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Tutorial Tools Display Modes
Air Pump Simulator for 2 Bank all 6 Cylinders
Air Pump Simulator for 2 Bank all 6 Cylinders
Published by xxxJohnBoyxxx
12-10-2008
Default Air Pump Simulator for 2 Bank all 6 Cylinders

I have created a air pump simulator for all 6 cylinder BMW engines with 2 upstream O2 sensors. It is the same size as the M44 unit but controls both bank 1 & 2 for a 6 cylinder engine. I'm shipping one off today for testing and will post pictures and wiring diagrams when I get some time later this week. Just an FYI.

***This is to be used for test purposes or on track cars only***
Tutorial Tools

  #1  
By xxxJohnBoyxxx on 12-10-2008, 01:48 PM
Default




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  #2  
By xxxJohnBoyxxx on 12-10-2008, 07:27 PM
Default



DIY Secondary Air Pump Simulator. 2 Bank all 6 cylinder BMW

Secondary Air Pump Parts Needed (All Purchased @ Radio Shack):

1 - Component PC board (#276-149 $1.99)
1 - Component Project Enclosure (#270-1802 $2.69)
2 - SPDT * PC relay miniature 12vdc 10V (#275-248 $9.38)
1 5V Voltage regulator (# 276-1770 $1.59)
2 - 100K ohm Micro Potentiometer (#271-284 $2.98)

Tools Needed:

Soldering pen 7 watts or higher
Solder
Wire
Digital volt meter


Place both relay, potentiometers and regulator on board as shown in picture. Solder all pins on back side of board. Go to wiring diagram and make connections. When finished test unit by hooking to 12 volts and set potentiometers with a screwdriver to 200mv from pin DME wire to ground. Potentiometers should be between 45,000 and 50,000 ohms if you want to ohm it out. Questions to jsmith50@tampabay.rr.com

***This is for off road use only***
***I accept no responsibility for items burned out or damaged by mis-use of this devise. The DME & O2 are sensitive devises and can be destroyed by sending the wrong voltage to the units***
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  #3  
By bluesteel on 02-14-2011, 03:48 AM
Default

I recently added the air pump simulator to my 97 TI with an S52 motor and it works great. I created a PCB layout for me and anyone else who would like to use it. I got all the parts from radio shack and etched the board. Pin 1 in the circuit below is the square pin on the board. If you do not feel like making a board I uploaded the board files to batchpcb so you can buy one pre made for fairly cheap. http://batchpcb.com/index.php/Products/53138

The PCB can also be used for the 4 cyl engines, just don't populate a relay and a potentiometer.

Here is the parts list that I used from Radio Shack:
1 - 7805 +5VDC Voltage Regulator (#276-1770 $1.59)
2 - 100K ohm Micro Potentiometer (#271-284 $2.98)
2 - SPDT Mirco Relay 12VDC (#275-0241 $9.38)
1 - Project Box 3x2x1 (#270-1801 $2.49)






PCB Image.png

AirPumpBoard.pdf AirPumpSchem.pdf AirPumpDesignFiles.zip

***This is for off road use only***
***I accept no responsibility for items burned out or damaged by mis-use of this devise. The DME & O2 are sensitive devises and can be destroyed by sending the wrong voltage to the units***
Last edited by bluesteel; 02-14-2011 at 02:08 PM..
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  #4  
By dantesboyz on 04-11-2011, 07:42 PM
Default

how have these simulators been doing since installation? any CEL issues. bluesteel, i really like the board you had designed. i'm thinking about buying a few & building some for my friends & I.
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  #5  
By xxxJohnBoyxxx on 04-11-2011, 08:35 PM
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No issues on the single simulator that I've run and many others for over two years no issues reported on the dual bank since they have been in service.

John S
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  #6  
By 18ri@comcast.net on 05-11-2011, 12:34 AM
Default Secondary Air Pump Simulator

will the Secondary Air Pump Simulator work on a 2003 Z4, 2.5, 5speed?
Thanks
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  #7  
By bmwconnect on 05-11-2011, 04:36 AM
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love this DIY!
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  #8  
By Marv17 on 05-11-2011, 06:05 AM
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where do you connect the wires to?
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  #9  
By xxxJohnBoyxxx on 05-11-2011, 07:58 AM
Default

Quote:
Originally Posted by Marv17 View Post
where do you connect the wires to?
Air pump positive and negative to activate the simulator, then you clip the signal to your O2 sensors and patch the other simulator wires in. When the simulator is off it is a pass-through like you never cut the signal line. When the DME calls for air pump the simulator goes active and cuts O2 signal and sends a 200mv signal to the DME fooling it into thinking there is additional fresh air in the exhaust from the air pump system working.

Best, John Smith
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  #10  
By NeilM on 07-14-2011, 11:15 PM
Default

Bringing this thread back from the almost-dead: why would you build a 6-cyl/double O2 sensor) version with two SPST relays instead of one DPDT?

Neil
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  #11  
By xxxJohnBoyxxx on 07-15-2011, 01:20 AM
Default

Quote:
Originally Posted by NeilM View Post
Bringing this thread back from the almost-dead: why would you build a 6-cyl/double O2 sensor) version with two SPST relays instead of one DPDT?

Neil
My original simulator was for the I-4 motor and then I was asked to make one for the I-6 so I made it with extra parts I had for the I-4. Please feel free to make your version I-6 with the DPDT and post the schamatic.

Oh also you need to check to ensure Radio Shack sells the DPDT. IDK since I never looked for one in my local store. People like all parts in one location.

John S
Last edited by xxxJohnBoyxxx; 07-15-2011 at 01:25 AM..
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  #12  
By NeilM on 07-15-2011, 01:32 PM
Default

Quote:
Originally Posted by xxxJohnBoyxxx View Post
Oh also you need to check to ensure Radio Shack sells the DPDT. IDK since I never looked for one in my local store. People like all parts in one location.

John S
Good point - RS doesn't offer a DPDT micro relay.

The Omron G5V-2-H-DC12 ought to do nicely, Digikey P/N Z771-ND for $3.22 each. See http://search.digikey.com/scripts/Dk...l&name=Z771-ND.

Adapting it to your reference circuit is then trivial.

Neil
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  #13  
By xxxJohnBoyxxx on 07-15-2011, 03:02 PM
Default

Quote:
Originally Posted by NeilM View Post
Good point - RS doesn't offer a DPDT micro relay.

The Omron G5V-2-H-DC12 ought to do nicely, Digikey P/N Z771-ND for $3.22 each. See http://search.digikey.com/scripts/Dk...l&name=Z771-ND.

Adapting it to your reference circuit is then trivial.

Neil
Do a digikey parts list for the forum. These can be made for much less but I was doing with local parts that anyone can purchase right away the day they want to do it. You could do one for half the price on-line which some people might want to do.

Someone needs to start making these. I get requests all the time but turn them down due to the time involved. I get emails weekly concerning these simulators for all kinds of cars and they work on anything with an air-pump. They can be adapted to wide-band with a little tweak of the voltage sent to the DME or ECM. Also you can use resistors instead or pots but I like the pots incase you get a car that need a voltage tweak to get the computer happy.

Best, John S
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  #14  
By NeilM on 07-15-2011, 07:57 PM
Default

Quote:
Originally Posted by xxxJohnBoyxxx View Post
Do a digikey parts list for the forum. These can be made for much less but I was doing with local parts that anyone can purchase right away the day they want to do it. You could do one for half the price on-line which some people might want to do.
Digikey

a) +5VDC Voltage Regulator (P/N LM7805CT-ND, $0.65)
http://search.digikey.com/scripts/Dk...me=LM7805CT-ND

b) 100K-ohm Micro Trimmer Potentiometer (P/N 987-1060-ND, $2.02)
http://search.digikey.com/scripts/Dk...me=987-1060-ND

c) DPDT Micro Relay 12VDC (P/N Z768-ND, $3.00)
http://search.digikey.com/scripts/Dk...l&name=Z771-ND

Notes:
- I picked components that are higher in spec, especially operating temperature range.
- The DPDT relay handles dual O2 sensor applications, but it's so cheap you could just not use the second pole for single sensor applications (e.g. 4-cyl).
- Although Digikey's mail order prices are much lower than Radio Shack's store prices, you may run into minimum order and service charge adders, an then there's shipping cost.

I think you're better off to pick up a project box and breadboard at RS.

Radio Shack

1 - Project Box 3x2x1 (#270-1801 $2.49)

Quote:
Originally Posted by xxxJohnBoyxxx View Post
Someone needs to start making these. I get requests all the time but turn them down due to the time involved. I get emails weekly concerning these simulators for all kinds of cars and they work on anything with an air-pump. They can be adapted to wide-band with a little tweak of the voltage sent to the DME or ECM. Also you can use resistors instead or pots but I like the pots incase you get a car that need a voltage tweak to get the computer happy.
Yeah, not me either!

Neil
Last edited by NeilM; 07-17-2011 at 02:42 PM..
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