PWR_out5 (J1)
- 7. GCU PWR_out6 (J2)
- 8.Solenoid +12V SUPPLY
- 9. Solenoid 7 to GCU PWR_out7 (J3)
- 10. Solenoid 8 to GCU PWR_out8 (J4)
- 11. Solenoid 9 to GCU PWR_out9 (K1)
- 12. Solenoid +12V SUPPLY
- 13. GCU PWR_out10 (K2)
- 14. Not in use
- Check if all soldering connections are good quality and
then secure all of those points with silicone packing to protect
it from short circuits.
- Wire “Solenoid +12V SUPPLY” to switched IGNITION (voltage
has to be present when HTG GCU device is powered on). Circuit needs
to be able to provide constant 25AMP.
Pressure Sensors have solder pads labeled: VCC, SIG, GND.Stock
controller is connected to pads around it with thin aluminium wire.
- Remove all wires with tweezers. While removing pay attention
to hold them as close to soldering pads as possible so minimal length
of them remains (preferably none).
- Solder Wires:
- PS_pad 1 to PS_A VCC and PS_B VCC ( later
GCU +5v_out (M1) )
- PS_pad 2 to PS_A SIG ( later GCU AN_in7 (D3) )
- PS_pad 3 to PS_B SIG ( later GCU AN_in8 (D4) )
- PS_pad 4 to PS_A GND and PS_B GND ( later GCU s_GND
(L2) )
Those connections allow to transfer signals outside of
stock TCM’s box. Follow easily visible traces on FLAT FLEX cables
and connect according to above instructions “(later ...)”Keep in mind
that s_GND and +5v_out connections are common for mentioned earlier
sensors so can be joined together on various points.
- After soldering ensure there are no short circuits between
pads. Apply silicone seal on solder pads and sensors, and on wires
to prevent them from moving around and avoid connection failure,
as well as to protect from potential transmission fluid influence.
- Reinstall rubber seal before mounting the cover back
and reapplying rivets. Cover has to be sealed - if transmission
fluid would enter to inside of pan pressure sensors may get damaged.
- It is STRONGLY RECOMMENDED to separate loom of valves
from sensor loom, so noisy wires are not braided with noise vulnerable
sensor signals. It is also recommended to put all wires in heat
shrink sleeves inside transmission case to maximize protection.
- OEM round connector will only be used as a passage through
transmission case - please drill a hole in it and lead all the wires
through it and seal it with silicone packing afterwards (eg. Victor
Reinz Reinzosil).
There are numerous aftermarket round connectors fitting
OEM connector sleeve - it is recommended to use such connector in
order to have easily disconnectable internal loom from external
patch loom.
This guide is just INFORMATIONAL one. It shows quite easy
and safe method of wiring VWDQ500 transmission to work with HTG
GCU, but it can be also done with different method as long as connections
remain unchanged between point and GCU.
HTG GCU requires main (MAIN RELAY’ed) battery +12v applied
to +12_const (M3, M4), as well as ignition +12v signal applied to
+12_IGN (L1).
Even though HTG GCU has internal protection
it is advised to secure IGN signal with 5Afuse to prevent failure
of the device.
Ground connections GND (L3 and L4) should be
made on engine or chassis, as long as chassis ground point is confirmed
to be efficient.
+12v_out (M2) can be used as supply for shifter,
paddles or other low power auxiliaries that need voltage feed.
For proper functionality
HTG GCU needs to be fed with ECU signals. Those signals are used
to configure and map transmission operation.To communicate with
ECU AN_out1-4 (A1, A2, B1, B2) can be used and CAN_1 and CAN_2CAN
bus has to be terminated with 120ohm resistor.
Click here to see Interconnector pinnout