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DIY: Do It Yourself
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Old 10-27-2016, 04:03 AM   #1
blink977
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DIY: Start/Stop button

I'm editing my first post, in order to start posting DIY. I'm gonna do it step by step, because it is long process, and it is done by 90 percents yet. I faced some problem from the beginning of the project and solved them, only 2 problems left and currently I don't have much time to work on this, but I'm gonna figure it out soon.
So, what I have for now:
1. E60 key locks/unlocks my E46 without any modification of the key itself
2. start/stop works perfectly with key in the slot, no issues at all
3. starter disengage board assembled, tested, and works perfectly
4. PassiveGo. Well, this is main headache, and the last part of the project. PassiveGo does not works as it should. Sometimes with the key in car interior, and button press, nothing happens. sometimes once, sometimes twice. it feels like CAS won't recognize the key randomly. This is the main thing to figure out. By the way, some help and advice would be appreciated. Again, with key in slot, it works perfectly, no problems at all.
Second problem with PassiveGo is start sequence, well, this is not huge thing, I can live with this, but I like to figure this out also. In the E60, when you have your key inside interior, and ignition is in position 0(everything off), the engine should be started immediately by pressing start button once, I mean, ACC, ignition and starter are activated all together. In my case it will activate only ACC first, and I have to press button once more to start the engine. I'm gonna post video soon. Actually, this happens because of CAS module can't communicate with DSC module. It is confirmed, because I have disconnected DSC in E60, and button acted the same, two button pushes needed to start the engine. The good news, this is configurable via the NCS expert, because CAS module has huge amount of options on how engine can be started, for example you can choose options like engine will be started only in park or not, clutch pedal depressed or not, brake pedal depressed or not. I just need a bit of time to figure this out.

Now let's start with the components list. For the full project with remote key, and PassiveGo, you will need next modules/components:

CAS module.



This is the main thing, it does everything begining from signal reception from the remote key, ending with starter engagement. The correct module we will need is from past 2007 vehicles. It can come from E60, E70, E90 etc. no matter. The main thing is that we need CAS module without Electric Steering Lock. This modules are usually stamped C4, and are CAS3+ modules, their hardware also differs from the older modules hardware. We can't use CAS2 modules for this project, because they all came with ELV, and there no non-ELV software exists for them. These are white color modules, and the only way to use them is to have ELV lock mechanism connected and wired up, or you can use ELV emulator boards, 120$ from ebay. Without ELV, CAS will not release ignition clamp, only ACC is released. Usually ELV is quite problematic and fails often, so BMW got rid of them. I'm not sure in top of my head, but according to TIS all past 2007 cars, came without ELV. I tried to re flash CAS3 with non ELV software, but it was not impossible due to different hardware. So, your best bet is CAS3+, with C4 stamped on it.

Key.



There was 2 types of keys: with Comfort Acces, and without it. This is easily seen with battery cover in the bottom of the key. Keys with CA has battery cover, while key's without CA are solid. Of course, CAS and key needs to be matched.

Key slot with ribbon cable.



You can use any slot from E60, E90, E70. They all are technically the same, difference is only from the outside.

Start/stop button. Again, any button from these car models will work.



FBD receiver.



These are different also. I'm using one from facelift E60. Don't know if other models will work. FBD receives signal from the remote key, and forwards them to CAS. It is needed to remote lock/unlock and also needed in order to PassiveGo work. It is installed in different places in different models. I have installed it in my rear view mirror. Open/close range is somewhere 15 meters, just like stock.

Central Gateway Module (KGM module)



This module is installed only in E60's and after 2005/09. E9X models use JBE modules instead. So, I'm assuming you will get KGM module, because I have not deal with JBE's. KGM's are responsible for front door locks and power windows. also responsible for diagnostics. You can't just hook any kind of diagnostic software on to the CAS for example, it will not work. All modules in the E60 are connected via CAN-bus or other bus with KGM module, and next goes to OBD2 connector. There are a lot of things to code out from CAS in order to make it work, so you will need KGM module anyways.

Comfort Access (PassiveGo module).



This mid sized white module is needed to talk with the key in interior. Antennas also needed, I have 2 of them installed, one under the climate control, second in the arm rest. In E60 4 of them installed, but we don't need luggage compartment.

Aerial(PassiveGo antenna):



All modules should come with connectors of course. I'll be posting wiring diagrams and pinouts later

Components placement:

This is optional, but I have installed CAS module in my footwell, mount it with 10mm plastic bolt, which usually holds EWS module.
Key slot is installed on steering column, where your ignition barrel was. What I did, I have got spare steering column, and cut out the steering lock, and round ignition barrel housing. Then installed instead of my steering column.
Installation place of start/stop button is visible on videos.
Next comes KGM and PG modules. I have installed them behind the glove box, where you have your GM module. There are a spare places in module holder, PG fits perfectly inside, but in order to fit KGM you will have to remove center plastic piece. I ran wires from glove box to CAS, behind the heater. It's a bit tricky, but worth it.

Starter disable board parts list:
U1 - Attiny85 controller - I used sop8 package because of dimensions, you can use dip8 package
R3, R4 - two 10kohm reistors - again, I used smd ones
T1 - 2N3904 transistor - SOT-323 package with t04 marking on it
U2 - 5V voltage regulator - L250 marking I have pulled it from old pcb board, with corresponding capacitors(C2, C3 depends on which voltage regulator you will use, see datasheet). you can use any 5 volt voltage regulator.
ZD1 - 4.7V zener diode
R2 - 2.2kohm resistor
R1 - 4.7kohm resistor
C1 - 1uf capacitor

https://drive.google.com/drive/folde...GtkLTd1UVpEUUk

Archive contains Arduino sketch, Sprint Layout software and pcb board design. Install Sprint Layout, and open 1.lay file. You can print and fabricate pcb now

Last edited by blink977; 04-08-2017 at 04:12 PM. Reason: spacing
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Old 11-06-2016, 06:22 PM   #2
blink977
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DIY: Start/Stop button

FBD portion removed from E60 antenna assembly:





And installed into my rear view mirror:



After removing antenna plastic cover, you will see that whole board is pre-cut into pieces, so first piece with connector is FBD receiver itself. Just break it and don't worry about damaging anything. Other pieces are radio, navigation, and TV, so we don't need them.

Pinout:

FBD pin 3 -> CAS pin 33
FBD pin 4 -> PassiveGo pin 3
FBD pin 6 -> constant +12v
Thick bottom wire with round connector -> Ground
Also solder 20 centimeter wire on the contact of the windshield antenna

Last edited by blink977; 03-08-2017 at 05:01 PM.
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Old 11-09-2016, 01:54 PM   #3
KnockKnockVanos
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Dude, that's dope! Keep posting - this is something I've been thinking of. Props for keeping it OEM style.
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Old 11-09-2016, 02:48 PM   #4
blink977
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CAS module pinout:

pin 2 -> ACC relay coil +12v
pin 8 -> Ignition relay coil +12v
pin 12 -> Ground
pin 19 -> Wake Up signal
pin 21 -> CAS voltage supply
pin 22 -> Starter
pin 25 -> Ground
pin 26 -> CAN bus LOW
pin 28 -> Starter shut off input
pin 30 -> PA bus
pin 33 -> FBD receiver output
pin 34 -> CAS voltage supply
pin 35 -> CAN bus HIGH
pin 41 -> start input from clutch/brake pedal switch

PassiveGo module pinout:

pin 1 -> CAS pin 30
pin 2 -> CAN bus LOW
pin 3 -> FBD pin 4
pin 6 -> Rear armrest aerial
pin 7 -> Front aerial
pin 14 -> PassiveGo voltage supply
pin 15 -> CAN bus HIGH
pin 16 -> Ground
pin 19 -> Rear armrest aerial
pin 20 -> Front aerial

Last edited by blink977; 03-08-2017 at 05:14 PM.
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Old 11-09-2016, 03:09 PM   #5
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That'd be awesome! I'd love to see the work that goes into this. I'd really like the push start as my ignition tumbler is starting to show signs of wear. That and I always love a DIY project - Do the e90/e60 keys work out of the box as far as lock/unlock functions go? I think they use the same 315Mhz radio. I've got an auto-tragic transmission in my daily, think it'll be more difficult will it be setting up? Looking forward to the write up!
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Old 11-09-2016, 03:31 PM   #6
blink977
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Quote:
Originally Posted by KnockKnockVanos View Post
That'd be awesome! I'd love to see the work that goes into this. I'd really like the push start as my ignition tumbler is starting to show signs of wear. That and I always love a DIY project - Do the e90/e60 keys work out of the box as far as lock/unlock functions go? I think they use the same 315Mhz radio. I've got an auto-tragic transmission in my daily, think it'll be more difficult will it be setting up? Looking forward to the write up!
Keep your ignition tumbler even if will fail, you will need it's connector side
As far as lock/unlock function goes, unfortunately it is impossible to make smart key or CAS module work directly with E46 GM module. In E60 or E90 cars the remote signal from key is received with remote module, sent to CAS, which is main module for lock/unlock, then CAS sends it to KGM(central gateway) module within canbus, then to KBM(basic body module). The system in E60 is quite complicated, because same functions are distributed between 3 modules. But there is solution: I was able to put my E46 keyfob pcb board into E60's smart key, soldered button wires from E46 pcb to E60 keyfob pcb and it worked perfectly. all you have to do, is to desolder EWS antenna an transponder chip form E46 key

Last edited by blink977; 11-09-2016 at 03:35 PM.
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Old 11-11-2016, 01:56 AM   #7
KnockKnockVanos
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Quote:
Originally Posted by blink977 View Post
Keep your ignition tumbler even if will fail, you will need it's connector side
As far as lock/unlock function goes, unfortunately it is impossible to make smart key or CAS module work directly with E46 GM module. In E60 or E90 cars the remote signal from key is received with remote module, sent to CAS, which is main module for lock/unlock, then CAS sends it to KGM(central gateway) module within canbus, then to KBM(basic body module). The system in E60 is quite complicated, because same functions are distributed between 3 modules. But there is solution: I was able to put my E46 keyfob pcb board into E60's smart key, soldered button wires from E46 pcb to E60 keyfob pcb and it worked perfectly. all you have to do, is to desolder EWS antenna an transponder chip form E46 key
Smart thinking! It's savvy guys like you who drop the knowledge bombs that make these retro fits possible & bring good info to the table. I figured it wouldn't be easy. I had considered hacking up and relocating the antenna from the ignition so I could move it else where (say the ash tray) where I could just drop the key into and add a acc/start/stop button in the dash. That way a transponder is still needed to start the car. My only major issue would be some kind of kill switch while the key wasn't in the car - that way you couldn't just get in and switch it to the on position. I had considered some kind of magnetic solution where when the key is inserted in to its slot it closes some kind of switch completing the acc/start/stop button's circuit. Another issue would be solving how to turn the car off - would hitting the start button try to activate the starter? I'm sure an Arduino module could probably sort this out. I'm skilled enough to follow instructions; just not skilled enough to write a solution.
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Old 11-11-2016, 02:11 AM   #8
blink977
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Well, with CAS module it is pretty straightforward and oem, because it has direct voltage from battery, I mean it is always ON, so you can just hook it up and leave without any problem. Also, if you don't wont to remove ignition barrel and steering lock, you can find keyfob receiver from E89/xxx cars, they have it on the dash, while E60 has it on steering column.
Leave this thoughts I have almost figured out everything, a soon I will add a DIY here
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Old 11-21-2016, 01:13 AM   #9
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This would be incredible work and I am definitely interested in a DIY. I am actually working on a DIY for the e90 chime retrofit, so these would complement eachother very well.
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Drivetrain: ECStuning Lightweight Flywheel + E34 M5 Clutch kit, 545i shifter
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Old 11-21-2016, 01:58 AM   #10
blink977
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The problem is, I don't have CAS module right now I have borrowed it before, for experiments.
I have one CAS module, but it is with ELV software, and won't turn ignition ON. Currently I'm searching forums and trying to reflash it with software without ELV. Once I'll be done, I will continue to post results.
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Old 11-21-2016, 12:20 PM   #11
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How much is a CAS module?
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Suspension: Koni Yellow Struts, Rob43 Shocks, H&R Race Springs, ZHP Control Arms, Meyle HD bushings
Drivetrain: ECStuning Lightweight Flywheel + E34 M5 Clutch kit, 545i shifter
Interior: GSP Mason Clutch Pedal, M3 Seats, M3 Steering Wheel (Coby), ZHP Knob
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Old 11-21-2016, 12:32 PM   #12
blink977
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Originally Posted by The Snake View Post
How much is a CAS module?
you mean price?
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Old 12-06-2016, 12:24 AM   #13
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subd
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Old 12-06-2016, 12:54 AM   #14
blink977
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Still trying to make CAS work without ELV...
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Old 12-22-2016, 12:14 PM   #15
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I'm back again, with correct CAS module, and almost everything needed for install Will proceed with installation soon and post pictures
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Old 12-22-2016, 12:16 PM   #16
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Can't wait! Did you change CAS modules?


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Old 12-22-2016, 12:23 PM   #17
blink977
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Originally Posted by KnockKnockVanos View Post
Can't wait! Did you change CAS modules?


Sent from my iPhone using E46Fanatics mobile app
As long as I don't have expensive key programming hardware, I have found CAS module with key, without ELV. I also spent some time figuring out Comfort Access option, to retrofit it also
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Old 12-22-2016, 03:40 PM   #18
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it looks really interessing.
can't wait to see it work
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Old 12-23-2016, 12:16 PM   #19
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fabricated this adapter today. It is for easy plug and play connection



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Last edited by blink977; 12-23-2016 at 12:17 PM.
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Old 12-23-2016, 12:17 PM   #20
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Looking good!!


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