XDI200 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 ........................................................ 6 1.1 ELECTROMOTIVE, INC. PRODUCT WARRANTY .......................................... 6 2 Forward................................................................................ 7 2.1 Improvements of the XDI200 over the TECgt ................................................... 8 2.2 Fundamentals of the System ............................................................................ 8 3 Installing the Hardware .................................................... 10 3.1 Pre-Installation Checklist ................................................................................ 10 3.2 Mounting the Main Computer and DFU .......................................................... 10 3.3 Trigger Wheel and Sensor Installation ............................................................ 12 3.3.1 Crankshaft Trigger Installation for 60(-2) Tooth Wheel ............................... 12 3.3.2 Hall Effect or Magnetic Crank Sensors ....................................................... 13 3.3.3 Crank Sensor Installation ............................................................................ 13 3.3.4 Wiring a Magnetic Trigger Sensor ............................................................... 15 3.3.5 Verifying Trigger Wheel Timing ................................................................... 16 3.3.6 Camshaft- & Distributor-Mounted Trigger Setups ....................................... 18 3.3.7 Individual Cylinder trim application – Cam Synchronization ........................ 18 3.3.8 TDC Tooth Setup Software Adjustment Parameters ................................... 20 4 Wiring the System ............................................................ 23 4.1 Introduction ..................................................................................................... 23 4.1.1 Suggestions on Crimp Terminals… ............................................................. 23 4.2 Wiring ECU & Main Power .............................................................................. 24 4.2.1 Power Harness Installation ......................................................................... 24 4.3 Wiring Ignition Coil Primary Sides................................................................... 25 4.3.1 Introduction ................................................................................................. 25 4.3.2 Standard Direct Fire Units, DFU’s ............................................................... 26 4.3.3 Wiring Standard DFU’s Coils ...................................................................... 26 4.3.4 Spark Plug Wiring High Voltage Side .......................................................... 28 4.4 Ignition Firing Order ........................................................................................ 30 4.4.1 Common Engine Sparkplug Wiring ............................................................. 31 4.5 Coil Firing Schemes ........................................................................................ 32 4.5.1 Coil Firing Patterns for EVEN-FIRE Engines .............................................. 32 4.5.2 Coil Firing Patterns for ROTARY Engines ................................................... 33 4.5.3 Coil Firing Patterns for 2-CYCLE Engines .................................................. 33 4.5.4 Coil Firing Patterns for ODD-FIRE Engines ................................................ 34 4.5.5 Examples of Typical Engine Setups ............................................................ 34 4.5.6 Common Firing Orders ................................................................................ 37 4.5.7 How to find the TDC Event Order : .............................................................. 38 4.5.8 TDC Tooth for DFU “2” needed for an Odd-Fire Engine: ............................ 38 4.5.9 Harley-Davidson Applications ..................................................................... 38 4.5.10 Rotary Engines............................................................................................ 38 4.5.11 Dual Plug Engines ....................................................................................... 39 4.6 Spark Plug Wire Selection .............................................................................. 39 4.7 Spark Plug Selection ...................................................................................... 40 4.8 Driver on Coil Logic Driven Coils .................................................................... 42 5 Wiring Sensors & Other Inputs ....................................... 43 5.1 The Manifold Air Pressure (MAP) Sensor ....................................................... 43 ________________________________________________________________________ XDI200 Manual Version 0.0 - Page 2 - ©2016 Electromotive, Inc. 5.1.1 MAP Sensor Data ....................................................................................... 44 5.2 Throttle Position Sensor ................................................................................. 45 5.3 TPS Wiring ..................................................................................................... 46 5.4 Coolant Temperature Sensor ......................................................................... 47 5.5 Manifold Air Temperature Sensor ................................................................... 49 5.6 The Exhaust Gas Oxygen Sensor .................................................................. 50 5.6.1 Mounting the EGO Sensor .......................................................................... 50 5.6.2 Wiring the EGO Sensor ............................................................................... 50 5.6.3 EGO Functionality ....................................................................................... 51 5.6.4 About One-Wire EGO Sensors ................................................................... 52 5.7 Wideband O2 Sensor ..................................................................................... 52 5.7.1 Wideband EGO Information and Installation Instructions ............................ 52 5.8 Secondary EGO sensor input ......................................................................... 53 5.8.1 EGO FAQ’s and Troubleshooting Tips: ....................................................... 53 5.9 Knock Sensor ................................................................................................. 53 5.10 Auxillary Temperature Sensor Input ............................................................ 55 5.11 General Purpose Inputs (GPI’s) .................................................................. 55 5.11.1 Available General Purpose Input (GPI) Functons ...................................... 56 5.11.2 Wiring the GPI’s .......................................................................................... 57 6 Wiring Outputs .................................................................. 59 6.1 Idle Air Control Motor ...................................................................................... 59 6.1.1 Wiring a 2-wire IAC: .................................................................................... 60 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 XDI200 ........................... 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 Getting the Engine to Idle ............................................................................... 69 8.4 Tuning the Idle Air Control Motor .................................................................... 69 8.4.1 Configuring the New Electromotive Idle Speed Control .............................. 69 8.4.2 Idle Speed primer ........................................................................................ 70 8.4.3 Getting the IAC Started ............................................................................... 70 8.4.4 Error Sensitivity ..........................................................................................