Nachgerüstet : ESP Off, HSA und DDS

Hello again,

You fellow Corsa fans may remember my last message from a couple of months ago. I had successfully retrofitted my '07 Corsa Sport with the trip computer display in instrument panel and shared this story with you here.

My next project was to retrofit my Corsa with :

1. The ESP off switch, normally available only in GSI and OPC,
2. HSA (Hill Start Assistant - Berganfahrhilfe)
3. DDS (Deflation Detection System - Reifendruckverlust-Überwachungssytem)

For this message, I'd like to keep the very long story as short as possible, and give you only the basic information about required parts and some photos. But I can supply all the details on how to implement these changes to anyone, anytime. I'd just like you to know that I had spent a long time for this project, and success didn't come easily.

First of all, your car should already have ESP system. The Corsas without ESP can have DDS, but not HSA, and ESP off switch, obviously.

The first item in my list, the ESP Off button, was the easy one to implement.

The required parts and procedures :

1. A new center-console switch group (schalter) with the "ESP Off" button.
(There are many switch group parts with different functions, and you should have some parts knowledge to choose the right one for your exact purpose.
I picked the one with the ESP off and also DDS buttons because I'd like to implement the DDS also.)

2. A new center-console cover (blende) which has the correct-width opening for the new six-button switch group.

3. Three new wires (kabel) should be laid from the switch group to the body control relay module (BCM) under the lighting switch (behind the fuse box). Two for the ESP Off button, one for the DDS.

4. The ESP Off button should be activated in related BCM and IPC submenu items of Tech2 diagnostic computer.

The second and third items in my list, HSA & DDS, are related and comes together as a package. These systems are controlled by ABS/ESP control unit, and there are four major varieties of this unit : 1. Standard ABS, 2. ABS with DDS, 3. ESP, 4. ESP with HSA & DDS. My car already had ESP, so the more advanced option for my car was the ESP with HSA & DDS.

Required parts and procedures :

1. A new ABS/ESP control unit (steuergerät) with HSA & DDS support
This part is located under the ABS/ESP hydraulic unit at the engine compartment, behind the battery. Hydraulic unit & control unit is removed from their place together as one piece. Then at the outside, the existing control unit is removed and the new one is attached to the hydraulic unit. Then they are installed back at their place. (Then the brake fluid should be refilled also)

2. A new ESP sensor (with HSA support)
This part is located in central tunnel, under the handbrake lever. It is relatively easy to replace.

3. Programming of ABS/ESP control unit using Tech2. This is the tricky part and I have discovered the correct procedure by myself, having spent a lot of time with Tech2, TIS and the Internet. The programming procedure requires a chassis number (VIN) and normally the technician enters the VIN of your car. But the new ABS/ESP control unit can not be programmed for HSA/DDS using your VIN because your car does not have those options originally. You have to enter a VIN that belongs to a car equipped with HSA/DDS at the factory. Only this way you can program the new ABS/ESP control unit to support the HSA/DDS functions. I have spent sleepless nights at the computer keyboard, checking all Corsa's starting from the chassis number 000001 one by one, using the EPC software. Luckily, I found one that matches my car's engine & transmission and also has the HSA/DDS. I used that VIN to program the ABS/ESP unit, and it worked magically

4. The DDS should be activated in related BCM and IPC submenu items of Tech2 diagnostic computer.

5. The new ESP sensor should be calibrated, and the DDS system should be reset, both using Tech2 again.

Warning : Both new parts are very expensive. The ABS/ESP control unit is listed at something like € 1000, and the ESP sensor is listed at € 500. Of course you may get some discount from your Opel dealer but they would be still expensive. I started looking, and found the control unit in England via Ebay. The part was brand new, not used, and very cheap at £ 100, yes I know I was very lucky There were a lot of risks, but I bought it anyway. Also I bought the ESP sensor from Germany, again via Ebay, but this time the part was second-hand and I got it for € 70.

For anyone considering these retrofitting works for their car, I wish you best of luck in obtaining the parts cheaply. I can provide all the help you would need to determine the correct part numbers and also information on installation, programming and activation procedures.

Best regards from Istanbul,
Serdar

Standard 2-button switch group (central locking and front passenger airbag off)

[Blockierte Grafik: http://img585.imageshack.us/img585/1314/dsc00556g.jpg]

Center console gets removed

[Blockierte Grafik: http://img689.imageshack.us/img689/8273/dsc00560yw.jpg]

Radio/CD unit, display, air vents and cover are all removed.

[Blockierte Grafik: http://img220.imageshack.us/img220/315/dsc00561z.jpg]

Removed parts are lying on the seat.

[Blockierte Grafik: http://img515.imageshack.us/img515/4084/dsc00562fd.jpg]

New six-button switch group and the matching new cover are mounted.

[Blockierte Grafik: http://img252.imageshack.us/img252/7210/dsc00563w.jpg]

The ABS hydraulic unit is sitting alone, and the technician holds the new ABS/ESP control unit in his hands.

[Blockierte Grafik: http://img846.imageshack.us/img846/5595/dsc00570n.jpg]

Hydraulic and control units are mounted as a single piece.

[Blockierte Grafik: http://img252.imageshack.us/img252/4288/dsc00571o.jpg]

Required activations via Tech2 are done, and DDS warning in the rev counter lights up yellow at the startup.

[Blockierte Grafik: http://img195.imageshack.us/img195/5576/dsc00559ma.jpg]

The new ESP yaw sensor which supports the HSA system is mounted on the central tunnel, under the handbrake lever.

[Blockierte Grafik: http://img689.imageshack.us/img689/4456/dsc00587tr.jpg]

My old ESP yaw rate sensor sits at the front passenger seat

[Blockierte Grafik: http://img221.imageshack.us/img221/1808/dsc00588wv.jpg]

One of Tech2 programming screens

[Blockierte Grafik: http://img714.imageshack.us/img714/1791/dsc00592nf.jpg]

After the new switch group is mounted and started working

[Blockierte Grafik: http://img577.imageshack.us/img577/1203/dsc00598r.jpg]

When ESP button is pressed, ESP warning in speed dial lights up constantly and central display shows "ESP off"

[Blockierte Grafik: http://img12.imageshack.us/img12/5677/dsc00599jc.jpg]

And finally the result of our tire deflation test today : The DDS warning in rev counter lights up red to warn us about the deflation

[Blockierte Grafik: http://img515.imageshack.us/img515/3296/dsc00614c.jpg]

Thank you.

I'll be back shortly with new projects

Zitat

Original von jb79
Hello saytamaner!

Great work!
As I understood the only part that needed for the modification is the ESP switch (and of cause the two wires).

Could you please explain the necessary steps in detail?
Where in the BCM and IPC configuration it has to be swiched on, is there some additional configuration required, maybe "Variantenkonfiguration"?
Could you tell us the pins where the switch should be connected to on the BCM?

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Hello, and thanks!

For ESP Off function, you need only new switch unit that contains ESP Off button. That switch unit has six buttons, so if your car currently two-button switch unit, you will also need a new upper console cover that has a wide aperture for the six-button unit.

It is a little tricky to find the correct part numbers, so you have to be careful when ordering the new parts. When you decide to start this project for your own car, I can help you about that using the chassis number (VIN) of your car.

As for the pin numbers :

From: Pin 11 of switch unit connector --> To: Pin 28 of BCM connector (X13)
From: Pin 12 of switch unit connector --> To: Pin 13 of BCM connector (X13)

Tech2 activation :

1. Body --> BCM --> Variant Configuration --> ESP/TC Off Switch --> Yes
2. Body --> IPC --> Variant Configuration --> ABS/ESP --> ABS/ESP for OPC

HSA and DDS functions are another story, I can provide help about that too.

Cheers,
Serdar

Zitat

Original von huego
Hi! Very good tutorial!
Some time ago I wrote a manual for the German guys about retrofitting the ESP-Button. You can find it in the wiki.

Hello Sebastian

I have read your manual and it is my source of inspiration for this project

After reading it, I decided to take things a little further, and now here I am with my HSA- and DDS-equipped little Corsa :auto:

Thank you very much for the effort you spent preparing the manual.