Table of Contents Table of Contents.......................................................................... 1 Terms and Conditions .................................................................. 5 Direct Sales and Value Added Dealers........................................................................... 5 Warranty ......................................................................................................................... 5 Repairs and Returns ........................................................................................................ 5 Pricing Policies ............................................................................................................... 5 Legal Disclaimer............................................................................................................. 6 Forward ......................................................................................... 7 3 A. Installing the TEC System .................................................... 9 A.1. How it All Works: The Two Pages You Need to Read ......................................... 9 A.2. Pre-Installation Checklist..................................................................................... 11 A.3. Mounting the Main Computer and DFU.............................................................. 12 A.4. Trigger Wheel and Sensor Installation................................................................. 14 A.4.a. Crankshaft Trigger Installation for 60(-2) Tooth Wheel............................... 14 A.4.b. Magnetic Crank Sensor Installation.............................................................. 15 A.4.c. Wiring the Magnetic Sensor.......................................................................... 16 A.4.d. Verifying Trigger Wheel Timing.................................................................. 17 A.4.e. Camshaft- & Distributor-Mounted Trigger Setups ....................................... 19 A.4.f. Full Sequential Applications – Cam Synchronization................................... 20 A.4.g. TDC Tooth Setup Software Adjustment Parameters .................................... 22 A.5. Wiring the TEC3................................................................................................... 25 A.5.a. TEC3 Main Power Connections .................................................................... 25 A.5.b. Power Harness Installation............................................................................ 26 A.5.c. Wiring the Fuel Injectors............................................................................... 28 A.5.d. Wiring the DFU’s.......................................................................................... 28 A.5.e. Wiring the Engine Sensors............................................................................ 29 B. Tuning Guide......................................................................... 31 B.1. Adjusting the Timing Advance ............................................................................ 31 B.2. Establishing Proper Starting Enrichments............................................................ 32 B.3. Getting the Engine to Idle .................................................................................... 33 B.4. Establishing Proper Acceleration Enrichments.................................................... 34 B.5. Adjusting the VE Table........................................................................................ 35 B.6. Using TPS/MAP Blend ........................................................................................ 35 B.7. Tuning for Cold Engines and Cold Weather........................................................ 36 B.8. Tuning the Idle Air Control Motor....................................................................... 37 B.9. Tuning the Knock Control.................................................................................... 38 B.10. Using the Injector Trims .................................................................................... 38 B.11. Using the Ignition Advance Trims..................................................................... 39 B.12. Tuning the EGO Sensor ..................................................................................... 39 C. Direct Fire Units (DFU’s)..................................................... 41 C.1. Wiring the DFU’s................................................................................................. 42 C.2. Spark Plug Wire Routing ..................................................................................... 46 TEC3 Manual Version 1.7 - Page 1 - ©2003 Electromotive, Inc. C.2.a. Common Engine Setups ................................................................................ 46 C.2.b. Special Note for Coil-Per-Plug Applications................................................ 48 C.3. Coil and Injector Firing Schemes......................................................................... 49 C.4. Common Firing Orders ........................................................................................ 61 C.5. Odd-Fire Engines ................................................................................................. 62 C.5.a. To find the TDC Event Order:....................................................................... 63 C.5.b. TDC Tooth for DFU “B” needed for an Odd-Fire Engine:........................... 63 C.5.c. Harley-Davidson Applications ...................................................................... 63 C.6. Rotary Engines ..................................................................................................... 64 C.7. Dual Plug Engines................................................................................................ 64 C.8. Spark Plug Wire Selection ................................................................................... 65 C.9. Spark Plug Selection ............................................................................................ 66 D. Fuel Injector Configurations ............................................... 67 D.1. High vs. Low Impedance Injectors ...................................................................... 67 D.2. Injector Firing Schemes ....................................................................................... 70 D.2.a. Staged Injection............................................................................................. 70 D.2.b. Throttle Body Injection (TBI)....................................................................... 71 D.2.c. Phase-Sequential Injection ............................................................................ 72 D.2.d. Full Sequential Injection ............................................................................... 73 D.2.e. Rotary Engine Injection ................................................................................ 74 D.3. Injector Wiring..................................................................................................... 75 D.4. Fuel Injector Pulse Width Derivation .................................................................. 76 D.4.a. Introduction ................................................................................................... 76 D.4.b. User Adjustable Pulse Width (UAP) ............................................................ 79 D.4.c. Pulse Width Offset Time (POT).................................................................... 82 D.4.d. Volumetric Efficiency Table Corrections..................................................... 84 D.4.e. TPS/MAP Blend Corrections........................................................................ 86 D.4.f. Oxygen Sensor Corrections ........................................................................... 88 D.4.g. Warm-Up Enrichments (Coolant Temperature-Based) ................................ 91 D.4.h. Manifold Air Temperature Enrichments....................................................... 92 D.4.i. Throttle Position Sensor and MAP Enrichments........................................... 93 D.4.j. Starting Enrichments...................................................................................... 95 D.4.k. Battery Voltage Compensation ..................................................................... 96 D.4.l. Deceleration Fuel Cut-Off ............................................................................. 97 D.4.m. Summary...................................................................................................... 98 E. Fuel System............................................................................ 99 E.1. Injector Sizing .................................................................................................... 100 E.2. Fuel Pump Selection........................................................................................... 104 E.3. Fuel Pressure Regulator Selection...................................................................... 104 F. TEC3 Output Functions and Wiring……….……………..107 F.1 Idle Air Control Motor......................................................................................... 107 F.2. Tachometer Output ............................................................................................. 110 F.3. The Fuel Pump Relay Output ............................................................................. 111 F.4. The General Purpose Outputs (GPO’s) .............................................................. 112 F.4.a. Available GPO Functions ...........................................................................