TECs200 Product Installation Manual & User’s Guide DRAFT v0.0 Electromotive, Inc. 703-331-0100 9131 Centreville Road 703-331-0100 fax Manassas, VA 20110 [email protected] Table of Contents 1 Terms and Conditions ........................................................ 7 1.1 ELECTROMOTIVE, INC. PRODUCT WARRANTY .......................................... 7 2 Forward................................................................................ 8 2.1 Improvements of the TECs200 over the TECgt ................................................ 9 2.2 Fundamentals of the System .......................................................................... 10 3 Installing the Hardware .................................................... 11 3.1 Pre-Installation Checklist ................................................................................ 11 3.2 Mounting the Main Computer and DFU .......................................................... 12 3.3 Trigger Wheel and Sensor Installation ............................................................ 13 3.3.1 Crankshaft Trigger Installation for 60(-2) Tooth Wheel ............................... 14 3.3.2 Hall Effect or Magnetic Crank Sensors ....................................................... 14 3.3.3 Crank Sensor Installation ............................................................................ 15 3.3.4 Wiring a Magnetic Trigger Sensor ............................................................... 16 3.3.5 Verifying Trigger Wheel Timing ................................................................... 17 3.3.6 Camshaft- & Distributor-Mounted Trigger Setups ....................................... 19 3.3.7 Full Sequential Applications – Cam Synchronization .................................. 19 3.3.8 TDC Tooth Setup Software Adjustment Parameters ................................... 21 4 Wiring the System ............................................................ 24 4.1 Introduction ..................................................................................................... 24 4.1.1 Suggestions on Crimp Terminals… ............................................................. 24 4.2 Wiring ECU & Main Power .............................................................................. 25 4.2.1 Power Harness Installation ......................................................................... 25 4.3 Wiring the Fuel Injectors ................................................................................. 26 4.3.1 High vs. Low Impedance Injectors .............................................................. 27 4.3.2 Injector Firing Schemes .............................................................................. 28 4.3.3 Staged Injection .......................................................................................... 28 4.3.4 Phase-Sequential Injection ......................................................................... 29 4.3.5 Full Sequential Injection .............................................................................. 30 4.3.6 Injector Channel Pinout ............................................................................... 32 4.4 Wiring Ignition Coil Primary Sides................................................................... 32 4.4.1 Introduction ................................................................................................. 32 4.4.2 Standard Direct Fire Units, DFU’s ............................................................... 32 4.4.3 Wiring Standard DFU’s Coils ...................................................................... 32 4.4.4 Spark Plug Wiring High Voltage Side .......................................................... 34 4.5 Ignition Firing Order ........................................................................................ 36 4.5.1 Common Engine Sparkplug Wiring ............................................................. 36 4.6 Coil and Injector Firing Schemes .................................................................... 37 4.6.1 Injector and Coil Firing Patterns for EVEN-FIRE Engines ........................... 37 4.6.2 Examples of Typical Engine Setups ............................................................ 38 4.6.3 Common Firing Orders ................................................................................ 39 4.6.4 How to find the TDC Event Order : .............................................................. 39 4.7 Spark Plug Wire Selection .............................................................................. 39 4.8 Spark Plug Selection ...................................................................................... 40 4.9 Driver on Coil Logic Driven Coils .................................................................... 42 5 Wiring Sensors & Other Inputs ....................................... 43 5.1 The Manifold Air Pressure (MAP) Sensor ....................................................... 43 _____________________________________________________________________ ___ TECs200 Manual Version 0.0 - Page 2 - ©2016 Electromotive, Inc. 5.1.1 MAP Sensor Data ....................................................................................... 44 5.2 Throttle Position Sensor ................................................................................. 44 5.3 TPS Functionality and Wiring ......................................................................... 45 5.4 Coolant Temperature Sensor ......................................................................... 46 5.5 Manifold Air Temperature Sensor ................................................................... 48 5.6 The Exhaust Gas Oxygen Sensor .................................................................. 49 5.6.1 Mounting the EGO Sensor .......................................................................... 49 5.6.2 Wiring the EGO Sensor ............................................................................... 49 5.6.3 EGO Functionality ....................................................................................... 50 5.6.4 About One-Wire EGO Sensors ................................................................... 51 5.7 Wideband O2 Sensor ..................................................................................... 51 5.7.1 Wideband EGO Information and Installation Instructions ............................ 51 5.8 Secondary EGO sensor input ......................................................................... 52 5.8.1 EGO FAQ’s and Troubleshooting Tips: ....................................................... 52 5.9 Knock Sensor ................................................................................................. 53 5.10 Auxillary Temperature Sensor Input ............................................................ 54 5.11 General Purpose Inputs (GPI’s) .................................................................. 54 5.11.1 Available General Purpose Input (GPI) Functons ...................................... 55 5.11.2 Wiring the GPI’s .......................................................................................... 56 6 Wiring Outputs .................................................................. 58 6.1 Idle Air Control Motor ...................................................................................... 58 6.1.1 Wiring a 2-wire IAC: .................................................................................... 59 6.1.2 Wiring a 3-wire IAC: .................................................................................... 60 6.2 Tachometer Output ......................................................................................... 62 6.3 Fuel Pump Relay Output ................................................................................ 62 6.4 General Purpose Output (GPO) functions : .................................................... 63 6.4.1 Outputs ....................................................................................................... 64 6.4.2 Available GPO Functions ............................................................................ 64 6.4.3 Wiring the GPO’s: ....................................................................................... 65 7 Communications Ports on the TECs200 ........................ 67 7.1.1 PC communications, USB port .................................................................... 67 7.1.2 PC communications, RS232 Serial port ...................................................... 67 7.1.3 CAN bus serial port ..................................................................................... 67 8 Tuning Guide..................................................................... 68 8.1 Introduction ..................................................................................................... 68 8.2 Adjusting the Timing Advance ........................................................................ 68 8.3 Establishing Proper Starting Enrichments ...................................................... 69 8.4 Getting the Engine to Idle ............................................................................... 70 8.5 Establishing Proper Acceleration Enrichments ............................................... 70 8.6 Adjusting the VE Table ................................................................................... 71 8.7 Using TPS/MAP Blend .................................................................................... 72 8.8 Tuning for Cold Engines and Cold Weather ..................................................