Engine Wiring Harness - aeonSolutions/AeonLabs-AI-Volvo-MKII-Open-Hardware GitHub Wiki
Main Page >> Wiring, Fuse Boxes and Relay Diagrams >> Engine Wiring Harness
Last update 07-04-2024
Figure 1 - Factory original wire hardness for the engine (see wiring diagrams manual, page 113)
After removing all electrical wiring including CAN communication from a 2001 Volvo S60 and after cleaning it all and removing all protective plastic it was possible to understand how wiring is connected in a P2 Volvo, in particular how it connects on the engine bay to the ECU.
Figure 1 - Photo with all wiring installed on the engine bay of a Volvo P2 (Petrol) with the Relay box, the ETM , the ECU and a few sensors connected
The first immediate conclusion was all high-power electrical wiring packed together with all other wires including sensors and CAN communications. This is well known to cause interference and even errors in both communications and also on sensor values measured by the ECU. In summary, the installation on the engine bay needs to change so high-power wires are installed apart from all other wiring to avoid unnecessary interference.
Another option is to replace all sensor wires with only 4 wires in total capable of sensing each individual sensor value to the ECU located on the right side corner of the engine bay. I've pre-selected the RG 178 coaxial cable, suited for GHz electrical signal wrapped inside a heat-resistant protective sleeve for increased durability. This will require purposely designed hardware electronics capable of doing sensor measurement translation and sending it to the ECU. This can be achieved with an ESP32 C3 microcontroller and an I2C Compatible Dual Bidirectional Bus Buffer, for instance, the P82B96 installed along the new wiring near each individual sensor.
Another point of failure is located in the engine, the wires for the ignition and the injectors, constantly under high temperatures during engine operation.
ðĒ Fully tested and working
A green circle means the hardware electronics or the programming code was fully tested, each of its functionalities and capabilities. And it can be installed in a vehicle. Keep in mind this does not mean errors won't happen. As in everything related to electronics and software, there are revisions and updates. This open hardware is no different.
ðŊ Fully tested & working, no improvements necessary - already being sold online
ð Fully Open hardware \ source code
ðĪŠ There's better than this. don't use it
ð Fully closed hardware \ source code
âĄïļ fully tested and working, however, it is a dangerous solution to deploy
ðĄ Not tested. Working capability is unknown, it may work or not.
A yellow circle means the hardware electronics or the programming code was not fully tested, each of its functionalities and capabilities. This does not mean it not working, it simply means testing is needed before giving a green circle of approval.
ðī Fully tested but not working.
A red circle means the hardware electronics or the programming code was fully tested, and found some kind of critical error or fault. This means the electronics or firmware code cannot be used in a vehicle.
â Not started.
The hourglass means the hardware electronics or the programming hasn't started. Most likely because is waiting for the necessary test components needed for reverse engineering and also engineering of the new open solution.
ð New updated contents
The new icon means the link next to it was recently updated with new contents
ðŽ Comments on the Discussion page
The comments icon means there are useful and even new comments on the discussions page of the repository important for what you are seeing or reading.
Join the beta program to test and debug to provide feedback, ideas, modifications, suggestions, and improvements. And in return, write your own article blog, or post on social media about it. See participation conditions on the Wiki.
The Beta Participant Agreement is a legal document being executed between you and AeonLabs that outlines the conditions when participating in the Beta Program.
Bug reports and pull requests are welcome on any of AeonLabs repositories. This project is intended to be a safe, welcoming space for collaboration, and contributors are expected to adhere to the code of conduct.
- Contributing
Please make sure tests pass before committing, and add new tests for new additions.
You can get in touch with me on my LinkedIn Profile:
You can also follow my GitHub Profile to stay updated about my latest projects:
The PCB design Files I provide here for anyone to use are free. If you like this Smart Device or use it, please consider buying me a cup of coffee, a slice of pizza or a book to help me study, eat and think new PCB design files.
Make a donation on PayPal and get a TAX refund*.
Did you like any of my PCB KiCad Designs? Help and Support my open work to all by becoming a GitHub sponsor.
Before proceeding to download any of AeonLabs software solutions for open-source development and/or PCB hardware electronics development make sure you are choosing the right license for your project. See AeonLabs Solutions for Open Hardware & Source Development for more information.