Alrighty.
Both the aux output and digital input were what they should be.
For DI-4 (Aircon request), one of the settings is "Pullup resistor ON/OFF" - this was set to OFF.
Changed "Pullup resistor" to ON, stored to ECU, disconnected, then started car
-AC button turning pump on and off correctly (engine would almost stall when I turn it off though)
Connected to ECU while engine running and tried pressing AC button again
-not working (pump stuck on)
Confirmed "Pullup resistor" still set to ON
-it is
Stored to ECU again
-still not working
Disconnected ECU, turned engine off, connected to ECU, stored settings to ECU again, disconnected ECU, started car again
-button working again
Connected to ECU
-not working (pump stuck on)
Disconnected, turned car off, started engine, connected, stored to ECU again, disconnected ECU
-still not working
Disconnected ECU, turned engine off, connected to ECU, stored settings to ECU again, disconnected ECU, started car again
-button working again
It seems that simply connecting to the ECU while the engine is running breaks the function of the AC pump settings even though I have not changed a thing. I don't remember the outcome of connecting to the ECU while engine isn't running, then disconnecting without changing a thing and turning engine on once more, but I'm 99% sure it has the same outcome of breaking the AC pump settings. The only way to make it work again, is to store to ECU while engine is off before disconnecting.
So:
-tuner didn't do this setting correctly, or it just doesn't make a difference whether pullup resistor is on or off.
-connecting to ECU will cause this AC function to stop working correctly
-fixed by storing settings to ECU when engine isn't running, then disconnecting before starting engine
-Engine will stall, or come VERY close to stalling when the pump is turned OFF - more than likely just requires idle tuning tweaked or something, since they could only tune it with the pump running in the first place. (running a MAP sensor FYI, if that makes a diff)
Anyone shed any light on this? I would try updating the ECU firmware, but I wouldn't expect it would be necessary as it would have either been the latest version when the ECU was fitted, or the tuner would have already done this....plus I just don't want to risk breaking something by doing this.