Powerjection III Installation Instructions
Contents
1. ing and loading a new cedibration file will over ante cumrert E Press OK te cortine File Edit Setup View Ab Open calibration from file Save calibration to file Read calibration data from ECU Exit 3 A pop up will appear asking you to confirm that you wish to load a new SS a meee Calibration File This will overwrite the current profile in the ECU EMS Note You may wish to save the previous profile in the ECU EMS to the 2 Open Calibration from file This will Calibration File folder before loading in a new file Click OK to save file open a window on the laptop that lists e Save calibration to file Stored calibration files and calibration e Read calibration data from ECU files made and stored by you Calibra e Exit tion files use the extension RSC Open calibration from file Save calibration te file Read calibration data from ECU 1 Under File you have four options e Open calibration from file Open calibration trom file Save calibration to file _ Big Bleck Base 2 tice Read calibration data from ECU Boosted Lipu bit wyector 21 2 Muna Tune biedy Farsh Wena 2 lene Small Bloch Gage Throttle Fellevees Disabled J Jai Small Block Base Thaottie Follower Enabled 2 1 rc Smal Block With dddetiomal korel Boreck 2_ ec Open calibration trom file Save calibration to file Read calibration data from ECU 5 Save Calibration to File This allows saving the current loaded calibration in the ECU EMS wit2. Sure Adjust and test for proper fuel pressure again INSTALLING THE DASHBOARD SOFTWARE 1 The supplied software is designed to be used with the Powerjection III and is compatible with the Windows 7 operating system You will need a PC laptop with a CD drive to complete the installation 2 Insert the supplied Dashboard CD into the CD drive The Install Wizard will pop up and guide you through the installation process If the Wizard does The connect your laptop to the Powerjection III port in your laptop not pop up go to My Computer and double click the drive the CD is in Then the Install Wizard should pop up to continue the install process Once the Software is installed into your laptop you will need to connect it to the Pow erjection III throttle body harness 3 See photos and notes below to complete this stage of the installation Cable from throttle body Shown with dust cap removed 4 Replace dust cap when af disconnected from ll laptop Ignition key should be off when these connec tions are made Connect the other end of the cable assembly into the single pin connector from the throttle body OPENING THE DASHBOARD ON YOUR LAPTOP 1 The icon at left will be on your lap top desktop Click on it to open your Dashboard soft ware on your throttle body O MAP KFA AIR FUEL 0 IDLE KEY 0 TEMP DECEL OF SENSOR CLOSED LOOP ADAPTIVE LEARNING CONNECTING DATALOG S CONNECT TO
3. gether and tape For best results try to match wire color when making connections This will simplify troubleshooting if necessary Brown wire is not used It is for a future feature Wire Legend Orange Wire Fuel Pump Yellow Wire Ignition Key Red Wire 12V source Green Wire Tach Output of amplifier box MSD 6A Black Wire Negative side of coil if using a ready to run two wire distributor No amplifier box Brown Wire Not used This is for a future feature 1 Connect the 12V fused red wire directly to the battery 2 Connect the orange Pump wire to the positive side of the electric fuel pump If using your existing fuel pump eliminate your previously installed power feed to it 3 Connect the yellow Key wire to a source that supplies battery voltage when the key is in the On position and in the Crank position Also verify that the voltage to the yellow ignition wire does not drop below 9 volts when cranking the engine You can connect the Key wire to the pos itive side of the ignition coil only if you are not running an MSD ignition with an amplifier box If a ballast resistor or resistor wire inline is used DO NOT connect the Key wire to the coil Lo cate a place before the resistor that is 12V or at the ignition switch or fuse panel 4A If using a ready to run type distributor you will need to connect the black SP wire to the neg ative side of the ignition
4. page 8 and switch both Adaptive Learn Fuel and Closed Loop to the active status each row which also represents an RPM range By entering the value you want in each of the cells allows you to vary your A F ratio in various rpm ranges in concert with various vacuum levels Note that 10 0 is very rich and 20 0 is very lean To alter a cell one at a time double click on the cell and enter a new value If you want to change all the cells to the same number double click on the cell below Fill and enter a new number Then click the Fill button and all the cells will change to that number If you want to increase or decrease all the cells by the same percentage you can use the Multiply function To increase all the cells by 10 enter 1 1 in The numbers in the cells are expressed in percentages For example a Cell with a 30 means that the ECU EMS has learned that 30 more fuel is needed to achieve the targeted air fuel ratio as set in the Air Fuel table It then adds this 30 to the base profile number to obtain the correct pulse width PW for the injectors A 30 means that the ECU EMS is subtract ing 30 of the fuel from the base profile to obtain the correct PW in order to achieve the target air fuel ratio You may wish to make changes to this table because you have found that a particular RPM range of your engine combination likes either more or less fuel in order to get the maximum power and performance the cell below
5. too low and it will run lean The default number is 300 lb ft To change it double click on the number for torque enter your value and and click outside the area to save it We use torque because it represents the fuel required by the engine The number Should be the maxium rear wheel torque of your engine Horsepower is a math equation derived from torque and RPM and does not provide an ac Curate fuel requirement for your engine like a torque listing does 8 8 3 10 INJECTOR PW 16 3 VAC Note on Torque Specs Many torque figures given in engine spec sheets are flywheel torque Our profiles use rear wheel torque If you start with a fly wheel torque value reduce it by 20 for the purposes of developing your engine s profile For a quick approximation of your engine torque go to the Professional Products website www professional products com and then click on Handy Formulas See CID To Torque Comp Ratio chart Number of Injectors This value will always be four unless you are running one of our dual EFI setups and then it will be eight Injector Flow Rate This value will always be 62 unless you have a custom setup with different flow rate injectors If you have something other than 62 lb hr injectors enter the correct number in this box Camshaft Choose based on engine vacuum Stock 16 18 e Mild Stock 15 17 Street Performance 14 16 e Performance RPM 13 15 e Hot Street 11 14 Strip Street 9 12 e P
6. AE to be in use The Fill High will auto fill from 20 100 the value entered In the AE table and also the duration table You can independently fill each cell with the desired value by clicking on the cell and entering the value To make the values apply you must click the Send button under each table The Decel function is to reduce the fuel injected while decelerating You can enter the pulse width you desire and at what RPM and throttle angle it becomes active After entering the values click Send to update the profile After making any adjustments to the tables you can click Close to close the window The Fuel Prime can be thought of as an accelerator pump on a carburetor when you step on it before starting The EMS will open the fuel injectors to Spray fuel for easier start ups for a desired amount of time 1 to 60 mil liseconds The default value will be sufficient 99 of the time You also have the option of choosing when the Fuel Prime occurs You can choose to prime the engine while you begin cranking or you can prime after a specified delay time from when the EMS receives key power COLD ENGINE This section of the window allows for you to add a percent age of fuel to the profile for cold engines to allow proper running until it reaches operating temperature This section can be thought of as a choke system of a carburetor Cold Engine continued on next page COLD ENGINE continued After Start Enrichment
7. and fuel return port in the fuel tank You will need a wire stripper crimper and a Small assortment of wire terminals and wire While we attempt to supply every needed component with these systems each vehi cle application may require different style s of terminals and thus are not included Read through the installation process prior to Starting the installation and determine the Style and quantity of terminals needed for your specific application On the Powerjec tion Ill system if you have power brakes and or a transmission vacuum modulator you will need the appropriate vacuum splice Use Professional Products 1 4 NPT x 06AN fitting in fuel pump and filter if using O6AN hose 15239 blue or 16239 black or 17239 polished or T to connect to a 3 8 inch vacuum port These are available at most auto parts stores The fuel pump and EFI supplied inline filter require male 1 4 NPT fittings The fuel lines need to be a minimum of a 3 8 inch hose or O6AN hose All fuel lines on the pressure Side of the fuel pump to the throttle body are required to be EFI pressure rated hose and we highly recommend the use of factory steel lines or AN style fittings and hose Note that Professional Products offers a full line of hose and fittings including a 1 4 NPT x 3 8 Use Professional Products barbed fitting 10244 specifically designed 1 4 NPT x 3 8 hose barbed to be used with the supplied Powerjection III fitting if you are using
8. cold enrichment percentage programmed Adaptive Learn Fuel The percentage value the ECU has learned Closed Loop The Percent of change the closed loop is making toward the Adaptive Learn Fuel Cell The current cell that the engine is in A F The air fuel ratio currently read by the oxygen sensor Target A F The programmed targeted air fuel ratio Battery Volt The current battery voltage read by the ECU IAC Target The programmed target of the Idle Air Control Motor IP Adress Status Closed _ J Ly ty 2 ee eaten Tene AFTER START DECAY p y TEMP BASED MODE eo RPM FOLLOWER eo IAC POS The current position of the Idle Air Control Motor Fuel Usage Gal Hour The amount of fuel the engine is using in gallons per hour at that exact time Total Run Time The total time the ECU has been active Key on power TPS The current position of the throttle position sensor Max Allowed Injector PW mS Max allowable Pulse Width at the current RPM and Load Injector PW mS Injected pulse width at that exact time Injection Mode 1 Crank 2 Auto 3 Manual 4 Deccel 5 Standby KOEO 6 Clear Flood 7 Fixed PW 8 Idle Cell Tach Input The input style selected during the setup in setup gt main setup Key Green indicates the key is on Black indicates the key is off Fuel Pump Relay Green indicates the relay is active Black is off 02 Sensor Green indicates the 02 senso
9. from ECL NOTE If you make changes this way you need to save this as a pro file to your laptop CALIBRATE TPS Under Setup select Calibrate TPS This procedure is used to calibrate the TPS so that the EMS knows what the closed throttle and the fully opened throttle positions are To calibrate the throttle position sensor TPS click on Setup and choose Calibrate TPS The TPS calibration window will open With the accelerator released and throttle closed press the Calibrate TPS Min button Next fully depress Push to the floor the accelerator and while held down click the Calibrate TPS Max button Release Throttle and Press Calibrate TPS Min Depress Throttle Wide Open and Press Calibrate TPS Max E Calibrate TPS Max Note If you accidently click Calibrate TPS Max before the minimum calibration has been set a pop up window will display telling you to set the minimum value first 16 REMOTE CONNECTION This feature allows you to connect live via the internet to Professional Products Techni cal Support so that Technical Support can view what you are viewing on your Stage III Dashboard at the same time live To use this function you must have a broadband Internet connection not dial up and contact Technical Support By phone at 323 779 2020 When speaking with you on the phone Technical Support will supply you verbally the needed information to input to complete the remote co
10. in Cranking mode the AC motor will position itself to the value entered in the IAC CRANKING PO SITION cell It will then decay reduce the position in steps entered for each revolution of the engine after started down to the value entered in the C TEMP BASED IAC BASE POS The value on the C Temp based IAC position table is the number of steps the IAC is open for the corresponding temperature B STALL SAVER This feature helps to prevent engine stalling You can enter a value RPM that you want the feature to become active and the amount of steps you want it to add to prevent stalling when the throttle plates rapidly close The decay value is the number of steps per revolution to re duce back to the IAC position on the C Temp table NOTE The above parameter usually does not require change C RPM FOLLOWER The RPM Follower lets the IAC motor control the en gine idle speed automatically The follower can be used to make up for dif ferent loads applied to the engine while idling such as A C and putting an automatic transmission in gear RPM must be less then RPM must first be less than this value for the RPM Fol lower to activate NOTE Throttle Position must always be less than 2 for RPM Follower to become active IAC Control With our new and improved IAC controls you easily change from two different modes RPM Target and Step Target RPM Target means 15 STALL SAVER lt RPM STEPS AD
11. s in the cell and then enter the new value The value for MAP must be kPa values and the vacuum line above f 4 Mfo 100 1300 1600 will change automatically to correspond with the en tered value affer Send is pressed B You also make the cylinder selection tuning strategy learning ability closed loop and tach input TUNING STRATEGY Choosing Automatic allows for the EMS to calculate a seeenacemee eee oosing Automatic allows for the o calculate ij 50 E65 BLEND fuel delivery Manual tuning will be discussed in the O TOOK ERS future in an advanced tuners manual CLOSED LOOP selecting Closed Loop On allows for the Stage III EMS to learn the fuel curve of the engine In order to work Adaptive Learn ing must also be in the On position Closed loop comes on at 40 degrees Fahrenheit In the Off position it will not use the O sensor reading in the equation to adjust the fuel delivery On motors using leaded fuels the 0 sensor life will be shortened You may wish to use the 0 for some learn ing and then turn closed loop off When Closed Loop is off the EMS will use the learned data in the Adaptive Learning to calculate fuel delivery Note Running leaded fuel and turning CL off does not save the sensor FUEL WIZARD Under Setup select Fuel Wizard We used part of the Fuel Wizard in the Creating Your First Profile Here we will discuss more details about what you can do with the Wizard Wit
12. slip EFI fuel pump and filter See the Profes on and clamped fuel hose sional Products website for fittings and hose lines This type of fitting is required on pressure side www professional products com INSTALLING THE POWERJECTION III EFI SYSTEM 1 Disconnect the battery for safety 2 Disconnect the fuel lines and linkage from the stock carburetor 3 Left Remove the carburetor following the vehicle manufacturer s guidelines 4 Right Install the Powerjection III throttle body insulating mounting gasket supplied with your system The thickness of this gasket assists in insulating en gine heat affecting the fuel in the throttle body It also features reinforcement bushings to prevent over tightening which can cause distortion of the mounting flange s Replacement mounting gasket is Walker Fuel systems part number G1037 5 Left Install the Powerjection III throttle body assembly onto your manifold Note You may need longer carburetor studs Use Professional Products 20151 Connect your throttle linkage and the throttle return spring Mount with nuts and washers and tighten The EMS grounds through the mounting of the throttle body 6 Right Install the 3 8 NPT Coolant Tempera ture Sensor into one of the manifold water ports You may need a reducer bushing Connect harness from throttle body to the coolant temperature sensor 7 Connect your power brake If equipped vacuum line to
13. vented fuel cap WILL NOT be sufficient Minimum vent size should be 1 4 inch This system also requires a return fuel line from the throttle body unit back to the fuel tank Unless you are also incorporating our FuelOnDemand kit It is necessary to install a vent and provisions for the return fuel line if these are not already present If these modifications need to be performed remove the fuel tank using the vehicles manufacturer s guidelines and have experienced person nel make the modifications If any welding is performed on the tank it must be fully flushed all gasoline and gasoline fumes The Powerjection III throttle body will fit the common square bore intake manifold that a Holley 4150 will fit The linkage of the throttle body is the Same as a Holley 4150 so there should be no need to modify the linkage for the accelerator if the vehicle is presently equipped with a Holley Carbure tor adapters can be purchased from speed shops to adapt your intake to the 4150 square bore If you have a spread bore carburetor style manifold you can utilize a Professional Products 52111 Manifold Adapter Plate Kit to allow the Powerjection III to fit your manifold 70020 Shown Satin Finish life of your electric pump and also lessen the pump noise at idle or low Speeds particularly on very large pumps We also offer our 70108 Fuel Line Kit for use with returnless systems All Powerjection III systems are tested live in a test engine c
14. you will need to turn off the Closed Loop feature PULSE WIDTH This refers to the length of time that an injector nozzle is open and injecting fuel into the airstream It is measured in milliseconds This is controlled by the ECU EMS mounted on the Powerjection III throttle body While this setting can be changed it normally is left alone and the basic map you are using determines what it Should be under varying condtions MAP Sensor The manifold absolute pressure sensor provides instantaneous mani fold pressure information to the ECU EMS The data is used to calculate air density and determine the engine s air mass flow rate which in turn determines the required fuel metering for optimum combustion INTRODUCTION Thank you for your purchase of the Professional Products Powerjection III Fuel Injection System In this manual we will outline the procedure for in Stalling the unit on your vehicle as well as how to navigate and use the Stage III Dashboard software We feel this is the easiest system to install and uti lize If during the installation you have any question about the installation procedure please call our Technical Support Line at 323 779 2020 The Technical staff is fully equipped and knowledgeable to assist you with every Step of the installation and programming VARIOUS POWERJECTION III VERSIONS The Powerjection III is available in two different versions The Throttle body assembly part numbers 70020 Satin Finish a
15. your Closed Loop Status When lit the EMS ECU is operating in desired number We will discuss setting your desired target closed loop Adaptive Learning Status When lit the EMS ECU in the Advanced Tuning section is learning and updating Status Lights DATA LOGGING When Data Logging is turned on a com plete record of your vehicles operation is stored in the com puter You can go back at any time and review all of the Stored data Data logging is turned on by toggling the switch Shown at right Switch is white in the down position when turned off and red in the up position when turned on See pages 19 and 20 for complete details on how to access and use the Data Logging capabilities of your Powerjection II System USING YOUR STAGE IlI SOFTWARE There are a number of adjustments that can be made while driving the car alone We suggest you have a friend assist One person drives while the with your laptop connected to the Powerjection III System Note Never at other person monitors the laptop and makes the adjustments Trying to do tempt to make corrections or adjustments to your system while driving it by yourself could lead to losing control of your vehicle With your Dashboard open on your laptop at the top left you will see several choices File Edit Setup View and About We will discuss each of these various choices in M File Edit Setup View About detail on the following pages P a ee pee i Pa PPOTES Shon J af
16. 50 i FUELUSAGE GAL HR 142 GASOLINE TOTAL RUN TIME 122 hr 60 E85 HISTOGRAM This feature allows you to see what is occurring in real time with e RPM e TPS e MAP Vac m e Injector Pulse Width 550 600 650 700 750 800 550 600 650 700 750 800 e A F Air Fuel Ratio RPM 2852 TPS 35 e Battery Voltage PEAK 15820 PEAK 100 Also displayed are the peak value the EMS recorded during the current key on run session Under the MAP screen is a choice of NA and BOOST Click the appropriate one for your application It changes the scale for load on the left side of the MAP screen Clicking Reset All will reset the peak values that have been recorded 550 600 650 700 750 800 Se Ssu ee If you are data logging you can click Bookmark to mark a specific lo a anes alae or Bey ess ty ms ives cation you saw while observing the histogram for ease in finding while reviewing the data log Bookmark Button Bookmarking can be used for troubleshooting With the Histogram open press the Bookmark button when the issue oc 7 0 curs and a placemark will be saved in the log file You must be data 550 600 650 700 750 800 550 600 650 700 750 logging at the time in order for this to occur N BAT VOLT 11 8 11 8 PEAK File Edit Setup View About Real Time ECU Data Histogram About opens a box displaying informa tion about e Dashboard Version e Release Date e Calibration File Version e Firmware Versio
17. 70108 Fuel Line Kit these kits will have all the necessary fittings you need Remove the fuel inlet 70191 Pump supplied Outlet and outlet fittings from in EFI Kit the fuel pump Install your pre selected fit tings into the removed fittings using blue Loc tite 246 sealant Never use Teflon tape in the fuel system If you at tempt to install your fuel line fittings into the inlet and outlet fittings of the pump with the fittings still installed in the pump you may damage the pump Reinstall the fuel inlet fitting onto the fuel pump taking care to not over tighten Next install the brass outlet fitting on to the pump making sure the sealing washer is in place Tighten the outlet fitting taking caution not to over tighten The inlet threads are fragile and may break if over tightened Install the fuel pump The fuel pump must be mounted in a position below the fuel tank level and within 2 feet of the fuel tank so that fuel can gravity feed and prime the pump This is true of all electric EFI fuel pumps not just the Professional Products pump Connect a ground wire on the negative side of the fuel pump and ground to the chassis Install a fuel line from the fuel tank supply outlet to the fuel pump inlet A pre filter should NOT be used inline between the fuel supply and the fuel pump inlet unless you have the correct filter Many of the commonly avail able filters used before the fuel pump will cause a vacuum
18. Base Profile sec tion starting on page 8 of these instructions DEFINITION OF SOME COMMON TERMS USED IN THIS INSTRUCTION BOOKLET ECU EMS ECU engine control unit or EMS engine management system are in terchangeable terms and are used to describe the miniature computer mounted on the throttle body MAP This term is actually used to describe two different things We have tried to dif ferentiate by using lower case for one and caps for the other The map or MAP is the program that is created to map your engine s functions MAP stands for manifold ab Solute pressure See kPs for more detail kPa This abbreviation stands for kilopascals and is the metric term used for both vac uum and pressure You are probably used to seeing inches of vacuum and pounds per square inch of pressure We use kilpascals because the measure terms are the same 0 100 kPs covers the vacuum part of the scale while 100 and up is the pres Sure part of the scale A reading of 100 kPs is zero inches of vacuum and zero PSI While your Dashboard software shows the kPs reading as the dominant number di rectly below that reading we convert the number to inches of vacuum or PSI WATER Some of the charts and tables in Dashboard software use the term water This terms applies to your engine coolant DASHBOARD This is the software that is on the supplied disc This provides you with the ability to infinitely tailor your system Also contains features for ad
19. DED DECAY STEPS REVOLUTION RACK TO TEMP POS APM FOU as ial ak THEN 80F THEN 80F 110 2 20 UPPER STEP LIMIT LOWER STEP LIMIT 5 RPM MUST BE LESS THEN T0 ENABLE AND TPS LESS THEN 2 1300 STATUS CLOSE POSITION CRANK POSITION AFTER START C TEMP DECAY TEMP BASED OPERATION RPM FOLLOWER STALL SAVER MANUAL MODE STEP TARGET that the EMS will attempt to automatically control your engine idle RPM based on coolant temperature You just need to enter your desired idle speed for each coolant temp displayed Further IAC control is found under RPM Follower where you can set minimum and maximum step limits based on coolant temperature Always be sure to set the RPM threshold 500 to 1 000 RPM higher than your maxium target RPM In the RPM Target mode the Stall Saver setting becomes inactive because it is not needed The further the actual RPM is away from the target RPM the faster the IAC moves to com pensate In the Step Target Mode the IAC motor will stay in the position you com mand as long as the Stall Saver and cranking positions are not needed In this mode you must manually set each IAC position based on coolant tem perature When using Step Target the RPM Follower parameters are not used After entering your desired values you must click Send to update the pro file The bottom portion of the window allows you to see the status of the IAC motor e Close Position is active when the key is off e Crankin
20. ECU 3 If the Dashboard cannot find your ECU a blank Dashboard screen will come up If you get a blank screen then in order to connect to your Stage III ECU you can either turn your key to the on position and hit the Connect to ECU button to start the ECU search again or you can close and re open the Dashboard program with the key on to commence the new auto search When the Dashboard finds the ECU you will see a window come up as Shown above with the word Connecting in yellow See above left image 4 When fully connected to the ECU the status will change from the yellow Connecting to the green ECU Connected See above right image A pop up in the middle of the screen lets you know the system is reading the ECU 2 When the Dashboard opens you will see the window at right that tells you the Dashboard is Searching through 29 Comm Ports to locate the Stage II ECU ECU is the computer mounted Searching Searching for Stage Ill ECU Please Wait Com Port 13 MAP KFA 20 5 VAC AIR FUEL IDLE KEY Reading Calibration File from ECU Please Wait DECEL r r CLOSED LOOP ADAPTIVE LEARNING CONNECT TO ECU ECU CONNECTED Fieading from ECU Piespe eit calibration files When the load status completes the pop up goes away and you are now online with your Powerjection III ECU 7 CREATING YOUR BASE PROFILE FOR THE POWERJECTION III EFI SYSTEM We will take you through the steps necessa
21. Here you can enter a value as a percentage above base for added fuel at certain temperatures after the engine has immediately started For example in the window at right at 40 degrees of coolant temperture the system will add 20 more fuel and at 50 degrees it drops to 15 more fuel and by the time the temperature reaches 230 degrees it will not be adding any additional fuel It will add the fuel for the allotted time entered into the Decay Time field and then transition over to the C Temp Enrichment C Temp is Coolant Temperature The After Start Enrichment is enabled if the engine temperature as read by the coolant temperature sending unit is less than the value en tered into the Enabled If cell Note The value in the ENABLED IF CT LESS THAN cell should never need adjusting C Temp Enrichment This is the percentage of fuel being added to the profile after the decay time has expired of the After Start enrichment This is the choke system of the injection system The enrichment percentage typically would decrease from high values AFTER START ENRICHMENT TEMP F ADDED FUELS DECAY TIME SEC i ENABLED IF CT LESS THEN 240 40F TO 1006 Pwius SEC 200 2 TOF 230F PwiuS SEC mo 2 C TEMP ENRICHMENT TEMP F ADDED FUEL mo i110 120 122 22 ji20 118 j2 jro hoe 105 at cold temperatures to 100 at 170 degrees Intermediate Pulse Width To avoid a situation where an en
22. IR FUEL 66 Fa Md a poy J oo Ez g 1 Paai T oo o0 in oo cm g ee oo oo in at oo a 90 98 a a ats wail P md wal ee Ph Po wail Lo Lm cae In oo 35 fiz aa f Md wal i Ph Ba i mhi wall Lo Lm Ba ea oo eal ee Md Md l to im 49 pe B wall Target Air Fuel This table allows you to alter the targeted air to fuel ratio that the ECU EMS uses in closed loop Across the top are the MAP Mani fold Absolute Pressure boundaries and down the left are the RPM bound aries Note that each MAP column has two numbers which represent a high and low range MAP is expressed in kPa The RPM also has two numbers for DECEL P Edit Under Edit you can edit the following e Target Air Fuel Ratio e Adaptive Learning Fuel e Adaptive Learning Cell Protect e Accel Decel e Crank Cold Engine e Idle Air Control IAC Target Air Fuel Fl Adaptive Learn Fuel F2 Adaptive Learn Cell F3 Accel Decel i Crank Cold Engine 3 K ADAPTIVE LEARN FUEL DECEL f mad Lm E IDLE 3 EE Clear ADL ho Pa to mW ea naa wn Edit OFF aii RV i fia lii ha ing ia jaa it aja L mn oii i a ia Ni Wa i it os Adaptive Learn Fuel This table shows the amount of learning that your ECU EMS has performed in the specific Load RPM cell Note In order for this feature to work you must go to the Main Setup see
23. NDER SELECTION TUNING e geranean haai complished by placing a b Damm aa your cursor over the regi ee FUEL BLEND OFFSET TALER ADAPTIVE seep toggle switch and lett T as MEARNS SET clicking your mouse Boon A es EEE Adaptive Learn a hous 1 5 2AE papa ap AIZEN 13 E 4 AR ra ing The default Fie erase Hoe EFEN hak Edad T setting should i im p m 1300 1600 TET Praan zam an 29m oem jean an foam pan Fram ean pan imie RPM sma i i CYLINDER SELECTION TUNING CLOSED LOOP IDLE CELL SETUP be On li not Eol STRATEGY On fe O CELL EMASLED iH r m4 en toggle to On FUEL BLEND OFFSET TACH INPUT ADAPTIVE imma F F si E55 SL2ND SRAN nxi i LEARNING she Po rah TACH ies j coi OFF Cees Fixed PW By checking the Fixed PW box you can set a fixed desired pulse width for idle This fea ture can be used for an engine that has a lot of valve overlap rough idle It can also be used as a trouble shooting tool to fix the fuel delivery at idle to diagnose a non fuel related problem There are specific values that need to be met to achieve the idle cell RPM Must be less than the number in the box TPS Must be less than the number in the box MAP Must be less than the number in the box FUEL WIZARD Next select Fuel Wizard from the Setup See image at below left G Protessone Products Stage Hl Dashboard vad 1 3 a Fie Edit Setup View About bimn Setup Fined Aizarna Cal
24. Professional Products POWERJECTION III Installation Instructions amp User Manual for 70020 70021 70026 amp 70027 Kits and 70028 70029 plus 70120 through 70129 Kits 70027 Kit Shown Other kits will vary The appearance of the fuel inlet kit portion slightly in appearance and kit contents of this system may vary from this photo Professional Products 12705 S Van Ness Avenue Hawthorne CA 90250 Tech 323 779 2020 www professional products com Entire Contents Copyright 2010 POWERJECTION IlI INSTALLATION INSTRUCTIONS TABLE OF CONTENTS Introduction P II Versions Powerjection III System Component Check List Before Getting Started Tools and Additional Parts Needed Installing Your Powerjection III System Oxygen Sensor installation Fuel System Installation Wiring Harness Installation Installing the Dashboard Software Connecting Your Laptop to the Stage III EMS Opening Your Dashboard Creating Your Base Profile MAIN SETUP Fuel Wizard Calibrate Throttle Position Sensor 11 Starting Your Vehicle for the First Time 11 Navigating the Dashboard 11 Using Your Stage III Software 12 FILE 12 Open calibration from file 12 CO COCO NNN OO O1OT amp BW W W 0 save Calibration to file 12 Read calibration data from ECU 12 EDIT 13 Target Air Fuel 13 Adaptive Learn Fuel 13 Adaptive Learn Cell Protect 14 Accel Decel 14 Cranking Cold Engine 14 Idle Air Control 15 SETUP 16 Main Setup 16 Fuel Wiz
25. REATER THEN 1500 AND TPS 1S LESS THEN PULSE wiDTH l0 a a 24 28 a2 36 a0 aq ag 5z 56 60 id Eg 7 76 go B4 Ba ga 36 w Note The adjustments made to this window are recommended to be made by experienced tuners The default values will work fine for the vast majority of applications If you experience hesitation issues adjust the targeted air fuel ratio for the given RPM load or add subtract fuel in the Adaptive Learn table in the cell which is causing your hesitation On the above Accel Decel table you can adjust the pulse width for your ac celeration enrichment the duration of time you want that percentage added as well as deceleration fuel cutoff values The Acceleration Enrichment AE acts like an accelerator pump on a Car buretor it shoots additional fuel upon the event of a rapid throttle opening The quicker you open the throttle the more fuel your engine will require This window allows you to adjust your AE for your specific vehicle The AE Acceleration Enrichment and the Duration Tables can be rapidly filled by using the Fill Low and Fill High buttons The acceleration pulse width cells can not be less than 1100uS Microsec onds or more than 32000uS The AE Fill Low button will auto fill the pulse width entered for the accel eration from 0 to 12 TPS time TPS 5mS Speed of throttle opening The duration Fill Low will also auto fill the time Milliseconds you wish for the
26. ard 16 Calibrate TPS 16 Remote Connection 17 VIEW 17 Real Time ECU Data 17 Histogram 18 ABOUT 18 Boosted Applications 19 Data Logging 19 Revisions Latest Instruction Revision is 6 1 10 IMPORTANT READ THIS FIRST The Powerjection II EFI System comes from the factory with a basic profile program already installed in the ECU EMS mounted on the throttle body See the supplementary Quick Install instruction sheet If your engine matches or is close to the engine that our basic profile is designed for you do not need to do anything but install your Powerjection III System pages 3 through 7 in this instruction book and drive it We also have several other basic profiles called Calibration Files Stored on the Dashboard install disc packaged with this kit Again read the information on the Quick Install sheet to see if any of these other Calibration Files match your engine If they do you will need to follow the directions in this manual start ing on page 7 with opening the Dashboard Then jump to FILE on page 12 In Step 4 you can choose any of the other avail able basic Calibration Files assuming one of them fits your engine Follow the instructions on page 12 on selecting a new map and substituting it for the default map loaded into your system from the factory If none of the installed Calibration Files work for you you can very easily program your own by just entering a few sim ple inputs as outlined in the Creating Your
27. ate modified E Desktop 0 Stagelll Log Filet 53L Recent Places Computer When the window at right opens you will need to go to C gt Program Files gt Stage IIl Dashboard Software V2_1 gt stage III Log Files gt Month gt Date Highlight the Date that you want to open and click on the Open button at the bot tom right of the window Documents Pictures Pecently Changed Searches E bluse F Pubi Then the file s for the day will display If more than one data log file was created the same day each of the created logs will be numbered numerically in the order the log was created See below Next highlight the particular file Open Ki Stagelll Log Files 2010June Juni MP raanire 44 ya P Kea Folder i F aro Name Date modified Type Desitop H Recent Places Comput Documents Pictures Mi e y Recenth Changed Searches Public Folder a Fle name Stagelll_log File S3L As you click on each parameter that you want to view it will move to the left see arrows at right under the Chart column After you have made your choices of the parameters you want to view choose as many as you want then click on the OK button in the lower right of the window The viewer will now open See below In this sample the RPM MAP and A F were selected to view Each parameter has a vertical red cross hair that can be moved laterally by moving your mouse The Y valu
28. between the pump and filter This vacuum situation will cause the fuel to aerate and cavitate in Side the pump Using the stock sock screen type filter located in the gas tank will be sufficient in P catching any large debris that can cause damage to the fuel pump However if you feel you want to use a pre filter we have tested and had good luck with the i Professional Products L a ao 10210 red blue or E Inlet line connects to 10211 aluminum Inline Return line connects Street Filter This filter has 3 8 NPT ports and you can use a pair of Professional Products 10232 2 to a pack 3 8 hose nipple fit tings This filter is used on the low pressure side of the pump so ordinary hose nipple fittings and clamps are suitable Install a fuel line from the pump outlet to the supplied 70026 70027 only EFI inline fuel filter If you are supplying your own fuel filter it must be EFI rated and filter to 10 microns Install a fuel line from the EFI filter to the fuel inlet on the right front of the Powerjection III throttle body NOTE All Fuel lines from the fuel pump to the fuel pressure regulator need to be a minimum size of 3 8 inch inside diameter hose or O6AN lines and must be rated for high pressure fuel injection use NOTE The fuel pump and all fuel lines need to be mounted and or shielded and routed away from any 10210 Pre Filter heat source which may create vapor lock Install a return fuel line from the fu
29. coil 4B If using an MSD ignition system with an amplifier box you must use the green CP wire and connect it to the tachometer output Very Important Note Do not connect both the Green CP Wire and the Black SP Wire at the same time It has to be one or the other Tape off the unused wire So it cannot ground itself against metal This is very important as severe damage to the computer can occur The unused brown wire does not have to be taped off as it is not live Green wire connects to tach output on spark box FINAL STEPS TO THE MECHANICAL PORTION OF THE INSTALLATION 1 You need to make sure you have the battery negative cable grounded to the engine block and that you have a quality engine to chassis body ground Strap An improper ground connection will result in erratic performance 2 The vehicles battery must be fully charged Be sure the throttle body is properly tightened and secured with lock washers 3 Re install and connect the battery Turn the key to the ON position only and look for any visible fuel leaks If you have fuel leaks correct before pro ceeding any further with the installation 4 Adjust the fuel pressure by turning the adjustment screw on top of the fuel pressure regulator to 42 45 PSI as read on the fuel gauge If the initial read ing is higher you may need to turn the key off and bleed the pressure off by loosening the fuel supply line to the fuel inlet rail and reducing the fuel pres
30. e Powerjection III system with Stage III EMS has the ability to data log many parameters The parameters are MAP Vacuum Water Temp Fuel Pressure CE Cold Enrichment TPS Injector Mode Fuel Gal Hr i Target A F LAC Position aS ES a A ian Mimes Ronitows eeprom rst waxatoncarw incom Max Pw Chew Many of these parameters are for engineering diagnostics and may only To Data Log you need to have your laptop connected to the EMS and toggle need to be viewed if you are asked to data log for diagnostic purposes by the the data logging button to ON Red on the Dashboard It will begin log Tech Support department The most common items you may utilize are ging After you have accomplished your data logging turn the toggle off e RPM The data log file is automatically saved during the data log run e MAP Vacuum The files are saved in the Log Charter folder under year gt month gt day gt num e A F ber See window at lower right See next steps to access that window e Target A F To view a data log after you have created one you need to click on the Log e TPS Charter shortcut icon lower left on your desktop This will open the log Haire vem charter window lower center Then select File and then Open See the win dow below center This will then open the window below e Injector Pulse width ETS I Log Charter V2 Open Kes stagen gt 2010 June Jun 2 re he bpe Vie oes Py eee f i Name D
31. e at the left of each window indicates the value at the cross hair Across the top are time tables The value shown in the time tables represent where the cross hair is in the log you wish to view and click the Open button You will see the window shown at below This is the the Parameter Selection window Select the parameters you wish to view Right HMouse clack lo ehyp piaia M Logd last profile automatically Load fast profile and chart aubomecelly Right Mouwse chick to setup profiles THA Se parameters pou rash fo chet TAAGT IAC POS CAANEING LED RPM INDE WATER TEMP FUEL PRESSURE BASE IMDM O40 ADL LED LOG TIME CL STATUS VERSION FUEL PRES EEPROM STAT RUR Mae anoun ECU TEMP EEPROM TEST IHJ MODE MAS ALLOW Pia ADIL FUELS a FLEX FUEL Mak P CHECKE TARGET AJF O2 STATUS INJECTOR OEA BATTERY C TEMP INDEX FUEL GALHA aC POS MAP INDEX r Click the parameters pou vash to chart TARGT IAC POS FOOE MARE CRANKING LED RPM INDEX BASE IND 0440 WATER TEMP ee CL STATUS FUELPRESSURE COMM STATUS 4 ADL LED VERSION EEPROM STAT CEA FEY BASE IND 0 48 IAC STATUS RUN MIN RUN HOUR ECU TEMP EEPROM TEST 70020 INST Rev 06 01 10
32. een cofessional Products Stage M Dashboard V2_1 ms ext File Edit Setup View About Main Setup FT Fuel Wizard Fe Calbrate TPS Remote Connection Depress Throttle Wide Ope This next step is to Calibrate the Throttle Position Sensor TPS Click on Setup and select Calibrate TPS erator released and the throttle fully closed press the Calibrate TPS Min button Next depress the accelera tor pedal fully to the floor and while fully held down click the Calibrate TPS Max button Release Throttle and Press Calibrate TPS Min and Press Calibrate TPS Max If you accidentally click on Calibrate TPS Max be fore the minimum calibration has been fully set the above window will alert you to that fact Then you need to repeat the Calibrate TPS Min step After both Min and Max have been set close the set TPS window by clicking on Close in lower right corner of window STARTING YOUR VEHICLE FOR THE FIRST TIME WITH THE POWERJECTION III EFI SYSTEM Note When you turn the key to the on position you will hear the fuel pump come on for a few seconds and then shut off This is normal The EMS needs to receive a distributor reference signal when the engine is turning over to maintain power to the fuel pump This is a safety feature built into the system in case the vehicle is in an accident and the engine stops power is shut off to the fuel system 1 Turn the key on Confirm that the fuel pump activates a
33. el tank forward to the bottom of the fuel pressure regulator and connect It is not required that the return fuel line be EFI rated Note If using a regulator not supplied with your system be sure you know which port is for the return The above instructions are extremely important and must be followed Please carefully read the above instructions and make sure that you perform all of the steps exactly as outlined Typical Plumbed System for 70020 or 70021 FUEL TANK VENTED FILTER Typical Plumbed System for 70026 or 70027 mFuct PRESSURE POWERJECTION Ill THROTTLE BODY FUEL PRESSURE REGULATOR MruUEL PRESSURE OMO FUEL PRESSURE FUEL SUPELY LINE POWERJECTION Ill THROTLE BODY ONO FUEL PRESSURE FUEL TANK VENTED FILTER FUEL PRESSURE REGULATOR RETURN LINE WIRING HARNESS INSTALLATION The supplied wiring sub harness has a 6 pin connecter with six wire leads coming out You will need to have additional wire and connectors to connect four of these wires to their appropriate connections When selecting your wire it must be of the same gauge as the wire you are splicing it to Sol dering your wire to the appropriate wire on the sub harness and protecting the connection with heat shrink is recommended for making these connec tions Crimp style butt connectors may work although they are prone to hav ing poor connections and may not make a positive connection Do not twist wires to
34. ell to en Sure they are fully operational as part of the extensive quality control meas ures maintained throughout the entire build process of the Powerjection III system Butterflies are adjusted and the idle is set for you on a running en gine Set for a SB engine you may need some minor adjustment Powerjection Ill Fuel Injection System Component Check List 1 Throttle body with EMS and dual feed inlet 2 Throttle body mounting gasket 3 Air cleaner mounting gasket 4 Coolant temperature sensor 5 Wide band 0 sensor 6 Sub harness 7 02 sensor bung 8 Bung gasket 9 2 Worm gear clamps for installing 0 sensor bung 10 Stage III Dashboard Software CD 11 Installation User manual 12 USB to Serial Cable Adapter 13 Fuel Pressure Regulator 70026 70027 Only 14 Fuel Pressure Gauge 70026 70027 Only 15 Fuel Pump 70026 70027 Only 16 Fuel Filter 70026 70027 Only We recommend the installation of a pre filter to avoid damaging the fuel pump in case you have foreign particles in the gas tank Note that most small filters sold for EFl systems will not work properly We have tested a number of common filters and they cause fuel cavitation and erratic operation We recommend the Professional Products 10210 or 10211 Inline Filter TOOLS AND ADDITIONAL PARTS YOU MAY NEED The tools required to install the Powerjection III EFI systems are common hand tools Excluding tools for modifications to install a fuel vent
35. g Position is active when the RPM is 400 or less e After Start C Temp Decay active for the amount of time in the decay table e Temp Based Operation IAC function is active when Step Target is selected e RPM Follower IAC function is active when the RPM Target is selected e Stall Saver is active when the EMS reads the parameters entered in Stall Saver e Manual Mode This is used for troubleshooting purposes only SETUP In this section you can make a number of fine tuning adjustments in cluding tips on how to configure your system if you are running E85 gasoline You can also further refine your fuel delivery by using slider bars while driving the vehicle as opposed to entering values as previ ously discussed This section also discusses calibrating the TPS and how you can connect your laptop to our technical support personnel so that we can view what screen is showing at the same time you are look ing at it This can be valuable when trouble shooting a problem that you cannot resolve on your own or over the phone MAIN SETUP Main setup is where you will input values for RPM boundaries and MAP boundaries if you need them to i differ from the default settings You just double click os T 21 7 21 1 ey We 17 5 ry 152 A F 116 104 j 41 449 j 45 33 5 J Setup Under Setup you can se lect the following e Main Setup e Fuel Wizard e Calibrate TPS e Remote Connection VAC BOOST REF z eee a oe a MAP
36. gine starts and pulls an ex tremely high vacuum at a relatively low rpm causing the injector pulse width to drop to the minimum 1100 we have incorporated an Intermediate Pulse Width You will find these values in the Afterstart Enrichment area of the cold engine parameters You can follow the from to line at the bottom of the page from your cranking pulse width over to the intermediate pulse width As soon as the engine starts and exceeds 401 RPM it will inject the intermedi ate pulse width for the entered number of seconds The best way to figure out what the intermediate pulse width should be is to look at your Injected Pulse Width on the Real Time Data screen F11 for the given temperature Gener ally 2 3 seconds is an acceptable amount of time To make the any changes active you have to click Send Clicking Close will close the window IDLE AIR CONTROL IAC IAC CONTROL The injection system is equipped with an Idle Air Control Motor that assists in start up idle speed control and prevents engine stall on deceleration The motor controls a valve that meters bypassed air to enter the engine The movement of this valve takes place in Steps The total number of steps the valve has is 130 C TEMP BASED IAC BASE POS This is the base position for the IAC at the given temperatures This value should not exceed 23 when warm and the idle is properly set Butterflies A IAC CRANKING POSITION When the engine is
37. h the changes you have made in your laptop You need to name the file some thing descriptive so you can easily recognize it 4 The Calibration File Folder will open and then you select the file you wish to load into the ECU EMS By default if you do not see the Calibration Files go to C Program Files Stage Ill Dashboard Software V2_O Stagelll Calibration Files Open calibration from file Save calibration to file Fead calibration data from ECU Exit 12 6 Enter the file name and date and click Save 7 Select Read Calibration from File This downloads the current profile in the ECU EMS to the Dashboard 8 Select Exit This closes the Stage IIl Dashboard In the Edit portion of the software you can make a number of changes to your Powerjection IIl EFI System Please note that most of the items covered in this section are for advanced users who want to fine tune their system for specific uses or for engines that are radically modified If you elected to use the Base Calibration or any of the op tional calibrations already loaded into the system see page 12 then in most instances you will not need to perform any of the adjustments or settings outlined in this section of the instruction manual How ever in some instances you may need to make some minor adjust ment and in that case you will need to utilize the information provided in this section of the instruction manual TARGET AIR FUEL it a jet A it Fu TARGET A
38. h your engine running you can click on the UP or DN button to add or remove fuel for a given RPM listed below the bar graph No MAP re lationship You may find that your engine will run more efficient by adding or sub tracting fuel while the engine is in operation You should lock the slider prior to making any changes to the bar graph This prevents you from accidently recalculating which will change any changes you made to the bar graph Q Why would you want to alter this A It is a quicker method of altering the fuel delivery than typing values into individual cells of the Adaptive Learn Table CYLINDER SELECTION 600 160 7300 a 2500 ates 3100 a 3700 4000 4007 4300 4500 RPM se TUNING CLOSED LOOP IDLE CELL SETUP STRATEGY ON IDLE CELL ENABLED a J DFF Automatic TACH INPUT ADAPTIVE Engne MUST be OFF Rey ON to change LEARNING FFRPMISLESS ff THEN AND TPS 15 LESS THEN AHD MAP IS LESS THEN Sm COL from contamination You will need to physically remove the sensor and insert a plug in the bung ADAPTIVE LEARNING With Closed Loop on and Adaptive Learning on the ECU EMS will learn fuel values for your engine and place the learned percentage on the Adaptive Learning Table If any cells have a value Learned or manually input in a cell the ECU EMS will use the value even if Closed Loop is off Main Setup Fuel Wigand Calibrate TPS Remote Connect t Calibration File Losded
39. ibrate TPS AIR FUEL Remote Connection MAP kPA 16 3 VAC 199 TEMP f CLOSED LiF a ADAPTIVE LEARNING s 1000 13 7 43 5 s COMMECT TO ECU DATA LOG T Cakbation Fie Loaded from ECU When the Fuel Wizard window opens see above right you will need to set several options as follows e Estimated Maximum RW Torque or actual if known e Number of injectors This will be 4 unless running a dual EFI e Boost if supercharged or turbocharged e Injector Flow Rate Default is 62 Ibs hr e Intake Manifold Type We provide selections for you e Camshaft Type We provide selections for you Torque The first value to be entered see chart above right torque box is highlighted is Torque This needs to be a realistic value If you are running a stock engine the torque values can be researched online If you have a Fue Wizard Generator ing Py Max Tumpe E of ling Boos Inj Flow Hale 62 Manifold T ype 2 Cam Tepe Shock 16 19 Ver BFA 83 83 90 93 95 97 Os GES ISR TOOF OOS 99 Sh 99 89 Obs Bee Po Pe PB 221 25 1a RPM AIR FUEL 46 13 9 crate engine the supplier of the engine should have supplied you with a max imum torque rating If you don t know what your maximum torque figure is try to find a crate motor listing that is similar to your engine and use that number If you enter a wrong value it can be changed later If you put in too high of a number the engine will run rich
40. mp 70021 Polished Finish come without any fuel system These part numbers will require the user to Supply the following components e EFI Rated Fuel Pump EFI Rated 10 micron Fuel Filter e Fuel Pressure Reg ulator Fuel Pressure Gauge These versions were designed for those who already have existing compo nents or wish to supply their own components The second version part numbers 70026 Satin Finish amp 70027 Polish Fin ish come with the above listed components as an all inclusive package for those needing all the components 70027 Shown Polished Finish All systems will require the use of a return fuel line A return fuel line is a Separate fuel line that allows unused fuel to return back to the fuel tank We offer a return fuel line kit part number 70107 for use with the Powerjection Ill systems This kit includes 25 feet of O6AN stainless braided fuel line and all necessary O6AN hose ends and fittings to plumb the fuel pump fuel fil ter and to connect to the EFI system Note that any of the Powerjection III systems can be converted to a returnless setup by incorporating our 70035 FuelOnDemand Kit This kit also provides many other features that extend the BEFORE GETTING STARTED Check the list at the right to make sure you have all the necessary compo nents required to make up the Kit Almost all EFl systems require a vented fuel tank This system is no excep tion The fuel tank MUST be vented and the use of a
41. n e Comm Port the ECU is using PROFESSIONAL PRODUCTS AND RCP LLC PROFESSIONAL PRODUCTS COM COPYRIGHT 2005 2010 PATENT PENDING STAGE II DASHBOARD VERSION 2_1 RELEASE DATE 1 4 10 STAGE Ill GAL FILE VER 2_0 STAGE Ill FIRMWARE VERSION 12406 ECU COM PORT 1 18 BOOSTED APPLICATIONS If your engine is running a Supercharger or tur f bocharger you will need to set your MAP and Aaea RPM boundaries in Setup The Powerjection III ADAPTIVE LEARN FUEL DECEL MAP sensor integrated into the EMS is a 2 5 Bar i MAP and will measure up to 21 pounds of boost If you are a draw through blown supercharger or tur bocharger is downstream from the EFI throttle body system you will need to relocate the vacuum line that now runs from EMS to the throttle body Remove the vacuum line from the throttle body cap the nipple and route it to the intake plenum SO the MAP can sense boost If you are a utilizing a blow through system there is no need to relocate the vacuum line a4 H F a 3 h ll oo All boosted applications will require a vacuum line routed from the vent nipple on the fuel pressure regulator to the intake plenum The screen shot at right is of the boosted calibration file It already has some adaptive learning already in it You may find that on a boosted application up to about 7PSI loading this file may learn faster 42 66 3 6 w gz N pe pa Ta m Tama ai ia i DATA LOGGING Th
42. nd shuts off after a couple of seconds 2 Check again for fuel leaks and repair as needed 3 Start the engine And let it idle and come up to a temperature of about 150 degrees 4 Check and adjust the fuel pressure to 45 pounds as necessary To adjust turn the regulator top adjustment screw clockwise for more pressure and counter clockwise for less pressure On non boosted applications do not connect a vacuum line to the pressure regulator The nipple fitting on the regulator is a vent Do not cap or plug it Note These adjustment steps are for the fuel pressure regulator supplied with the fuel system if using another brand of regulagtor consult with the manufacturer for proper instructions on changing the pressure 5 Note the idle RPM The idle RPM warm engine temp 180 minimum Should be 900 1000 RPM If adjustment is needed read below Note when making idle adjustments place tape over IAC hole in top of throttle body The Primary and secondary throttle shafts need to move in an almost 1 1 ratio If you need to make an adjustment you will need to adjust the pri mary and secondary idle screws the same Keep in mind that adjusting one screw to the desired RPM will not work properly You need to adjust the pri mary to a 50 increase or decrease from the actual RPM to the desired RPM then adjust the secondary screw to the final desired RPM After the de sired RPM is set you will need to recalibrate the throttle position senso
43. nnection NOTE While connected to Technical Support the support staff has no control of your laptop computer A member of the support team may suggest request what changes need to be done and you the user will have to input the information on your laptop VIEW View allows you to view e Real Time ECU Data e Histogram Real Time ECU Data selecting this allows you to view in real time e RPM e MAP Vacuum e Water Temperature e ECU Temperature e Coolant Enrichment e Adaptive Learn Fuel Percentage e Closed Loop Percentage e Cell e Air Fuel Ratio e Targeted Air Fuel Ratio e Battery Voltage e IAC Target e AC Position e Fuel Usage In Gallons Per Hour e Total Run Time e TPS Position percentage e Maximum Allowed Injector Pulse Width e Injector Pulse Width e Injection Mode e Tach Style Input e Key on or off e Fuel Pump Relay active or non active e Oxygen Sensor Active or non active e Closed Loop Active or non active e Adaptive Learning On or off e Cranking In cranking mode or not e Gasoline 50 or 100 E85 Only one of the 3 will be active e Close Position e Crank Position e After Start Decay e emp Based Mode e RPM Follower e Stall Saver e Manual Mode RPM The Engine speed currently being monitored by the ECU MAP The MAP vacuum reading currently being monitored by the ECU Water Temp The coolant temperature of the engine and read by the ECU Coolant Enrich The amount of
44. pplications e RPM Boundaries Note Default value is 4500 RPM e Cylinder Selection of cylinders 8 is the default setting e Tuning Strategy Automatic is the default setting e Tach Input Coil is the default setting e Closed Loop On is the default setting MAP amp RPM For un ed SET A My HY ATS Ga 1h 44 12 11 lt td i al ae bats ed blown applications 2 8 ae ae tee baa Li leave the MAP and ox Ge RER Derd eed at Faa ft halal dae aa APM 2 RPM boundary tables en ee a at the default settings f We will further explain emen orrera __yaciaoyt the setup for these od Aii boundaries in Boosted Applications section Cylinder Selection Select the number of cylin ders of your engine 4 6 or 8 Eight is default TACH INPUT Engine MUST be OFF Key ON to change LEARNING CLOSED LOOP IDLE CELL SETUP ON fj IDLE CELL ENABLED 6 r FRED PW OFF 2500 1250 AND TPS IS i2 LESS THEN AND MAP IS 100 LESS THEN e IF RPM IS LESS THEN ADAPTIVE e Adaptive Learning On is the default setting e Idle Cell Setup Defaults Enabled RPM less than 1250 TPS less than 2 MAP less than 100 NOTE Do not adjust Fuel Blend Offset This is for future development If you are using E85 contact technical support at 323 779 2020 For the last four Tuning strategy Tach input closed loop and adaptive learning you will need to left click to toggle button icon and it will toggle between
45. prevents condensation and exhaust debris from pos sibly contaminating the sensor Drill a 5 8 inch hole Open both supplied MOUNT THE C2 SENSOR AN TWHERE ABOVE 9 O CLOCK AND 3 O CLOCK POSMONS NEVER MOUNT THE O2 SENSOR DOWN HERE hose clamps place on exhaust pipe and start the worm gear hose clamps Place the supplied gasket over the hole and place the stainless steel bung over the gasket holding it in place and tighten the hose clamps to secure the bung OPTIONAL You can weld the bung into place without the use of the gasket and clamps 9 Below Right Plug the harness cable from the throttle body into the cable from the Oxygen Sensor Using cable ties keep harness away from exhaust or moving parts Oxygen sensor replacement number is Walker Fuel Systems 250 25022 Extreme high temperature gasket Professional Products 71250 Clamp On Oxygen Sensor Bung Kit The bung itself is made of stainless steel and can either be clamped on or welded on to exhaust FUEL DELIVERY SYSTEM INSTALLATION The supplied fuel pump and the EFI fuel filter 70026 amp 70027 only have 1 4 female pipe threads on the inlet amp outlets You will need to supply the fittings necessary for each of these to connect your fuel lines to These fittings MUST BE 3 8 inch 06AN size or larger Install the fittings into the fuel fil ter using blue Loctite 246 Never use Teflon tape in the fuel system If you have also purchased either a 70107 or
46. r TPS following the same steps as outlined above in the Creating your pro file Note With the engine off and air cleaner off you should be able to look down in the bores of the throttle body and see that the openings for the pri mary throttle blades and secondary throttle blades are opened the same amount 6 Install an appropriate sized air cleaner 14 20 stud into the throttle body 7 Install the supplied air cleaner mounting gasket and your air cleaner mak ing sure to secure properly Drive your vehicle and enjoy NAVIGATING THE DASHBOARD Now that you have driven your car for some period and have given the Adaptive Learning feature the opportunity to dial your Powerjection III sys tem into your style of driving you can learn a lot about your system by re connecting your laptop and checking out the various settings You can also make a wide variety of adjustments in your system if desired Unless you have a highly modified engine the settings that either came as a default or the new map that these instructions walked you through earlier should pro vide optimum performance for your vehicle However for those of you who want to delve deeper into the Powerjection III s capabilities this section is for you When you open the dashboard it will display the telemetry of the engine as follows e MAP Vacuum Reading e Coolant Temperature e R P M When lit up the status items are active When not lit they are not acti
47. r desired changes click Send to update the ECU EMS To close the table click Close in the lower right hand of the window CRANKING COLD ENGINE COLD ENGINE C TEMP ENAICHWENT TEMP F ADDED FUELS CRANKING FUEL PUMP FUEL PRIME AFTER START ERRSCHMENT TEMP F ADDED FUEL DECAT TIME SECI E ENABLED IF CT LESS THEN PUMPPRIME is SEC 1 60 SEC FUEL PRIME DURING CRANEING FUEL PRIME BEFORE CRANFIMG gesageee i DELAY FROM FUEL PUMP PRIME TO FUEL PRIME SEC 1 60 5EC i FUEL PRIME SEC 1 60 mSEC 1 i BERS PEE In most instances the parameters in this window will not need to be changed This window allows you to change the cranking fuel start up enrichment cold fuel enrichment and fuel pump prime The pulse width for cranking is temperature dependent and the value is in microseconds CRANKING The cranking pulse width is only active while the engine is cranking and when the engine gets above 401 RPM the profile takes over the running fuel control If you are experiencing excessive cranking times you can adjust this parameter The Pump Prime will turn the fuel pump on when the key power is turned on for a period of time 1 to 60 seconds to prime the system and then shut off It will not turn on again until the engine begins cranking over and the ECU EMS receives a signal from the ignition system 14 ACCEL DECEL k ad DECEL DURATION mS TEMP F DECEL IF APM I5 G
48. r is being monitored used Note Green does not mean the sensor is good Over time oxygen sen sors will degrade from normal use and need to be replaced The re placement interval is approximately 30 000 miles Adaptive Learn Green indicates it is turned on Black indicates off This is turned off or on in the main setup Cranking This will be yellow when the engine is cranking only Gasoline This is the default value Only one of the 3 fuel types will be lit up green For E85 use contact Technical Support Close Position When the key is turned off the IAC goes to a Home or Closed Crank Position The IAC motor is in the cranking position After Start Decay The IAC motor is decaying from the crank position to the target base position Temp Based Mode IAC motor position is temperature based RPM Follower IAC motor maintains desired engine RPM Stall Saver The stall saver feature is active Here are screen shots of the Dashboard and Real Time Data You can see how the values from the Real Time Data match those on the Dashboard RPM a Se U U UO INJECTOR DUTY CYCLE 5 3 2 ADAPTIVE LEARN INJECTOR CONTROL CLOSED LOOP TACH INPUT COILI IAC STATUS 82 0 0 0 0 m acer FUEL PUMP RELAY CRANKPOSITON 3 8 gt 10 10 1 TARGET A F 1 O2 SENSOR AFTER START DECAY TEMP BASED MODE RPM FOLLOWER wy BATTERY VOLT 11 8 CLOSED LOOP IAC TARGET ADAPTIVE LEARN STALL SAVER i MANUAL MODE
49. re this is what you want to do before proceeding 13 EDIT continued ADAPTIVE LEARN CELL PROTECT gt 7 f arn z 30 54 Be MAP 20 n RPM 28 Td T1111 ds 797997778 In the previous Adaptive Learn Fuel table you could enter changes to the in dividual cells However as long as the Adaptive Learning feature was turned on these cells will change as you drive the vehicle The table above allows you to protect lock the cells that you changed on the Adaptive Learn Fuel table Entering 1 unlocks the cells and the cells can be altered in the Adaptive Learn Fuel table Note that 1 is the default set ting so you were able to make the changes without having to unlock the cell Entering 0 Zero locks that cell and the EMS ECU will not be able to au tomatically change the value unless it is unlocked by entering 1 You can manually double click a cell and change it from 1 to 0 to lock You can also use the Fill option by entering a1 or 0 and clicking fill This will fill all the cells to the option you chose The lock function is used if you have entered a number in the Adaptive Learn Fuel Table that you wish to remain constant and not update For instance you may have found that increasing or decreasing the value in the Adaptive Learn Fuel table made the vehicle respond better to your liking you may want to lock protect that cell so that the EMS does not update it After making you
50. ro Street Race 6 10 e Boost 14 16 Note After you start your engine and your vacuum reading is different from what you entered go back and select the correct cam type based on actual vacuum reading and then recalculate the base map Calculating is shown at right Left click on Cam Type slider and drag from left to right You will see the camshaft name and vacuum reading appear above the slider Just Slide it to your desired vacuum reading 10 Boost If your engine is normally aspirated unblown the value is zero and that is the default If running a blower then enter the maximum boost your engine is set up to produce Intake Type Choose from the following 1 Stock Cyclone Performer Ac tion Plus 2 Typhoon Performer RPM Stealth 3 Crosswind Air Gap 4 Hurricane Victor Super Victor Team G Calculate The last step in creating a base profile is to apply all the entered information Verify that the Slider is in the unlocked position If not left click on the toggle switch It will read Slider Unlocked Now with it un locked left click on the Calculate button You will see a change in the bar graph on the screen This is your new profile Now lock the slider by left clicking on it This will prevent inadvertant changes to your base profile Note We will explain how to move the bar sliders in the Using Your Stage Ill Software section Now close out of the Fuel Wizard by clicking Close in the lower right corner of the scr
51. ry to create your custom profile and get your vehicle started Most applications require answering a few questions only and will not require an advanced calibration The only time you may need to do an advanced calibration is if your engine is very radical with a big cam In the Using Your Stage II Software section we will break down and de fine what each item on each page represents and how to alter it for tuning File Edt Setup Wew About 26 228 27 211 Pa 187 175 ya 452 14 jo a z 1 6 104 33 81 69 your particular vehicle To create your first base map program make sure your laptop is connected to the Stage III EMS as explained earlier then turn your ignition key on and click the Dashboard icon on your desktop The main screen will appear See image at below left Then select Setup from the menu at the top of the screen and then select Main Setup See image at below right You will then get the Main Setup screen shown below VAC BOOST a 45 43 4 A REF 5 aa pe he om tian te Se CaCO ae MAP s Te GCE Ce od autor nuna PIGS a moles RPM Send j CYLINDER SELECTION fe zl TUNING STRATEGY 3 Automatic FUEL BLEND OFFSET i S0 E65 BLEND lo 100 85 6A TACH e COIL The Main Set Up screen will appear as shown above There are several in puts that may need to be made Details on each will be given below e MAP Boundaries Note Default values are for unblown a
52. the Multiply button then click on the Multiply button All the cells will rise in value by 10 creating a leaner A F mixture A 5 increase would use a value of 1 05 To decrease all cells by 10 enter 0 9 5 would be 0 95 and click the Multiply button All the cells will lower by 5 creat ing a 5 richer mixture When you have finished making all the changes click on Send to save the entered data to the ECU EMS Then click Close to close the window and save all the changes You can make changes to the learned values if you need to by clicking on Edit Then by clicking on the cell you want to change you can enter the value you want Changing the value will change the injection pulse width by the percentage that you enter Remember these numbers are percentages After you have made your changes click on Send to update Lastly click Edit once more so the ECU EMS will make changes automatically You can quickly zero all the cells by clicking on the Clear ADL button A pop up will appear confirming that you really want to do this If so click OK Note These values directly affect the mathematical formula that drives your ECU EMS By raising or lowering these values the output pulse width will be altered These values are also used as the target values for Closed Loop and Adaptive Learning Note Clearing the Adaptive Learn Fuel by clicking on Clear ADL will make them all zero even if the cell s are protected So be very su
53. the two available choices Fuel Blend The de fault setting is gaso line This system is capable of operating on E85 and various blends of gasoline and E85 Please call the Professional Products tech department if you want to run something other than gasoline Jd 50 SIT Pu as a7 178 4 LD 44 daii id ada ae bits aad 2 4 i i 6 am a fe ate Aara iE Em ho nie ma a MAP a W ji a aha mapala ana aan sant roe ao E a TE emo hor Gon ar REM J CYLINDER SELECTION TUNING CLOSED LOOP IDLE CELL SETUP ma STRATEGY ON PE ER Tuning Strategy E Please select Auto 4 epee pene segs ss E oa aw ak a oa a Se bh fh ke em ee a MAP x matic SO that the w WEE Geo oy Sao ata ie eo Ge Sa as eS ae Se ee a ee RPM seme computer can generate CYUNDER SELECTION TUNING CLOSED LOOP IDLE CELL SETUP Jo STRATEGY an wm Wee CELL EMMeREL the fuel curve We will i an si discuss Manual Tun mR i ne FUEL BLEND OFFSET ANN ADAPTIVE preasan ing in the Advanced ok el mO LEARNING gei Tuning Section of Las ae j these instructions P Tach Input Select 6A a a fa ks ai La k a E lz ki a la ka LE k fe iae c Tach if using an ampli 3E oa on o ats ata ssa Jo 20a jae fox a ane nope APR ton fier spark box MSD or sia aiii oasen a pus meron other and you used the i z rae ex j green wire Or Coil puet eeno orrser xf TAUT ren SA if connecting the distrib a ae utor reference black wire Leonie
54. the vacuum port on the rear base of the throttle body If the vehicle requires vacuum for the transmission modulator you will need to connect to this port as well If both a power brake unit and transmission modulator are used you will need to install a vacuum T to accommodate the vacuum lines The port nipple in the throttle body is a 3 8 inch If you are using a vacuum advance distributor connect distributor vacuum line to upper port on front base of throttle body Cap any unused vacuum nipples See below 7a Left Remove plastic cap from rear vacuum nipple in throttle body for power brake and or transmission vacuum modulator line 7b Right Remove plastic cap from front vac uum nipple white arrow in throttle body for vac uum line from vacuum advance distributor Existing vacuum line red arrow is for the MAP sensor which is built into the throttle body We do not recommend putting a tee in this line for any other vacuum use OXYGEN SENSOR INSTALLATION 8 Below Left If no previous oxygen sensor was used locate a suitable lo cation to install the supplied oxygen sensor bung The location should be just past where the head pipe connects to the exhaust manifold If headers are used make sure it is about 4 6 inches past the collector pipe If it is placed in the exhaust on a horizontal pipe make sure that the angle of the sensor mounting is between the 9 o clock and going over the top to the 3 o clock position this
55. to the coil Engine must be off and ignition Switch On to change the Tach Input Above It is very important that you select the Tach Input to match the way you wired the green or black wires from your EFI system See page 6 of instructions 5 Tip mo m 0 e Ts we 282 I 2 H fe e fe 28 49 4nd a 20 eh ar ds 2 224 aa i PEF 3 i 4 R j 7 ao as amp E i ae ia E 0 be fe MAP ya fone ea seo ea ioe ise eae on Gna eee i eo a oe APA ton l G I I P CYLINDER SELECTION TUNIM G CLOSED LOOP IDLE CELL SETUP E of STRATEGY ue TAT ed REFF J a r S20 fan Auhirmghe iid 7 tha a FUEL BLEND OFFSET TACH INPUT ADAPTIVE ti Pith FEG FIFH Easa MEEA Ka BRP a ee LEARNING yo ed aE ard rai ji Es wat TAH a Er i cOL z f os f inan idle situation Idle Cell Enabled This feature can be enabled or disabled by simply adding or removing the check mark in the Idle Cell Enabled check box idle Tuning The Idle Tuning strategy allows you to setup a specific idle cell that is separate from the fuel map This allows you to specify a sepa rate desired air fuel mixture for when the engine is Closed Loop The de F fault setting should be pi 2 On If not toggle to dai 4 ad di EF 4 4a 4a 2304 i i E 7 ie wma MAP ix fa har Sneha STS ST oa e a mi Seeded maa Hor rae RPM e WAC OST Arr 2 a d i E 1a ta Eal a le Ara fa et mm On Toggling is ac CYU
56. vanced tuners FUEL WIZARD This is the part of the Dashboard software that allows you to cus tomize the base map for your specific engine TARGETED AIR FUEL RATIO The base map installed in your computer or the map you otherwise select establishes what the computer thinks is your ideal air fuel ratio for optimum performance The Adaptive Learning feature of this system will also modify the actual Air Fuel Ratio as the vehicle is driven This A F ratio may change at various rpm s or driving conditions which is unlike a carburetor or some competitive fuel injection systems which attempt to run a fixed A F ratio all of the time DATA LOGGING The supplied software is capable of recording a wide range of data while you drive your vehicle and then will allow you to see a timeline of what has ac tually occurred during vehicle operation Laptop must be connected to do this ADAPTIVE LEARNING This feature was pioneered by Professional Products for af termarket EFI systems By using a wide band oxygen sensor the sensor can deter mine the actual air fuel ratio of the engine The computer then makes the necessary adjustments on the fly to maintain the targeted air fuel ratio at all times under all con ditions These adjustments are occurring on a constant basis as the vehicle is driven CLOSED LOOP Closed loop is the default setting for the ECU EMS With it turned on the Adaptive Learning feature is functional To shut off Adaptive Learning
57. ve These items are e Actual Air Fuel Ratio In 2 ples e Targeted Air Fuel Ratio e Key e Adaptive Learning e 02 Sensor e Idle e Closed Loop e Decel Also displayed is the status of the ECU connection the button to connect to the ECU and the toggle to turn data logging on and off MAP The MAP Manifold Absolute Pressure is displayed in both kPa and inches of vacuum or PSI Zero inches of vacuum equals 100 kPa Coolant Temperature The engine coolant temperature is expressed in degrees of Fahrenheit R P M This is the large round dial in the center of the screen It pro vides both an analog sweep arm and a digital readout Air Fuel Ratio This is displayed in two locations It shows numerically the air to fuel ratio The sample shows a 13 7 to 1 air to fuel ratio TARGETED AIR FUEL RATIO This is displayed beneath the STATUS LIGHTS The Status Lights will let you know Idle In tachometer It is a digital bar graph showing the actual dicates you are in the idle mode Decel Indicates that you are air fuel A F ratio at the top and the targeted air fuel ratio in the Decel Fuel Cutoff mode Ignition Key Status When key is TGT The targeted number comes from a table that is de in the On position the light will be lit Oxygen Sensor Status rived from the information you input to create the base pro When lit it indicates that the oxygen sensor is working properly file The targeted number can also be set manually to
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