HKS EVC IV Installation and User Manual
Contents
1. 1 1 1 1 2 To access this mode push the Mod button then dial in your setting by turning the volume control knob 10 AUTO ADJUST MODE Over a period of time as your turbocharger begins to wear and becomes less efficient the boost pressure may drop This mode allows the EVC IV to automatically adjust the wastegate in order to maintain the boost pressure WARNING Because this mode will cause the turbo to work harder in order to produce the same boost pressure it will contribute to the turbo s deterioration For this reason we recommend that the Auto Adjust Mode be turned off To turn the Auto Adjust mode off make sure the ignition key is on and the EVC power is off While holding the Mod button change the SW lt gt PO switch on the back of the unit from its current position Once you hear an audible beep return the switch back to its original position Again there will be an audible beep To turn the Auto Adjust mode back on simply repeat the same step above INHIBIT MODE Inhibit mode enables the EVC IV to be locked so that none of the preset values can be changed ro engage the inhibit mode make sure the ignition key is on and the unit power is off While holding down the Alt button change the position of the SW lt gt PO switch on the back of the EVC Release the Alt button and return the switch back to its original position The presets are now locked into the EVC N To turn the inhibit mode off make sure2. 3 on the EVC stepping motor Port 3 Connect to the port on the wastegate actuator o This hose should be as short as External Wastegate Turbocharger Kir Flow Meter A J Dual Port Actuator AR E y 4 es Plate gS fa T Air Flow Meter Intercooler k Y Wastegate fi TROUBLESHOOTING Note If at any time the EVC does not reset or readjust make sure the unit is not locked in INHIBIT mode see setup instructions EVC Control Unit Will Not Illuminate e Power Connection There must be a constant 12 volt power source under all conditions with the ignition ON e Ground Connection In some cases paint rust or a loose bolt will cause a bad ground e Electronic Splice Connector Visually from the outside wire connections may look good In some cases the wires are not making contact inside the connector Check the wires at both ends with a voltmeter to ensure continuity EVC Will Not Control Boost Make sure the SW lt gt PO switch on the back of the unit is in the correct position e Check the hose connections to ports 2 amp 3 on the EVC stepping motor EVC III IV and EZ stepping motors differ from EVC I and II stepping motors see installation diagrams e Check for continuity at each wire on the 8 pin harness for possible breaks in a wire If the pins on the main harness were disconnected while running the harness through the firewall make sure that the wire colors match the
3. EVC control unit plug Vehicle Is Not Building Enough Boost Underboosting Make sure the stock boost solenoid is disconnected Check for possible improper adjustment of the EVC unit Read the manual again to verify that you are following the correct procedure e The vacuum filters 4 amp 6mm may be clogged or dirty NOTE With additional engine modifications you must update the self learning data The unit must be reset and the learning mode must be implemented once again Vehicle Is Building Too Much Boost e Verify that there are no leaks in the hoses and that all connections are tight Check for hose damage such as pinholes or tears Make sure the vacuum filters 4 amp 6mm are not cracked e Wastegate valve may be too small or actuator may be too weak Turbocharger capacity may be too small In this case the boost curve will drop off during high rpm compared to the factory boost curve NOTE With additional engine modifications you must update the self learning data The unit must be reset and the learning mode must be implemented once again PARTS LIST Quantity Description Comments ontroller Unit ic Stepping Motor a O m Hose J au Vacuum o ce onnec x 1 Double Sided Tape s Wraps 00 5 png Motor Harnas sa HKS U S A Inc LIMITED WARRANTY Warranty Policy HKS U S A Inc HKS warrants to the original retail purchaser that the HKS product will be free from defects in mat
4. read H The EVC is now ready for your second pass Again do not engage boost until third gear Starting at 2000 rpm accelerate under boost util red line is reached Once the throttle is lifted an audible beep will be heard The Learning Mode was successful and the EVC N will go directly into the Boost Pressure Setting mode You can now skip down to step 5 If you have trouble setting the learning mode you can skip this step and go directly to step 3 below Due to the varying transitions between twin sequential systems such as the Supra Twin Turbo and RX7 Twin Turbo it is recommended to bypass the learning mode 3 STOCK BOOST SETTING If you do not have an HKS boost gauge or do not know your vehicle s stock boost you must do the following With Low and Set flashing turn the EVC s volume knob counterclockwise until the display reads 0 00 then press Sbc Enter 0 20 and press Sbc again Drive the vehicle under full boost in third gear and read the boost pressure once it stabilizes This figure is your stock boost Reset the EVC unit see directions on the next page Once the unit has been reset when Low and Set are flashing enter your stock boost pressure followed by pressing the Sbc button Note If at any time during the set up process the display flashes L or H it is an indication that you need to calibrate the volume knob If a flashing L is displayed turn the volume knob all the way counter clockwise If a flashin
5. service and repair procedures Always have access to a factory repair manual as some of the procedures and specifications required for the proper installation of this product may be referenced to the factory repair manual To avoid the risk of personal injury follow the lifting supporting and safety precautions contained in the factory repair manual ELECTRONIC VALVE CONTROLLER IV INSTALLATION INSTRUCTIONS PART 4503 RA006 NOTICE USER NOTES The EVC IV can be used on both internal and external wastegate type turbochargers The EVC IV is not capable of reaching boost levels lower than stock OEM levels The EVC IV will maintain it s programming even if the vehicle s battery is disconnected or the head unit is unplugged The serial numbers must match on the controller and the stepping motor in order for the unit to function properly The EVC IV is a sensitive electronic component and must be handled with extreme care Miswiring or shock will damage the unit Do not place near extreme heat water or areas prone to dirt and dust Most factory turbocharged vehicles come equipped with a secondary boost limiting system fuekcut system or pop off valve to safeguard against wastegate failure Due to this the EVC IV alone will not be able to raise the boost pressure beyond the point of the factory limit If this condition occurs consult your HKS distributor for information regarding products that can assist in this situation HKS Fuel Cut D
6. the key is in the on position and the unit power is off While holding down the Sbc button change the position of the SW lt gt PO switch on the back of the unit Release the Sbc button and return the switch back to its original position Inhibit mode is now turned off and all of your presets and programming can be changed EVC IV FLOW CHART How to advance between functions after initial set up Basic flowchart of how to get to each Detalled flowchari of how to get to different mode By pushing the Mod each different mode By pushing the button once you will progressively go Mod button once you will progres in this loop sively go in this loop God 1 Boost Pressure Controt Mode High Mode am Warning Boost 151 Setting 1997 HKSU SA INC bar to PSI Conversion Table re Bots Ven 2 18 0 60 8 70 085 1233 0 90 1305 mA MN 180 26 11 27 56 28 28 39 89 de PA Read this entire manual to understand how the EVC IV functions before beginning the installation process Do not attempt to Install or adjust the EVC IV without thorough knowledge of how this unit works This manual assumes that you have the knowledge in the operation of tools and equipment that are necessary to safely perform service operations on your vehicle This manual also assumes that you are familiar with typical automotive systems and basic
7. 1 on the EVC stepping motor Port 2 Connect to a source of pressurized air such as a turbocharger compressor housing discharge side or compressor outlet pipe before the intercooler using the 6mm hose e This hose should be as short as possible and should not exceed 100cm 3 4 Install the 6mm vacuum filter within 10cm 3 9 of port 2 on the EVC stepping motor Port 3 Connect to the port on the wastegate actuator e This hose should be as short as possible and should not exceed 100cm 3 4 Turbocharger Wastegate E i i um Port 1 Connect to an uninterrupted intake manifold pressure source after the throttle body such as a compressor bypass signal line using the 4mm hose Do not connect port 1 to the line that operates the fuel pressure regulator unless the supplemental instructions tell you to do so This hose should be as short as possible and should not exceed 100cm 3 4 e Install the 4mm vacuum filter within 1 0cm 3 9 of port 1 on the EVC stepping motor Port 2 Connect to a source of pressurized air such as the turbocharger compressor housing discharge side or compressor outlet pipe before the intercooler using the 6mm hose Use the tee fitting supplied with this kit to connect a pressure line to the secondary port on the wastegate actuator Both lines should be as short as possible and should not exceed I 00cm 3 4 Install the 6mm vacuum filter within 10cm 3 9 of port
8. ELECTRONIC VALVE CONTROLLER IV SET UP INSTRUCTIONS PART 4503 RA006 4503 RA009 IMPORTANT Read all instructions before attempting to set up the EVC IV When you begin the implementation read through each step again 1 TO BEGIN On the back of the EVC unit is a switch marked SW lt gt PO If you have a single port swing valve or internal type wastegate select SW If you have a dual port poppet or external type wastegate select PO 2 LEARNING MODE The learning mode will enable the EVC IV to read your vehicle s normal boost curve This information will widen your car s power band in order to optimize the benefits of your turbo For safety reasons we recommend going to a local drag strip to set the learning mode With the power on push and hold the Alt button While holding the Alt button push the Sbc button The unit should emit an audible beep and the display should show an L for Learning Mode The EVC IV is now ready for your first test run IMPORTANT Do not engage boost until the car is in third gear This will produce maximum load on the vehicle Starting at 2000 rpm accelerate under boost until an audible beep is heard After the beep lift off the throttle The EVC IV has learned the vehicle s stock boost If a beep is not heard before red line the vehicle is not producing stable boost Check all hose connections and verify proper installation After the first test pass is completed the EVC display should now
9. efencer HKS Vein Pressure Converter HKS Programmed Fuel Computer etc If the vehicle has a fuel cut defense system such as the HKS FCD make certain that the vehicle s boost pressure is not raised excessively as this will lead to engine and or turbocharger damage HKS will not warranty any damage caused be excessive boost levels Make sure the vehicle has a proper fuel management system that can handle higher boost pressures than stock OEM levels HKS will not warranty damage caused by improper fuel management lean air fuel ratio The EVC IV cannot control boost pressure above the maximum efficiency point of the turbocharger Boost pressure drop at high rpm may not be totally eliminated The EVC IV will not be able to compensate for pressure loss due to turbocharger sizing Boost creep or boost spikes due to inadequate wastegate flow capacity lean air fuel ratio poor compressor design or excessive backpressure may not be fully alleviated Increasing the boost pressure will also increase the intake air temperature If the intake air pressure exceeds 220 degrees Fahrenheit 100 deg Celsius performance increases may be minimal and detonation may occur For best performance and to safeguard against detonation always use the highest octane gasoline available 92 octane minimum Do not rely on the factory boost meter if equipped when adjusting the maximum boost pressure Install an HKS auxiliary boost pressure meter to monitor manifold boost press
10. erial and workmanship for one 1 year from the date of original purchase except for e Full stainless steel exhaust and piping which are warranted for four 4 years from original purchase e Turbochargers and wastegates which are warranted for one hundred twenty 120 days from original purchase e Clutches which are warranted for ninety 90 days from original purchase This warranty does not apply where the product has been used for competition racing e the product has been abused misused improperly maintained repairs have been made or attempted by others repairs are required because of normal wear and tear alterations have been attempted or made to the product e the product is a consumable e the product has been in an accident This warranty is limited to repair or replacement without charge of the product part found to be defective or at HKS option refund of the purchase price and does not extend to claims for other loss or damage arising from the defect If a part or component from an HKS system kit is found to be defective this warranty shall apply only to the defective part or component and shall not require HKS to repair replace or refund the complete HKS system kit In no event shall HKS liability under this warranty exceed the purchase price of the HKS product This warranty does not include the cost of removal or reinstallation of the product No person or representative is authorized to extend any warrantie
11. g H is displayed turn the volume knob all the way clockwise 4 STOCK BOOST PLUS SETTING In order to input your stock boost plus you must add 2 to your stock boost number For example if you entered 5 7 25 psi as your stock boost you must input 7 as your boost plus setting 5 2 7 With High and Set flashing turn the volume knob until your stock boost plus setting is displayed then press the Sbc button Note IF YOU HAVE ANY PROBLEMS AND WANT TO START AGAIN YOU CAN RESET THE UNIT With he ignition key in the on position and the power to the unit turned off push and hold the Mod button While holding the Mod button push and hold the Alt button Then while holding both Mod and the Alt buttons push and hold the Sbc button You should hear an audible beep You can then go back to instruction 1 above If you do not hear a beep your unit may not have presets programmed in the unit 5 BOOST PRESSURE SETTINGS The unit will display high while set is flashing Turn the volume knob until the desired boost number appears Immediately push the Alt button The unit will display low while flashing set Turn the volume knob until the desired boost number appears Immediately push the Mod button displayed during this process of setting the boost pressures you must recalibrate the volume knob Please refer to the bold print in step 3 for re calibration directions 6 OFFSET MODE This function enables yo
12. isplay shows a lower the offset number If the display shows a higher boost higher boost than what you had programmed lower the than what you programmed raise the offset number offset number SCRAMBLE BOOST SETTING This setting allows you to run higher boost for a predetermined length of time simply by pushing the Sbc button The additional scramble boost and time settings will be the same for both the high boost and low boost To gain access to this function push the Mod button The display should read 0 00 Input the amount of additional boost to be programmed by turning the volume knob For example if your boost is set at 1 1 and you want to be able to run at 1 3 for a short duration of tire you would dial in 2 1 1 2 1 3 SCRAMBLE TIME SETTING This mode will set the duration of time the Scramble Boost will stay in effect You can program this function to operate from 1 30 seconds Push the Mod button The display should read 00 Program the time duration for 1 30 seconds by turning the volume knob WARNING BOOST SETTING This mode is a safety feature that will act as an override in the case of an overboost condition When triggered the EVC IV display will flash set off a series of audible beeps and return your boost back to the stock level until you lift off of the throttle For example if your high boost setting is 1 1 and you want the warning boost setting to be 1 over your high boost setting you will set this mode at 1 2
13. pping motor The 6mm vacuum filter should be installed with the short side facing the stepping motor Inspect the filters every 3000 miles They must be clean for the EVC to function correctly If the filter is contaminated or dirty replace with a new one Do not attempt to clean the vacuum filter If the filters frequently need replacement relocating the pressure source may solve the problem Connect the red wire 2 pin harness from the EVC to a 12 volt ignition source Utilizing a voltmeter find a wire that receives at least 12 volts with the key in the IGNITION position Connect the black wire 2 pin harness from the EVC to a chassis ground Make sure there is no paint or rust on the ground surface If there is sand the surface until bare metal is exposed Determine if the vehicle is equipped with an internal wastegate single port actuator or an external wastegate or dual port actuator then proceed to the corresponding installation instructions INTERNAL WASTEGATE SINGLE PORT ACTUATOR INSTALLATION INSTRUCTIONS Port 1 Connect to an uninterrupted intake manifold pressure source after the throttle body such as a compressor bypass signal line using the 4mm hose Do not connect port 1 to the line that operates the fuel pressure regulator unless the supplemental instructions tell you to do so e This hose should be as short as possible and should not exceed 100cm 3 4 e Install the 4mm vacuum filter within 10cm 3 9 of port
14. product Retain the RGA number for reference 3 Send the product freight and or postage prepaid to HKS USA Warranty Claims Department 2801 East 208th Street Carson CA 90810 1102 Please Clearly mark the RGA number on the outside of the package and the mailing label PACKAGES WITHOUT THIS INFORMATION WILL BE RETURNED e Include a copy of your original invoice showing the a A detailed description of the problem b A list of ALL modifications to the vehicle c Part number d Date of purchase e The purchase price f Your name and address g Daytime phone number HKS is not responsible for products returned to HKS without a clearly marked RGA number and return address Please allow 6 8 weeks for inspection and determination of warranty claim Should the dealer no longer be an Authorized HKS Dealer or no longer be in business you should contact HKS U S A Inc directly ee other side for Warranty Policy Effective 4 16 0
15. s on behalf of HKS other than expressed herein or assume for HKS any liability other than expressed herein in connection with the sale of any HKS product HKS DISCLAIMS ANY AND ALL LIABILITY FOR ANY IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANDABILITY AND FITNESS FOR A SPECIFIC PURPOSE UNDER NO CIRCUMSTANCES SHALL HKS BE LIABLE FOR ANY INCIDENTAL INDIRECT SPECIFIC OR CONSEQUENTIAL DAMAGES ARISING FROM PURCHASER S USE OF THE PRODUCT Some states do not allow one or more of the above specified exclusions or limitations This warranty gives you specific legal rights and you may also have other rights which vary from state to state Effective 4 01 See other side for Claims Procedure HKS U S A Inc LIMITED WARRANTY Claim Procedure To make a claim under this warranty you must 1 Working with the HKS U S A Inc Authorized Dealer make every attempt to determine the problem attributed to the HKS product Please take all steps to ensure that the problem is not caused by installation error e misapplication e modification e abuse e accident An inspection fee will be charged for all products sent to HKS for inspection and found to be in proper working order or malfunctioning due to cause other than manufacturing defect e Electronics 120 00 e Non electronic 70 00 2 Ifthe problem cannot be identified obtain a Return Goods Authorization RGA number through the HKS Authorize Dealer from whom you purchased the
16. u to calibrate your boost levels If you have completed the Learning Mode the offset should automatically be calibrated You can verify by pushing the Mod button see flow chart If the display reads 100 your offset mode is correct and you can now advance to instruction 7 If you have not completed the Learning Mode you may need to calibrate the boost levels by adjusting the Offset Mode For example if you have a single port swing valve or internal type wastegate and have programmed the EVC for a low boost of 1 0 but it will only hit 9 The Low Offset Setting allows you to adjust the offset in order to match your programmed number In the example above if we dial the offset number down from 100 to 86 the readout for the boost you achieve should now match your programmed low boost of 1 0 Be sure to follow the instructions below for the specific type of wastegate you are using There are two offset modes One for the high boost setting and one for the low boost setting Program the offset using even numbers only and between the range of 50 150 The default or normal setting is 100 To calibrate your Offset Mode follow only one set of instructions listed below Dual port poppet or external type wastegates If the Single port swing valve or internal type wastegates If the display shows a lower boost than what you had display shows a lower boost than what you had programmed programmed raise the offset number If the d
17. ure levels The utilization of an HKS exhaust gas temperature EGT meter is recommended to monitor engine conditions rich or lean air fuel ratios Mount the EVC IV control unit and harness away from high power two way radios mobile phones and their respective antenna cables to prevent malfunction of the EVC IV unit CONTROL UNIT DIAGRAM Alt Button Mode Button high low boost level bution fen gaz 65 557 DIENTE nt ee Wastegate Selector Switch 4 Pin Connector for optional scramble boost trigger switch Power Button Analog Volume Knob A Scramble Boost Bution Pia Connector turns unit on and off acreses scramble boos mode 8 Pin Connector connects lo EVC stepping motor Disconnect the negative battery cable from the battery 6mm Vacuum 4mm Vacuum Filter EVC stepping motor installation Determine an ideal mounting location for the stepping motor 6mm Hose Mount the stepping motor to the chassis using the hardware provided with this kit 4mm Hose Do not install the stepping motor close to the exhaust manifold or any area of high temperature Do not install the stepping motor where it will be exposed to water or moisture Ports 1 2 and 3 must face upward with port number 4 pointing down Lengths on all hoses must be kept as short as possible Port 4 Vacuum Filter Installation Install vacuum filters per diagram to the right Make sure the filters are within I Ocm 3 9 length from the ste
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