500R problem.

[boosted]

Hi guys, I re-installed my 500R and changed my loom but I can't make it start again :) That's the situation. When I open the inginiton CDI led is continuously red when I try to crank the car the led goes off and no sparks IMO. How can I test the 500R. and is there a guide for the 500R's flashing led eror codes.

[boosted]

Anyone help ?

[MRMRacing]

Is the CDI new or used? I am no aware of any error codes are implemented in the CDI. Seems like you CDI may needs checking. Do you have any close you can borrow and test a new CDI from?

[boosted]

It's brend new.My SM2 loom is changed ,I made CDI's loom by my self according to manual. I bought it from Ray but there is no place I can barrow a CDI in my country. Probably ,I am the one and only :) As I remember it's the latest HF model. I don't know if the led shows any errors ,I just ask you guys. So since I can't compare the CDI with onther one ,how can I test the CDI.

[MRMRacing]

Normally you can have power on CDI, coils connected and use the Input wire. Connect this to 12 Volt thru a 10 K resistor, now short the wire to ground (the side where the CDI input is, and 12 volt across the resistor) and you would get a spark.

A common fault is that the wiring is done mirrored, look at the connector to verify you look into the wire side.

[boosted]

Thanks Robert ,I will check it out.

[Wroom]

Hi guys, I re-installed my 500R and changed my loom but I can't make it start again :) That's the situation. When I open the inginiton CDI led is continuously red when I try to crank the car the led goes off and no sparks IMO.
Are you sure the supply to the CDI is straight from the battery to pins 17 and 18?
And that pin 12 is not wired so it is shut off when turning the key to "start"?
Have you checked for broken or loose engine ground wires?
Is the battery good? What voltage do you have when you crank the engine?

How can I test the 500R. and is there a guide for the 500R's flashing led eror codes.
I don't think there is any flash codes on the 500R?
Does your 500R flash its LED? Could be due to some wiring problem.

[boosted]

Are you sure the supply to the CDI is straight from the battery to pins 16 and 17?
And that pin 12 is not wired so it is shut off when turning the key to "start"?
Could be due to some wiring problem.

I checked the battry connections they are all good but I am not sure about the connection.Can Anyone check if the connection is right ?

My coil outputs and how I wire to CDI for coil 1 (others the same) ;

pin 1 - trigger ------- CDI Pin7- Coil 1+ve

pin 4a - ground ------- to Engine ground also CDI ground

pin 15 -switched 12 v ------- CDI Pin8 Coil 1&2 -ve

Any comments ?

[Wroom]

First, i have to correct myself. Battery +12 Volt should be connected to pins 17 and 18 on the 500R. Not 16 and 17. Pin 16 should be left unconnected. Sorry about that.
Brains are soft - Reality is hard. ;)

I checked the battry connections they are all good but I am not sure about the connection.Can Anyone check if the connection is right ?

My coil outputs and how I wire to CDI for coil 1 (others the same) ;

pin 1 - trigger ------- CDI Pin7- Coil 1+ve

pin 4a - ground ------- to Engine ground also CDI ground

pin 15 -switched 12 v ------- CDI Pin8 Coil 1&2 -ve

Any comments ?
I'm not sure i understand your description of the pinning.
I will run through the connections to the CDI as a kind of checklist.
Sadly i don't know how many and what type coils you have.

Ground:
14 & 15 = CDI Ground. Separate ground in two 2,5 mm2 wires twisted together and connected shortest possible path to a chassis ground bolt with nothing else connected.

16 = Trigger ground. Do not connect! For special purposes only.

(Coil ground wires should be connected to its own chassis ground bolt with nothing else connected).
---

Power:
17 & 18 = Two 2,5 mm2 wires twisted together and connected directly to battery power through a 30 Amp fuse.

12 = Ignition key terminal 15. +12 Volts on this enables the CDI. Else it is shut off and dont draw power from terminals 17&18.
---

Trigger:
4 = Trigger3 input
5 = Trigger1 input
9 = Trigger4 input
10 = Trigger2 input

Keep these wires away from Coil/power/ground wires on the CDI.
---

Coils:
1 = Coil3+
2 = Coil4+
3 = Coil3- & Coil4-
7 = Coil1+
8 = Coil1- & Coil2-
13 = Coil2+

Keep these coil wires separate from other wires.

Every coil must have its own plus and minus wires all the way to the CDI connector. That is, the coil- pins should have one wire per coils crimped in.

Twist together each coils plus and minus wire all the way from the CDI to the coil.
---

Other signals:
6 = Tacho out
11 = Power select. Open=Low power; Short to ground=High power.
---

[boosted]

Wow...that a lot of info here.Thanks.I will check all data you gave me but however I am stil confused about my coil connection.I have 4 coils for 4 cylinders and each of them have the below outputs.

pin 1 - trigger
pin 4a - ground
pin 15 -switched 12 v

These are the pins numbers and the explanation of the coils ,the point is I can't decide which pin is coils possitive and negative , I know pin 4a is connected to engine gronund.

http://img266.imageshack.us/img266/6356/phpthumbgeneratedthumbnsx1.jpg

[Wroom]

Be careful that this coil seems to have an integrated power transistor. Then it will fry if you drive it with a CDI.

[boosted]

I am sure ,these 3 pins don't have power transistor. The ones with 4 pins have that.They have another pin which is connected at ECU ground location and a separate pin to valve cover ground.

[gti]

Yes, these coils don't have ignitors in them. The standard ignition amplifier is on the airbox.

[Wroom]

In that case it is simple.

1 = Coil minus.
15 = Coil plus.

That signal naming is older than a Volkswagen. ;)

You see the high voltage ground on the mounting holes of the coil. Very important that these have a good ground connection to the cylinder head.

4a is most probably the magnetic core shield ground. It could be connected to the high voltage ground on the mounting holes internally, but it could also be completely separate. Join the 4a from all the coils and ground it.

What is the Beru number on the coil?

pin 1 - trigger
pin 4a - ground
pin 15 -switched 12 v

These are the pins numbers and the explanation of the coils ,the point is I can't decide which pin is coils possitive and negative , I know pin 4a is connected to engine gronund.

[boosted]

Yea I agree with you Wroom ,signal names are old as hell :) Beru number 058 905 447 C for Audi A4 1.8T quattro. The OEm location of the ground is at the valve cover and I did't touch that so I hope it will be fine. But not sure for the other connections 1&15 ,looks like I connect the oposite;
pin 1 - trigger ------- CDI Pin7- Coil 1+ve
pin 4a - ground ------- to valve cover OK
pin 15 -switched 12 v ------- Shared input of CDI Pin8 Coil 1&2 -ve

[Wroom]

Thing is, if the coil is of the type with shared plus between primary and secondary, then i would connect it as you did.
If prim and sec is separated, then i should have connected it the other way around.

[boosted]

Finally ,I found something works. In the picture T1's (coils) pin 15 connected directly to 12V through Fuse 32.So my connection is wrong right ?

http://img87.imageshack.us/img87/8186/coilsvc3.jpg

[Wroom]

In fact, i said that i think your connection of the coils is correct. Coils are connected differently with CDI than with a dwell ignition system. That is because CDI operates the coil "ground referenced", and a dwell ignition operates the coil referenced to +12 Volts.

[Kevin Black]

I worked on a car with the same setup. 500R and these coils (Audi AEB engine code). The car made over 750 hp on methanol at 37 psi boost. The ignition never missed a beat.
The problem is, It was years ago and I cannot be positive of the coil wiring.

However, I have a pdf document of the wiring, given to me by an autronic user at the time. And the wiring is "backwards" as you describe. The shared
-ve wires went to terminal 15, and the individual +ve wires went to terminal 1.

I am 90% sure this is how I wired it.

Edit:
I also have an old diagram for a VW VR6 coil pack and the wiring is the same way, +vw to the 3 individual channels, and -ve to the common.

[boosted]

Oh well I feel beter now. I will check everting and try to crank again. Thanks for supporting me guys. Hey Kevin ,do you still have the cal. file of that A4 ,that may help me a lot. My e-mail is audi.turkey@gmail.com