TEC M Users Guide - Electromotive Engine Controls
Contents
1. 0 65mm Over 115 HP per Cylinder 0 022 0 55mm Over 12 1 CR or Over 14psi Boost 0 022 0 55mm Use of resistor plugs is highly recommended for optimum noise suppression If using anything other than a resistor spark plug wire a resistor plug MUST be used The bottom line is this the TECm system uses an inductive long duration charge at battery voltage charging method for the coils which is completely different than the capacitive short duration charge at higher than battery voltage charging method used by several TECm User s Manual v1 0 12 2013 Electromotive Inc other aftermarket manufacturers What may work well for these systems may not work well for ours Following our recommendations about spark plug and wire selections will yield excellent results 4 3 Wiring the DFU s NOTE Wiring in a DFU is only needed in applications where the stock BMW coils are not sufficient for the power output of your engine If you are using stock coils skip this section When wiring a DFU always use at least 16 Gauge wire when extending any factory wires The DFU connector uses pull to seat terminals DO NOT crimp the terminals onto the wires until you have fed the wires through the connector The 3 coil DFU s connect to the BMW harness as shown here Terminal A BMW Black White Coil 1 TerminalB BMW Black Green Coil 5 TerminalC BMW Black Yellow Coil 3 TerminalD BMW Green 12v supply WARNING The DFU chassis MU2. BE USED Do not be misled by spark plug wire manufacturers claiming to give you a power increase from their wire The bottom line is that with our charging method different spark plug wires simply do not make a difference in terms of spark energy However there is a huge difference in noise generated by different spark plug wire types solid core wires generate a very high amount of noise with our system Quoted from Magnecor s Website What is not generally understood or is ignored is that the potential 45 000 plus volts with alternating current characteristics from the ignition coil does not flow through the entire the length of fine wire used for a spiral conductor like the 1 volt DC voltage from a test ohmmeter but flows in a magnetic field surrounding the outermost surface of the spiral windings skin effect The same skin effect applies equally to the same pulsating flow of current passing through carbon and solid metal conductors A spiral conductor with a low TECm User s Manual v1 0 13 2013 Electromotive Inc electrical resistance measured by a 1 volt DC ohmmeter indicates in reality nothing other than less of the expensive fine wire is used for the conductor windings Electrical devices including spark plugs use only the electrical energy necessary to perform the function for which such devices are designed Spark plug wires are nothing more than conductors and whereas a bad ignition wire s inefficient conducto
3. it is useful to remove the ECU from the ECU bay is remove the top cover so these can be seen until the problem is solved Here are the readings from the LED s Ignition key on engine off Edge LED goes steady green Good the processors are getting power Edge LED does not turn on at all Either the TECm is not receiving 12V power from pin A or the ECU has an issue Engine cranking below 400 rpm Center LED changes color from red to green every other revolution Good the crank sensor is working correctly Center LED does not change colors The crank sensor is not functioning properly signal is not being picked up Engine running over 400 rpm Center LED is steady green Good the crank trigger is functioning properly Center LED flashes red every so often The TECm is getting a bad signal from the crank trigger The engine Most likely misfires whenever the light flashes red Engine is Hitting Rev Limiter Center LED changes color turns orange The first or second stage of the rev limiter is occurring Center LED turns red The third and final rev limiter stage is occurring Note If a misfire occurs during normal engine operation but the lower LED on the TECm was not observed to momentarily flash red the crank sensor may be at fault To test for errors in this situation turn the engine off without removing power from the TECm ECU this can be accomplished by unplugging the fuel injector harness or by hitting the lette
4. ET TEE 16 4 9 General Purpose Inputs GPI s and Outputs GPOel ue 16 4 9 1 Available General Purpose Input GPI FUNCTIONS eect eter eeeette eter teeta 16 Ae Examples of GPI Wiring Sissi ida 17 4 9 3 GP VO Wiring Harness Layout curia 18 4 9 4 General Purpose Output GPO functions occcccnnnnncccnnnnnccnnnnnnnnnnnnnnnnnnnnnnnnannns 18 4 93 Available GPO Functions cui ab 19 4 9 6 Examples of Wiring EI RE 19 5 Diagnose Senen ia 21 5 1 Trouble Codes from the LED s Mounted on the TECm kk 21 5 2 Trouble Codes turns on the Check Engine light oooommoocccncnnnncononnncnnnnnnnnos 21 5 3 Trouble Code DescniptiOnS ji ii 22 5 3 1 Using Her Eegeregie dake 23 6 TECm ECU SpecificationS ccccoommmmcconnnnnnnononenonnnnnnanns 24 BL OUTPUT sae eee A A A 24 6 1 1 Fuel Injector Drivers ini iii 24 Be EE eat ott es een eege oa 24 6 1 3 General Purpose Inputs or Outputs GP lI Oei 24 TECm User s Manual v1 0 2 2013 Electromotive Inc 6A Fuel PUMP CONTO acosa Ad eee 24 6 1 5 Tachometer Tree 24 6 1 6 Check Engine Light Outre c sence ces caedeceecesterea des erates es sel poets seca ssectag dese beertmaye sie 24 6 1 7 ECU Diagnostic LED internal ociosa ii lie 24 6 2 NRUTS A eich ae ths Nh ache RAN aa a ila ea ta aes a a 24 6 2 1 General Purpose Inputs or Outputs GP I Oiei 24 6 22 jJEngine Sensor inputs sisendi tas eege 24 6 2 3 Angle Based Timing Control E 2
5. Input or Output CAM Output Pin 7 Output ON OFF PWM IAC Inverted Pin 2 Output ON OFF PWM IAC Pin 29 Output ON OFF PWM EVAP Solenoid Pin 36 Output ON OFF PWM GPO Pin 9 Output ON OFF PWM A C Control Pin 48 Output ON OFF PWM A C Console Switch Pin 64 Input AC Load Datalog Enable Ignition Retard Input Pin 57 Input ON OFF Analog Voltage Park Neutral Input Pin 81 Input ON OFF Analog Voltage GPI 1 Pin 10 Input ON OFF Analog Voltage GPI 2 Pin 76 Input ON OFF Analog Voltage Speed Input Pin 42 Input ON OFF Speed Input The BMW factory harness does not use this pin Additional ECU pins with a pigtail can be obtained from any BMW dealer to add this function The BMW factory harness only uses this in automatic transmission vehicles Additional ECU pins with a pigtail can be obtained from any BMW dealer to add this function Most GP I O pins are assigned to factory controls such as the CAM control or the A C Switch The base program is set by default to use these channels for the default action So The A C Control controls the compressor based on the input from the A C switch on the console In cases where a particular factory function is removed such as the A C system these inputs and outputs may be repurposed for other actions For example if the A C is removed the output that would normally controls the A C clutch could be used to control a boost solenoid and the A C console switch can be used could be us
6. It is HIGHLY recommended to use a relay on the GPO channels regardless of amperage draw Only the FULL TABLE functions require NO RELAY or the use of a solid state relay A standard relay will not switch on and off fast enough when using frequency based functions An analog input is defined as a 0 5 volt signal TPS MAP and EGO sensors are good examples of analog output sensors A speed input is defined as a frequency signal When using a magnetic sensor as a speed sensor its output will be an AC sine wave When using a Hall effect sensor the output will be a 0 5 volt square wave One of the most useful functions of the GP I O s is trimming Using a simple potentiometer referenced to 5 volts and ground it is possible to configure the inputs to trim the fuel and spark curves based on the potentiometer knob position These functions are quite easily configured in the Wintec software 4 9 1 Available General Purpose Input GPI Functions Fuel Trim Trims the fuel curve by a set amount through the use of a potentiometer See Figure for wiring diagram Ignition Advance Trim Trims the ignition advance angle by a set amount through the use of a potentiometer See Figure for wiring diagram GPO Trim 1 and 2 These functions allow the user to add or subtract up to 50 percent Duty Cycle from the values established in the GPO table specified by the trim number GPO Trim 1 only effects table 1 GPO Trim 2 only affects table 2 TECm User s
7. channels support on off functionality for triggering of cuts and other ON OFF activation 6 2 2 Engine Sensor Inputs Crank Sensor 2 wire magnetic sensor compatible wi some OEM s Uses Electromotive spec 60 2 tooth crank trigger Ultra high resolution engine position input Cam Sensor Necessary for full sequential applications Once per cam revolution pulse Manifold Air Pressure MAP Sensor configurable for any MAP linear MAP sensor Mass Air Flow MAF Replaces the MAP sensor when used configured for the BMW factory MAF Throttle Position Sensor TPS Uses throttle shaft mounted rotary potentiometer Compatible with BMW 3 seriesTPS Coolant Temperature Sensor CLT TECm User s Manual v1 0 24 2013 Electromotive Inc Uses NTC thermister coolant sensor 2 wire Manifold Air Temperature Sensor MAT Uses NTC thermister manifold temperature sensor 2 wire Knock Sensor KNK Provides ability to detect pre ignition Compatible with 2 BMW knock sensors 2 wire Oxygen Sensor EGO Compatible with BMW 4 wire oxygen sensors and Wide Band converter modules 0 5v output 6 2 3 Angle Based Timing Control Ultra high resolution triggering Engine position known to within 1 8 6 2 4 Feedback Charging Control Monitors each coil firing event Coil current monitoring Consistent dwell adjustment Full coil charging without overcharging 6 3 Tuning Features 6 3 1 Ignition Timing Map 8 x 8 user definable tables of RPM vs MAP for ignition
8. very quickly to allow varying amounts of air into the intake manifold This way even with the throttle closed the IAC valve can supply the needed amount of air to the engine The Software Manual covers the tuning of the IAC Parameters The IAC will not be activated unless the TPS voltage is BELOW the TPS Closed Throttle Voltage value Be certain that the TPS Fully Closed voltage is set correctly to prevent drivability issues related to the IAC 4 8 Tachometer Output The tachometer output on the TECm is a 12 Volt square wave Suitable for driving the tach installed in the factory BMW dash In cases where the dash is replaced the tach signal is also compatible with aftermarket 6 cyl tachs The signal can be changed to drive a different configuration tach if needed 4 9 General Purpose Inputs GPI s and Outputs GPO s The General Purpose Inputs GPI s as well as the General Purpose Outputs GPO s will be referred to as GP 1 0 s they are configurable for many different input or output functions There are two dedicated GPO channels 3 and 4 output only The remaining three channels 1 2 and 5 can be configured to be either Input or Output A few facts that should be remembered when using the GP I O s e All the GPO s regardless of their function are pull to ground when they are activated That is they create a connection to ground when turned on e AMAXIMUM of 1 amp per GPO channel may be run on the TECm e
9. 5 6 2 4 Feedback Charging CONO coicicist aiii Viet 25 A Ll BETEN 25 6 31 ignition Timing Maps nic 25 6 3 2 Fiel Ee EE 25 6 3 3 Load Sensing Three Options ticos di ti a EA 25 e e E 25 6 3 5 On Fly Ri Une DEE 25 6 3 6 Compensation Features cintas 25 6 4 Supported Engine Management Configurations coommcccononnnccnccnnnnnnnnnnnnnnnnnnnannnes 26 6 5 Data logging Eent iman rads Riana ene ae ee 26 6 5 1 Internal Data logging ssl dd ad dos es 26 6 5 2 Laptop Data logging E 26 o AAA 26 6 7 Environmental Considerations EEN 26 6 8 PC REQUIEM Sut a ta 26 6 8 1 COMPUTE sei A AAA A a 26 6 8 2 Data DIOS aio costal 26 6 8 3 ERUN o aie 26 7 Calibration Softwarre ccccccccsssssssesesssseeeeeeeeeeseneneeeeens 27 Fels SOMWare COMING Ne Meute EE 27 2 2 Firmware Coding Mia ET 27 Td Firmware Upgrade Proc d re E 27 PAG JEE este A EE 28 TECm User s Manual v1 0 3 2013 Electromotive Inc 1 Terms and Conditions 1 1 Electromotive Product Warranty Only products Manufactured by Electromotive are covered by Electromotive s limited warranty for a period of one year from date of shipment by Electromotive Products not manufactured by Electromotive are expressly excluded from any consideration under these terms for information regarding products not manufactured by Electromotive you must contact the specific product s manufacturer Whenever possible Electromotive attempts to replace defective products
10. EC If the firmware upgrade was successful both LED s will go GREEN If the firmware upgrade failed the top LED will stay RED and the bottom will stay off If this occurs repeat the procedure Once this procedure completes successfully you may begin or continue tuning TECm User s Manual v1 0 27 2013 Electromotive Inc 7 4 Pin out Information Pin Primary Function _ Fuel Pump Output 18 Ground 8 Check Engine Light output NC EN NC Brown Green Green O E U Yellow EAN AAA Black Blue Black Violet Black Green Red 25 Coil5output sd EE ECU Relay Control 28 Sensor Ground Cd 30 37 NC INGO 39 49 TECm User s Manual v1 0 28 12 13 14 15 16 17 22 gt 24 Coil 6 output 25 26 27 28 Brown PWM GPO Black Green NES a VA e ees PWM GPO Brown ees APA SE Black Black O ET PWM GPO Black Blue O O Black White Black Red Black Yellow LH 2013 Electromotive Inc EAN SS EAS ET A E 66 68 N0 69 Lok Zut IL Deck AAA PEN PA A e e AO A o 82 88 NC ll TECm User s Manual v1 0 29 2013 Electromotive Inc
11. Manual v1 0 16 2013 Electromotive Inc A C Idle Speed Increase On TECm installations with an idle air control motor this feature allows the idle speed to be increased when the air conditioner is turned on See Figures for recommended wiring Valet Switch When a speed input is used the valet switch allows the user to set a speed limit on the vehicle The rev limiter will be activated when the desired speed is reached See Figure for wiring diagram Nitrous Retard Provides a set amount of ignition timing retard when nitrous is activated When used with the Electromotive 4 stage timing retard module the NOS Retard should be set to 30 consult the 4 Stage Nitrous Retard Instructions for wiring When used with a potentiometer the timing will be retarded linearly from O to 30 degrees when a 0 to 5 volt signal is placed on a GP I O input channels 2 9 Speed Input Only available on the Speed Input channel the speed input allows the input of a frequency based signal The base program has this input configured correctly for the stock final drive and wheel size Timed Advance When voltage either 12v or 5v is applied to the chosen GP UO channel this function allows the user to add or subtract up to 30 degrees of timing for up to 2 secs in 05 sec increments Timing will ramp up advance in the time specified up to 2 seconds in 05 sec increments or down retard when the channel is switched on Switching the channel off will ramp t
12. S failure TECm User s Manual v1 0 23 2013 Electromotive Inc 6 TECm ECU Specifications 6 1 OUTPUTS 6 1 1 Fuel Injector Drivers 6x peak and hold injector drivers 2 injectors maximum per channel Supports both high and low impedance injectors 6 1 2 Coil Outputs 6 x 9amp direct fire coil drivers Feedback charging loop for ideal cylinder to cylinder consistency No ignition modules or CD boxes needed 6 1 3 General Purpose Inputs or Outputs GP I O s 6 channels pull to ground O s 1 amp max All output channels have pulse width capability up to 2 different tables and other non table based PWM functions on off activation for fan relays torque converters waste gates etc 6 1 4 Fuel Pump Control Low current pull to ground output for activation of fuel pump relay Configurable for fuel system priming 6 1 5 Tachometer Output Drives modern 0 12 volt tachometers including the BMW factory tach Amplifier available for high voltage triggered tachometers 6 1 6 Check Engine Light Output Pull to ground output for instrument panel light 1 amp max current draw 6 1 7 ECU Diagnostic LED internal Warns of crank trigger problems Multi code diagnostics 6 2 INPUTS 6 2 1 General Purpose Inputs or Outputs GP I O s 6 channels control input All input channels except A C Console Switch and Speed Input have analog voltage input functionality for trims and other variable voltage inputs All input
13. ST be grounded A ground wire must be connected to the engine block FAILURE TO GROUND THE DFU S MAY RESULT IN SEVERE ELECTRICAL SHOCK Also poorly grounded DFU s may result in poor engine performance and can cause engine damage Use the drilled and tapped hole next to the yellow connector for the ground wire If desired the unit may instead be grounded at one of the four bolt holes However you will need to scrape off the anodizing under the bolt head The anodizing is an electrical insulator so unless it is scraped down to bare aluminum it will not provide a good connection to ground Additionally make sure that the coil screws are fully tightened at all times 4 3 1 Spark Plug Wire Routing The coils fire in a specific order for each engine configuration The proper coil must be connected to the correct cylinder in the firing order The Coils are connected to each cylinder via a spark plug wire in the following order Coil A Cylinder 1 and 6 Coil B Cylinder 2 and 5 Coil C Cylinder 3 and 4 4 3 2 Spark Plug Wire Selection The TECm outputs an extremely high energy charge for the ignition coils Resistor carbon core wires work best with this charging method since they absorb electrical noise generated by the coil firing events Use 8mm or larger RFI and EMI suppression wire with GM boots We recommend using a carbon core style suppression wire with a resistance of 3 000 to 5 000 ohms per foot SOLID CORE WIRES SHOULD NEVER
14. See notes on Computer Requirements Serial Connector Cable DB9 for PC and a USB to Serial Converter WINTEC4 Software Guide TECm User s Manual v1 0 6 2013 Electromotive Inc 2 2 Installing the TECm board in the BMW case Installing the TECm in the factory BMW case is simple but requires a number of steps and a few simple tools Tools required Torx T 15 screwdriver Flat blade screwdriver Pair of needle nose pliers Drill with a 3 8 drill bit To install the TECm 1 Remove the BMW engine controller from it s location in the firewall on the passenger side for left drive vehicles 2 Disconnect the BMW engine harness by lifting the metal lever away from the ECU 3 Using a flat blade screwdriver open the 4 tabs on the bottom of the ECU They may break off when lifting or when closing at the end This is not a problem the screws actually hold the ECU together 4 Remove the 4 Torx screws from the top and the 4 screws from the bottom This will allow splitting the case 5 Using the needle nose pliers remove the plastic support post from the middle of the circuit board This will release the circuit board from the ECU housing 6 Remove the plastic post from the bottom ECU plate Be sure to retain the plastic cover sheet for the bottom plate 7 Place the TECm on the bottom plate and reinstall the four Torx screws in the bottom Be sure to keep the plastic sheet in place before screwing the board down 8 Using the drill drill a
15. Staged Injection This firing scenario pairs cylinders that share their TDC s to the same injector channels As such one injector channel fires two injectors one on compression and the other on exhaust Each injector channel will fire once per revolution so each cylinder will see a shot of fuel on both the exhaust and compression stroke The primary reason to us this mode is to free up channels for use in staged injection This mode allows high horsepower applications to be reasonably well mannered by allowing smaller injectors to be used 2 per cylinder with the second set phased in as more fuel is needed usually with additional boost To wire this mode ECU Wire Injector 12 Volts Injector 1 Piman on 1 6 e Injector 2 Secondary on 2 5 Injector 3 Primary on 3 4 7 Injector 4 Secondary on 3 4 Figure Parallel wiring of Injector 5 Primary on 2 5 fuel injectors Injector 6 Secondary on 1 6 TECm User s Manual v1 0 15 2013 Electromotive Inc 4 7 Idle Air Control 4 7 1 Idle Air Control Valve The Idle Air Control IAC Valve is responsible for maintaining a smooth engine idle Using the Wintec software the IAC valve can be made to increase idle speeds during cold engine operation or air conditioner turn on The IAC valve control built into the TECm can be used with the three wire solenoid type Idle Air Valve that is stock on the BMW or a similar two wire solenoid The solenoid type valve allows the IAC to move open and closed
16. TECm BMW E36 Plug and Play Hardware Installation Manual Electromotive Inc Copyright 2013 TECm User s Manual v1 0 l 2013 Electromotive Inc Table of Contents L Terms and Conditions cccccccccccccecccneseresctececeectereceserereeests 4 EN e See e Prod et E e E A 1 1 1 Warranty Replacement iced dci ii dida 4 1 1 2 Warranty Coverage E 4 1 1 3 Lengthof EC aa ca ee 4 1 1 4 Who the Warranty Protects visi A A A 4 1 1 5 Wa manel NS de o a e dea ld 4 1 1 6 How to Obtain Warranty Services cis r ieren ad iras 5 1 1 7 Limitation of Implied Warrantes kk 5 1 1 8 Exclusion of Damages oi A eed ree 5 Za HOT W ANG it iaa 6 21 gt Pre pstallation Checklist cuate dae dd rro e delle lo ea AS 6 2 2 Installing the TECm board in the BMW Case EEN 7 3 E EE 7 Tt TE En A ee ee EAE Eare 7 3 2 Fuel Pump Selection iii iii 11 3 3 Fuel Pressure EE 11 47 WNO the TECM a aa 12 A IOOUCUON saeco teases sex EaR 12 4 2 3 Spaik Pl g Selection ou A A eee a 12 43 gt A Wat AE 13 4 3 1 pan Plug Wire Routing cack etait ola eta 13 4 3 2 Spark Plug Wire Selection eege it dt 13 deit Using a MAP SOM OM oi oaa e a A aa 14 4 5 Wideband O2 Sensor Installation Instructions cooconnnoncccnn nniconccnccnnnnanancncnonanannns 14 dp Fuel INjSCtor Wim soii a a rt t 15 4 6 1 Full Sequential Injection 2d tino Li ici EEN 15 4 6 2 Phased Staged Te TEE 15 Ed WONG DON O ed 16 4 7 1 Idle Air Control Valve iii 16 4 8 tachometer
17. TIME LOSS OF PROFITS LOSS OF BUSINESS opportunity LOSS OF GOODWILL INTERFERENCE WITH BUSINESS RELATIONSHIPS OR OTHER COMMERCIAL LOSS EVEN IF ADVISED OF THEIR POSSIBILITY OF SUCH DAMAGES ANY OTHER DAMAGES WHETHER INCIDENTAL CONSEQUENTIAL OR OTHERWISE ANY CLAIM AGAINST THE CUSTOMER BY ANY OTHER PARTY SHIPPING CHARGES TECm User s Manual v1 0 5 2013 Electromotive Inc 2 Forward The TECm Total Engine Control system is a custom designed engine management systems for use with BMW 3 series vehicles model year 1992 to 1995 The heart of the TEC series of engine management systems has always been a high resolution ignition which offers incredibly precise ignition timing even at the highest acceleration rates The TECm continues this tradition only what was once done with an analog ignition circuit is now done with a high speed microprocessor The TECm uses the stock BMW coils for ignition output by default For extreme applications an Electromotive 6 cylinder DFU can be used The TECm has 6 dedicated fuel channels for high or low impedance injectors Each output can drive up to two 2 ohm or greater injectors Sequential operation is available and used by default in the BMW wiring harness Phased staged injection is available with some wiring harness changes for high power street applications There are thirteen 13 user definable general purpose inputs outputs GP I O s included with the TECm to fully support all factory engine fu
18. Time milliseconds Sarre ee HH ck SH NONNNNNNNNNNW ooo0oo0000000000000000000000000 00 8000 10000 12000 14000 16000 18000 20000 RPM 2000 4000 60 Figure Time between revolutions for various engine speeds TECm User s Manual v1 0 9 2013 Electromotive Inc Phase Full Sequential Sequential 1 inj per rev 1 inj per 2 rev RPM ms ms 500 120 0 240 0 1000 60 0 120 0 2000 30 0 60 0 3000 20 0 40 0 4000 15 0 30 0 5000 12 0 24 0 6000 10 0 20 0 7000 8 6 17 1 8000 7 5 15 0 9000 6 7 13 3 10000 6 0 12 0 11000 5 5 10 9 12000 5 0 10 0 13000 4 6 9 2 14000 4 3 8 6 15000 4 0 8 0 16000 3 8 7 5 17000 3 5 7 1 18000 3 3 6 7 19000 3 2 6 3 20000 3 0 6 0 Table Peak injector pulse widths for phase and full sequential injector firing Injector recovery time of zero is assumed TECm User s Manual v1 0 10 2013 Electromotive Inc 3 2 Fuel Pump Selection When choosing a fuel pump two factors are important Flow Rating in lbs hr Pressure Rating in psi To find the flow rating required for a given engine multiply the engine horsepower by the BSFC and add at least 25 Example 400 HP Engine w 0 55 BSFC Fuel Pump Required 400 x 0 55 400 x 0 55 x 25 275 lb hr minimum As for the pressure rating a minimum of 7Opsi is typically used for multi port injection layouts High boost o
19. advance angle 65535 point interpolation between data points 1 adjustment increments 1 4 spark timing accuracy worst case 6 3 2 Fuel Map Two numbers define slope of fuel curve 8 x 8 tables of RPM vs MAP for volumetric efficiency corrections 65535 point interpolation between data points 1 adjustment increments up to 0 001 millisecond resolution 6 3 3 Load Sensing Three Options MAP sensor based TPS amp MAP based using TPS MAP Blend feature TPS Based using 100 TPS MAP Blend 6 3 4 Rev Limiters Progressive soft rev limiter 3 stages Fuel injector cutoff 1000 20000rpm capability for primary rev limiter 1500 12000rpm capability for auxiliary rev limiter 6 3 5 On Fly Tuning Glitch free real time tuning while engine is running Full control of all fuel ignition and input output parameters 6 3 6 Compensation Features Fuel Table Individual cylinder fuel trims Oxygen sensor closed loop corrections Starting cranking enrichments Cold start cold weather enrichments TECm User s Manual v1 0 25 2013 Electromotive Inc Accelerator pump enrichments Deceleration fuel cutoff Battery voltage correction for injector pulse widths Ignition Coolant temperature based advance adjustments Manifold air temperature based advance adjustments Smooth idle advance control integrated w IAC settings 6 4 Supported Engine Management Configurations BMW E36 6 cylinder using the OBD1 92 95 wiring harness w
20. alibrate your system to your specific engine The TECm is designed to be fully upgradeable with respect to its software and firmware The software is the operating system that is used to tune the engine The firmware is the embedded code that is installed in the TECm s processors Small changes in functionality can be covered with software changes Larger changes in functionality particularly the addition of new features generally require a firmware upgrade Both software and firmware upgrades are available on our website 7 1 Software Coding Information Electromotive calls its TECm Windows software WinTEC 4 X Y The 4 X Y portion of the WinTEC name is the code that is used to tell what the version of software is made for The 4 means simply the software version 4 platform e The X digit states the FIRMWARE version on which the software will function The Y digit states the latest build SOFTWARE version The software version is displayed when the WinTEC software is opened on a computer Software versions are compatible with the firmware version for which they are designed For example A 4 0 3 software version is compatible with a 4 0 0 firmware version A 4 1 2 software version is compatible with a 4 1 0 firmware version A 4 1 0 software version WILL NOT runs with a 4 0 0 firmware version Always use the PC SOFTWARE version for which the FIRMWARE is designed The X digit of the PC software must always mat
21. between the spark plug wire and the engine block instead of at the plug tip Arc over is worsened by the use of low quality wires or wires that have cuts in the insulation The load at which a spark plug fails is different for all spark plugs With the TECm s charging circuit the more load you put on an engine then more voltage will be applied to the plug This is a beneficial situation for a high compression engine the voltage at the plug will be inherently higher since there is more load The detriment is that spark plugs and wires are only rated to a certain voltage 30 40 000 volts is typical and can begin to blow out at around 40 000 volts If that voltage is exceeded by a large amount for a long enough length of time the spark plugs will either blow out break down or arc to somewhere other than the electrode often through the insulator directly to the engine block The solution is to run smaller plug gaps on high compression engines This is perfectly acceptable with our ignition charging method since the high load of the cylinder pressure will allow the voltage to be quite high at the electrode but the small gap will keep the plug from seeing an over voltage situation Use the recommendations below as a guideline for spark plug gaps Stock Street Engine 0 045 0 060 1 1mm 1 5mm High Performance Street 0 030 0 035 75mm 9mm Alcohol High Compression 0 025 0 65mm High Power 75 115 HP per Cylinder 0 025
22. ch the X digit of the Firmware 7 2 Firmware Coding Information The Firmware version is displayed in the Engine Monitor Screen The firmware code is 4 X 0 T3 The X digit must match the X digit of the software version see above This is the firmware version Firmware for the TECm starts with WTM02 The next two digits XX are the release version release changes new feature additions or some other major change will be signified in this number The last 3 digits are the build number Build number YYY indicates bug fixes from one release level to the next Example where firmware file number WTMO2xxyyy XX is the release number YYY is the build number 7 3 Firmware Upgrade Procedure Care must be taken when installing different firmware versions on your TECm ECU Follow the steps outlined below Download the Firmware upgrade from the Electromotive website Install the firmware upgrade on the PC that you will use to tune the engine Connect the TECm to the PC serial port and power it ON 1 Startup the WinTEC software it should show in the System console that the unit was found and display the firmware version In the main menu bar of the WinTEC Software click on Tools gt Options gt firmware upgrade A warning and some instructions will appear Click OK and an open dialog will display Find and select the new firmware file em3 you have downloaded 2 Once the upgrade is complete cycle the power to the T
23. ded for an engine you will need to know the pressure for which the flow rate was established Typically injector sizes are rated at 3 Bar or 43 5psi Therefore an injector rated at 55 lb hr at 43 5psi will only flow 55 lb hr when it is at 43 5psi More accurately it will only flow 55 lb hr when the pressure gradient across the injector is 43 5psi The pressure gradient is defined as the difference between the injector spray tip pressure this is generally the same as the intake manifold pressure and the fuel rail pressure often referred to as gauge pressure For a naturally aspirated engine at idle making 15 of Hg about 7 5psi vacuum you will need to decrease your fuel rail pressure by 15 of Hg about 7 5psi to obtain the same pressure gradient across the injector So for the 55 lb hr injector to actually flow 55 lb hr when the manifold is under 7 5psi vacuum you will need to decrease the fuel rail pressure by 7 5psi The rail pressure should therefore be reduced from 43 5psi to 36psi The same holds true for engines under boost for an engine with 10psi of boost pressure in the intake manifold the injectors will need to have 10psi added to the fuel rail pressure The fuel rail pressure would then have to be 53 5psi Though this all may sound complicated maintaining a constant pressure gradient sounds more difficult than it really is The BMW regulator has a manifold pressure reference and this source can be used for an a
24. e 53 GP I O 5Failure 5 3 Trouble Code Descriptions Code 12 Crank Trigger Error This code will register when the ECU has detected a problem with the crank trigger signal If any of the failure scenarios have been detected in the section above on the crank sensor LED diagnostic this code will be displayed Code 13 Cam Trigger Error The ECU is not getting an appropriate signal from the cam sensor A broken cam trigger wheel or a bad cam sensor could cause this error This code will only be displayed on sequential applications Code 14 ECU Internal Failure This code is displayed when there has been a substantial failure inside the ECU Call Technical support for further information Codes 21 amp 22 TPS High Low See above description Codes 23 amp 24 Manifold Air Pressure High Low These codes are set when the MAP sensor has gone outside its specified range This can be useful for a boosted application to trigger a check engine signal when an over boost situation has occurred Alternately it can be used to detect a short in the wires When this code is displayed the TECm will be using the MAP Failure Default value for MAP calculations As such there will be no load input to the TECm s ECU and the computer will enter into a limp home mode Codes 25 amp 26 Coolant Temperature Sensor High Low Once again these codes are set when the coolant temperature reading is outside its specified range Use this ligh
25. e if needed Finally the 0 5v output of the wideband module connects to the Yellow wire See the chart below The TECm would then need to be configured to use a Wideband O2 sensor in your engine calibration Green 12v Brown Power Ground White Signal Ground EGO Yellow EGO Signal EGO The installation of the oxygen sensor wiring of the controller should follow the wideband controller manufacturer s instructions Note Some wideband control units have a sensor ground and a ground for the heater Other units have only one ground You should connect the sensor ground to the White wire If there is only one ground it should be connected to the Brown wire 4 6 Fuel Injector Wiring The TECm is equipped with 6 peak and hold fuel injector channels These channels support up to 2 injectors per channel with either high or low impedance injectors The driver automatically compensates for high or low injector impedance The factory BMW harness has each injector wired to it s own injector channel and would normally be configured for full sequential injection 4 6 1 Full Sequential Injection When using an unmodified BMW harness this is the method used to fire the injectors This scheme fires each injector only once per engine cycle aligned with the intake stroke of each cylinder This gives the injector the most time between each injection event and will usually produce the best idle and low throttle operation 4 6 2 Phased
26. e sensor is not shorted to 12 Volts Codes 41842 43844 45846 478 48 all function like Codes 23824 except they are for the Analog to Digital Inputs Codes 51 54 GP I O 1 9 Failure These codes are set when the GP I O input outputs have been shorted to voltage or have been over drawn too much current Make sure that the total circuit draw for GP I O s 1 9 is less than 10 amps 1 amp per channel Code 55 Fuel Pump Output Failure The fuel pump output has seen an over current situation or is shorted to power Code 56 Check Engine Output Failure The check engine output has seen an over current situation or is shorted to power The code can only be seen with a laptop since the check engine light is likely at fault 5 3 1 Using the Trouble Codes The trouble codes are displayed for a sensor when the maximum or minimum value for a sensor has been exceeded Since the maximum and minimum points are user definable in the Wintec software a failure code does not necessarily indicate a failed sensor i e the failure parameters may be set incorrectly As an example let s look at the Throttle Position Sensor Parameters Before the parameters can be entered into the software it is necessary to know the TPS voltage at both fully closed and wide open throttle This can be observed in the monitor screen by opening and closing the throttle without the engine running If the closed throttle voltage was 1 0 volt and the wide open throttl
27. e voltage was 4 6 volts the TPS parameters should be set as follows TPS Fully Closed Throttle Voltage 1 1 Volts TPS Wide Open Throttle Voltage 4 5 Volts TPS High Voltage Failure 0 5V 4 8 Volts TPS Low Voltage Failure 0 5 V 0 8 Volts TPS Failure Default Value 0 5V 1 5 Volts As can be seen the Fully Closed Throttle Voltage setting is actually a bit above the actual closed throttle voltage 1 1V gt 1 0V This is done because the Idle Speed Control will only start working when the TPS reading is below the Fully Closed Throttle Voltage setting The Low Voltage Failure setting is made a few tenths of a volt lower than the actual closed throttle voltage 1 0V gt 0 8V This is done to display code 22 for throttle position sensors that have either rotated in their mount or have failed completely by outputting a lower than expected voltage Likewise the High Voltage Failure setting is made a few tenths of a volt higher than the observed wide open throttle voltage This will allow code 21 to be displayed in the event of a high voltage failure The Failure Default Value is the voltage that the TECm will use for its TPS based calculations when the TPS sensor has failed Since this is a fixed value there will be no TPS based acceleration enrichments when the TPS has failed However the Failure Default Value is useful for applications using the TPS MAP Blend feature because it defines a fixed amount of TPS to blend with the MAP sensor during a TP
28. ed That is they create a connection to ground when turned on A MAXIMUM of 1 amp may be drawn from each GP IO circuit It is HIGHLY recommended to use a relay on the output of the GPO channels regardless of amperage draw 4 9 5 Available GPO Functions Thermal Fan This function can turn on and off something as a result of temperature either engine coolant or manifold air temp This is usually used to activate a radiator fan but could also be used to trigger a warning light or a mechanism for cooling an intercooler Shift Light Turns on a shift light or any other rpm activated object at a user definable RPM See Figure for wiring diagram Torque Converter Control Use this GP I O to control a lock up torque converter You are able to define the MAP and Speed points at which the torque converter clutch is activated Since there is a multitude of different lock up transmissions an electrical schematic is not included for this feature Consult the shop manual for your application to find the wire that engages the torque converter lock up Use a GPO channel to activate the proper wire A relay should always be used for this function Duty Cycle Table This GP I O uses a 16 x 16 table of MAP reading vs RPM to allow the input of a duty cycle at each MAP RPM point Numbers are interpolated between cells to create a smooth curve The possibilities of this GP I O are extensive Typically it is used to control an rom load dependent solenoid suc
29. ed to activate internal data logging 4 9 4 General Purpose Output GPO functions Some of the most versatile functions of the TECm computer are its GPO s These outputs can control virtually any electronics device that is associated with engine operation Take for example a simple electric radiator fan Instead of retrofitting a thermo switch mounted somewhere near the radiator s air stream to turn the fan on and off you can simply use one channel of the TECm s GPO function To accomplish this task you would first select the Radiator Fan option from the GPO menu for the given channel Then you would input the temperature at which the fan should turn on and the temperature at which it should turn off The temperature readings are all obtained from the Coolant Temperature Sensor CLT so they are much more accurate and reliable than an external thermo switch The output of the GPO is a pull to ground so you would run the appropriate GPO wire for the channel you defined as Radiator Fan to a standard 4 position automotive relay pin 85 on the relay The opposite side of the relay pin 86 would be wired to 12 volts and the relay would be switching the power or the ground to the fan with pins 30 and 87 A few facts that must be remembered when using a channel for a GP I O function TECm User s Manual v1 0 18 2013 Electromotive Inc All the GPO s regardless of their function are pull to ground outputs when they are activat
30. ensor The third wire needed is the 5v supply which is tapped off of the TPS sensor The wiring is as follows BMW Red Yellow at TPS 5v must be spliced in as the TPS still needs 5v as well BMW White at MAF Signal Ground BMW Gray Yellow at MAF MAP Signal The MAP sensor is wired into these signals as show in the figure below MAP Sensor Connections White from MAF plug Sensor Ground a MAP sensor Gray Yellow from MAF plug MAP signal Red Yellow split from TPS 5 volts The MAP sensor should then be connected to the intake manifold where it can receive a solid representative pressure reading of the pressure at the intake ports On the stock manifold the sensor can be connected to 4 5 Wideband 02 Sensor Installation Instructions The TECm supports an input from most wideband sensor controllers The wideband controller must have an analog 5 volt output signal A typical configuration is shown in the figure below Wideband Oxygen Sensor A Wideband 12v Supply SR Y A Wideband Heater ground eg 0 laa O Ei Bate Wideband Signal BMW Yellow Wideband signal ground BMW White may not apply on all wideband controllers TECm User s Manual v1 0 14 2013 Electromotive Inc The factory pre cat narrow band O2 connector can be repurposed for wiring in a wideband O2 sensor The wideband module can pull 12v and power ground from the EGO heater leads Green and Brown and has a signal ground available on the White wir
31. ftermarket regulator as well TECm User s Manual v1 0 I1 2013 Electromotive Inc Be aware that when you use a fuel pressure regulator that regulates the fuel pressure to a value that is not the same as the fuel injector flow rating pressure the injector will no longer run at it s rated flow That is higher pressure will cause a higher flow rate To keep things straightforward try to run the fuel pressure for which your injectors are rated 4 Wiring the TECm 4 1 Introduction A normal installation of the TECm requires no wiring change be made The system is truly plug and play ona stock or mildly modified NA engine that can utilize the Mass Air Flow sensor and for those installations the sections after spark plug selection can be skipped This section covers instances where the wiring harness may be modified to use alternate sensors Electromotive DFUs or non stock injection schemes like staged injection WARNING Always disconnect the battery when doing ANY electrical work on a vehicle Use common sense when working around electrical systems particularly the ignition coils The voltage output of the coils can be well over 40 000 Volts at a given instant 4 2 Spark Plug Selection Spark plugs are generally more important to spark quality than spark plug wires Most spark plugs exhibit failure when exposed to a large load Failure usually consists of either intermittent sparking or arc over Arc over is when the spark occurs
32. h as a turbo waste gate You can select table 1 or 2 BMW A C Control This feature turns the air conditioner clutch off when the engine is above specific RPM and MAP values when the A C Console switch is turned on and the A C Coolant pressure is sufficient Auxiliary Fuel Pump This GP WO turns on an auxiliary fuel pump at a desired RPM and MAP value See Figure for wiring diagram The Intake Runner and Nitrous Controls function in the same manner as the Auxiliary Fuel Pump Control That is they activate as a function of RPM and MAP value Note that the Nitrous Control should not be used to turn on the nitrous directly Instead it should be thought of as a nitrous enable This essentially replaces the wide open throttle switch Use Figure for similar wiring Custom and Custom or Custom and uses both ranges RPM and MAP values The custom and function activates when within both the specified RPM range AND the specified MAP range The custom or functions when within either the RPM range OR the MAP range 4 9 6 Examples of Wiring GPO s This section covers the wiring that is necessary to use the various GP I O controls With one exception A C turn off the relays depicted in the schematics are all simple automotive 4 position relays The air conditioner turn off request needs a 5 position relay 4 position and 5 position relays are generally rated at 30 or 40 amps which should be more than adequate for most applications High qual
33. he timing back to the values in the Ignition Advance Table the ramp back will happen in the specified time programmed by the user within the software Datalog Enable Allows the use of on board data logging function Options are RPM to begin data logging and Frequency 5 10 20 Hz sampling rate Wires the same as any input that is switched such as the Valet Rev Limiter Voltage Input No options it just gives you a recordable voltage from 0 5 volts Timed Ignition Cut option for shifting requires minimum RPM and minimum MAP value amount of time for ignition cut in milliseconds amount of time before ignition can be cut again Finally there is an option to pull to 12v activate high or pull to Ov activate low Additionally the line must be released before the channel can be activated again 4 9 2 Examples of GPI Wiring Nitrous Solenoid to Nitrous TECm GPI Controller 10k Potentiometer pin 10 57 76 or 81 Ground 5v TECm pin 14 TECm pin 59 Nitrous Retard with Fixed Retard Amount Output Nitrous Solenoid to Nitrous Controller TECm GPI pin 10 57 76 or 81 Nitrous Retard with Driver Variable Retard Amount TECm User s Manual v1 0 17 2013 Electromotive Inc 10k Potentiometer Potentiometer wiring for Fuel Ignition and GPO Trim Inputs Ground TECm pin 14 TECm pin 59 TECm GPI Output pin 10 57 76 or 81 0to5VDC 4 9 3 GP I O Wiring Harness Layout GP I O channel ECU Pin
34. hole in middle of the rear face of the ECU cover opposite the main connector 9 Feed the push connectors of the TECm serial cable through the hole in the ECU cover and push the grommet on the serial cable into the hole 10 Push the wire onto the tabs on TECm circuit board in the following order a Bare Ground D Black RXD c Red TXD 11 Place the ECU cover onto the ECU and install the 4 Torx screws into the top 12 Bend the tabs on the bottom back into place if not broken off 13 Re connect the ECU to the BMW harness and re install the new ECU into the original location Leave the serial cable hanging out of the cover for the ECU bay to allow easy connection to the PC Once tuning is completed the serial cable can be tucked into the ECU bay to hide the cable 3 Fuel System BMW has already done a pretty good job of designing the fuel system in your car In many cases you will not need to make any changes to this configuration Installing a TECm usually means that other changes were made to the engine that will result in more horsepower which in turn requires more fuel This usually means upgrading the injectors and possibly the fuel pump 3 1 Injector Sizing The most important component of the fuel system is the fuel injector Injectors must be flow matched to maintain a consistent fuel supply for all cylinders Cylinder to cylinder fuel variations can lead to poor performance increased fuel consumption or even catastrophic de
35. is held open for 2 revolutions multiply AIT by 2 Example Engine Setup 250HP 6 cylinder with 6 injectors Sequential Injector Firing High Impedance Injectors 1 5ms IRT Peak HP occurs at 6500 rpm BSFC 0 45 TECm User s Manual v1 0 8 2013 Electromotive Inc Calculations TFFR 250 x 0 45 112 5 lb hr UIS 112 5 6 18 75 Ib hr AIT 120000 6500 18 462 ms MDC 18 462 1 5 18 462 0 9188 Required Injector Size 18 75 0 9188 20 40 lb hr 214 cc min Central to the topic of injector sizing is the RPM at which the engine will need the injectors to fire High RPM s shorten the amount of time between TDC events thus shortening the maximum injector pulse width The Figure Below shows the time per revolution as a function of RPM The Table shows the peak injector pulse width assuming an injector recovery time of zero that is possible using both once per revolution firing and once per engine cycle 2 revolutions on a 4 stroke firing modes If the operating pulse width approaches the values in Table E 1 1 the injectors are effectively maxed out Larger injectors would be necessary if the engine needed more fuel Note that the injector recovery time will be at least 1 0ms is practice Consequently the values given in Table E 1 1 should have 1 0ms subtracted from them to determine the actual pulse width peak Time for One Revolution vs RPM
36. ithout modifications and with the following modifications Replace MAF with MAP Replace factory coils with Electromotive 6 cyl DFU Conversion to phased injection 2 injectors per channel Conversion to staged injection 12 injectors in 2 sets 2 injectors per channel 6 5 Data logging Features 6 5 1 Internal Data logging Records all sensor data at user specified data rate Recording time 1 7 mins to 6 8 mins depending on data rate 6 5 2 Laptop Data logging Records to hard drive on laptop Sampling rate is approximately 50 samples per second Total data logging time is limited only by hard drive space 6 6 Form Factor Fits in BMW ECU for 92 95 OBD1 3 series 6 7 Environmental Considerations Silicon coated PCB for moisture dust and vibration protection Unsealed Bosch compatible connector for BMW 6 8 PC Requirements 6 8 1 Computer IBM Compatible PC Pentium 1 233 or better 1024 x 768 monitor resolution 256 colors 64 Mb of ram 10 MB of free hard drive space 6 8 2 Data Drives CD ROM or Internet connection for software installation 6 8 3 Communications RS 232 9 pin D sub connector compatible with commonly available USB to serial adapters COM 1 14 software selectable TECm User s Manual v1 0 26 2013 Electromotive Inc 7 Calibration Software The TECm Calibration Software is called WinTec4 and is available from Electromotive s website Please refer to the WinTEC4 software guide to learn how to use it and c
37. ity relays and relay sockets are available from Electromotive under part numbers 340 91200 and 340 91201 respectively Part number 340 91200 is a 5 position relay so it can be used for all applications depicted below TECm User s Manual v1 0 19 2013 Electromotive Inc x TECm GPO TECm Electric Radiator Fan Wiring pin Ed 12v Swtiched Ignition Battery 12v full time high amp FUSE BLOCK Figure Electric radiator fan wiring al To 12 Volts low amp Light Bulb Figure Shift light wiring SS N TECm GPO pin 2 7 9 29 36 or 48 TECm GPO pin 2 7 9 29 36 or 48 Auxiliary Fuel Pump Battery 12v full time pa S high amp FUSE BLOCK Figure H 2 4 Auxiliary fuel pump wiring 85 12v Switched Ignition TECm User s Manual v1 0 20 2013 Electromotive Inc 5 Diagnostics The TECm has two provisions for diagnostics an output wire for a check engine light and an LED on the ECU The two outputs perform different tasks that are outlined below 5 1 Trouble Codes from the LED s Mounted on the TECm The LED s mounted on the TECm are used to alert the user s attention to electrical and crank trigger problems They are also used to show the mode in terms of the rpm range in which the TECm is operating Since these are installed on the circuit they are not normally visible when the ECU is fully installed If you are having trouble with engine start
38. nctions and to allow additional functionality The GP I O s can be used to control anything from wastegates for turbo setups to simple electric radiator or intercooler fans One of the GPI s is a vehicle speed input which can process the signal produced in the transmission The other GPI s are analog inputs only and do not feature frequency based capabilities These channels can perform fuel trims timing trims and many other functions Besides the GP I O s several functions are built in to the TECm that are quite useful on most applications The following outputs are standard on the TECm Tachometer drives the factory BMW tach and most aftermarket tachs Fuel Pump Relay Ground activated at appropriate times by the TECm Fuel Consumption Gauge output ECU relay control activates many vehicle electronics The TECm uses the following inputs to perform engine management Crank Trigger 60 2 Cam Trigger stock BMW optional Mass Air Flow Sensor or Manifold Absolute Pressure Coolant Temperature Sensor Manifold Air Temperature Sensor Throttle Position Sensor Knock Sensor stock BMW sensor enabled optionally Exhaust Gas Oxygen Sensor O sensor narrow or wideband 2 1 Pre Installation Checklist To perform a complete TECm installation the following items are required TECm Computer 3 series 6 cyl BMW model year 92 95 Torx T 15 screwdriver Flat blade screwdriver Drill with x dirll bit Windows based PC type Computer
39. ne would require a total of 150 lbs hr of fuel flow The Injector Recovery Time is the time that is takes for an injector to open once it receives a voltage signal Typically a low impedance injector will have an IRT of around 1 3 milliseconds A high impedance injector will generally have an IRT of 1 5 ms The IRT determines two things 1 The minimum time that the injector can be pulsed 2 The maximum duty cycle If an injector is given a pulse width that is shorter than its IRT it will flutter This will cause erratic fuel metering and ultimately horrible engine performance This scenario sometimes occurs at idle on high revving high horsepower engines with large injectors If the IRT is not accounted for in high rpm situations the duty cycle will be too great and the injector will flutter This scenario occurs on engines with injectors that are too small To properly size an injector the following sequence of equations should be followed HP x BSFC Total Fuel Flow Requirement for the Engine TFFR TFFR of Injectors Uncorrected Injector Size UIS 60000 Peak RPM Available Injection Time ms per Revolution AIT AIT Injector Recovery Time in ms AIT Maximum Duty Cycle MDC UIS MDC Required Injector Size The above calculation assumes an injection scenario in which an injector is held open for a maximum of one engine revolution typical phase sequential setup For other firing options in which the injector
40. on on the face of this document There are no warranties of fitness for a particular purpose except as stated on the face of this Electromotive Product Warranty Any and all oral warranties are excluded and will not be honored Consequential damages will not be covered by this warranty 1 1 6 How to Obtain Warranty Service For information on warranty service contact your Electromotive Value Added Dealer or call Electromotive Technical Support at 1 703 331 0100 from 9am to 5pm Eastern Time Monday through Friday e mail support electromotive inc com To obtain warranty service you will be required to provide Original dated sales receipt Your name Your address The serial number of the product A description of the problem Contact information daytime phone number or email address Take or ship the product in the original or a suitable replacement container to Electromotive Inc 9131 Centreville Road Manassas VA 20110 1 1 7 Limitation of Implied Warranties THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION CONTAINED HEREIN INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE 1 1 8 Exclusion of Damages ELECTROMOTIVE S LIABILITY IS LIMITED TO THE COST OF REPAIR OR REPLACEMENT OF THE PRODUCT ELECTROMOTIVE SHALL NOT BE LIABLE FOR DAMAGE TO OTHER PROPERTY CAUSED BY ANY DEFECTS IN THE PRODUCT DAMAGES BASED UPON INCONVENIENCE LOSS OF USE OF THE PRODUCT LOSS OF
41. r K from the engine monitor screen when using a laptop If the lower LED is flashing red after the engine is shut off there was a crank sensor problem at some point during the run 5 2 Trouble Codes turns on the Check Engine light The trouble codes from the check engine output are related to the engine sensors If the check engine output wire is connected to a light bulb it will display a sequence of flashes depending on the problem The diagnostic codes are arranged such that there are two digits for each code The check engine light will give long duration flashes for the first digit of the code and short duration flashes for the second digit See Figure H 2 1 for a graphical representation of the flash sequence Here are the diagnostic codes asterisked items are not available with the first software release 12 Crank Trigger Error 13 Cam Trigger Error 14 ECU Internal Failure 21 Throttle Position Sensor High TECm User s Manual v1 0 21 2013 Electromotive Inc 22 Throttle Position Sensor Low 23 Manifold Air Pressure Sensor High 24 Manifold Air Pressure Sensor Low 25 Coolant Temperature Sensor High 26 Coolant Temperature Sensor Low 31 Manifold Air Temperature Sensor High 32 Manifold Air Temperature Sensor Low 33 High Battery Voltage 34 Low Battery Voltage 35 Knock too Long 37 Exhaust Gas Oxygen Sensor Lean too Long 38 Exhaust Gas Oxygen Sensor Rich too Long 51 GPO 1 Failure 52 GP I O 2Failur
42. r can reduce the flow of electricity to the spark plug an ignition wire that reportedly generates an increase in spark energy will have no effect on the spark jumping across the spark plug gap since the energy consumed at the spark plug gap won t be any more than what is needed to jump the gap For a more obvious example of this a 25watt light bulb won t use any more energy or produce any more light if it s screwed into a socket wired for a 1000watt bulb Due to the extremely high energy in the TECm coil charging circuit spark plug wires may wear out faster than with a standard ignition As such it is recommended that the wires be checked periodically for carbon tracking caused by a breakdown of the internal conductor element Looking at the plug wires in a dark area and wetting them with a spray bottle of water will reveal carbon tracking Pay close attention to the exposed section of the spark plug where the rubber boot ends during the test To maximize spark plug wire life keep the lengths as short as possible i e mount the DFU as close to the engine as possible Replacement of the wires on an annual basis is recommended for high rpm high horsepower applications 4 4 Using a MAP Sensor A MAP sensor allows application of boost and allows for making horsepower beyond the rated flow of the stock MAF sensor Wiring in a MAP sensor is relatively simple The MAF sensor connector can be removed and 2 of the wires are used to connect the MAP s
43. rather than repair them Replacement puts the Customer First and offers many benefits over repair the greatest benefit being the timeliness of the replacement process However in some cases replacement with a like new refurbished product is not possible and a warranty repair situation occurs In these situations Electromotive strives to keep our repair times to a minimum on average 2 to 3 business days upon receipt excluding the necessary shipping time Customers should follow the appropriate steps outlined below to initiate a warranty replacement or repair 1 1 1 Warranty Replacement Contact Electromotive Technical Support at 1 703 331 0100 9am to 5pm Eastern Time The customer must have the serial number and original proof of purchase available Electromotive s Technical Support staff will attempt to help you correct any minor issues that might be causing the problem If we are unable to fix the issue to your satisfaction a return merchandise authorization RMA number will be issued Under our Warranty program Electromotive will typically ship the customer a replacement unit on the same day the defective product arrives The replacement product will assume the remainder of your original product s warranty or 90 days whichever is greater 1 1 2 Warranty Coverage Electromotive warrants its products to be free from defects in material and workmanship during the warranty period If a product proves to be defective in material or wo
44. rkmanship during the warranty period Electromotive will at its sole option repair or replace the product with a similar product Replacement product or parts may include remanufactured or refurbished parts or components 1 1 3 Length of Warranty Electromotive products are warranted for one 1 year parts and one 1 year labor Warranty begins upon date of shipment from Electromotive 1 1 4 Who the Warranty Protects This warranty is valid only for the purchaser from Electromotive 1 1 5 Warranty Exclusions Any product on which the serial number has been defaced modified or removed Damage deterioration or malfunction resulting from Accident misuse neglect fire water lightning or other acts of nature unauthorized product modification or failure to follow instructions supplied with the product Repair or attempted repair by anyone not authorized by Electromotive Any damage of the product due to shipment Removal or installation of the product Causes external to the product such as electric power fluctuations or failure Use of supplies or parts not meeting Electromotive s specifications Any other cause which does not relate to a product defect TECm User s Manual v1 0 4 2013 Electromotive Inc Removal installation and set up service charges Shipping Charges Any warranty of merchantability express or implied is excluded except as otherwise set forth herein There are no warranties that extend beyond the descripti
45. t to warn of coolant temperatures that are too high When this code is displayed the TECm will be using the CLT Failure Default value for coolant based calculations As such there will be no engine temperature input to the TECm s ECU Codes 31 amp 32 Manifold Air Temperature Sensor High Low Works identically to codes 25 amp 26 except for the MAT sensor Code 33 Battery Voltage too High The battery voltage has exceeded 17 Volts A bad voltage regulator on the alternator can cause this Code 34 Battery Voltage too Low The battery voltage has gone below 7 5 Volts Check the state of charge on the battery Also check all power connections Code 35 Knock too Long The ECU has recorded a level of engine spark knock from the knock sensor for a duration that exceeds what was established in the software This code is indicative of either poor fuel quality or extreme engine temperatures leading to spark knock Some tuning will be required for the knock sensor trouble codes since all engines make noises that will trigger the knock sensor but which are not caused by spark knock TECm User s Manual v1 0 22 2013 Electromotive Inc Code 37 EGO Lean too Long This code is set when the oxygen sensor reading is lean for a prolonged period of time Make sure the sensor has not come unplugged Code 38 EGO Rich too Long This code is set when the oxygen sensor reading is rich for a prolonged period of time Make sure th
46. tonation Additionally the size of the injector plays a large role in tuning a vehicle Injector sizes flow rates are generally given in either pounds per hour lbs hr or cubic centimeters per minute cc min Note that 1 lb hr 10 5 cc min These ratings are either made by the injector manufacturer or by an aftermarket injector modifier In either case the importance of the pressure at which the flow rating was obtained must be realized As an example an injector that was TECm User s Manual v1 0 7 2013 Electromotive Inc rated at 40 lbs hr at 43 5psi pressure will NOT supply 40 lbs hr when operated at 30psi it will flow more like 34 lbs hr For an injector to be sized properly for an engine a few things must be taken into consideration Number of Cylinders Number of Injectors Engine Horsepower Peak RPM Brake Specific Fuel Consumption BSFC Injector Recovery Time IRT The Brake Specific Fuel Consumption BSFC is a scaling factor used for fuel flow calculations lts units are pounds per hour per horsepower lbs hr per HP Typically gasoline engines run BSFC s between 0 40 and 0 60 Alcohol engines generally run BSFC s between 0 80 and 1 20 A lower BSFC value indicates a more efficient engine The original 4 cylinder BMW M3 engine has a BSFC of around 0 43 A turbo engine will normally have a BSFC above 0 5 Example Engine Horsepower 300 BSFC 0 50 300 HP x 0 50 Ibs per hr HP 150 lb hr This engi
47. ver 20psi applications may suffer from problems with normal OEM fuel pumps Since many fuel pumps are rated at 43psi 3 Bar there is no information on what the pumps will flow at 60 or 70psi On a turbo engine with 25psi boost the fuel pump will see about 68psi No pump will maintain it s rated flow rate at this pressure As such it is highly advised that you buy a good quality aftermarket pump when running highly boosted engines and be sure that the minimum flow rate is maintained at the expected pressure If a high pressure pump is mounted above the fuel level in a gas tank a decreased pump lifespan will generally result Some high pressure pumps will fail very quickly when mounted above the fuel level The reason for this failure is that high pressure pumps often are not designed to pull suction As such any high pressure pump mounted above the fuel level should have a low pressure fuel pump before it A standard carburetor style fuel pump can be used for this task 3 3 Fuel Pressure Regulator Selection In most cases the factory BMW pressure regulator will be sufficient to maintain proper fuel pressure In cases where you have significantly increased fuel flow the stock pressure regulator may not be able to maintain proper fuel pressure in all operating conditions Installing an aftermarket regulator can help with these cases There are some guidelines that should be followed for selecting a regulator When you select the injector size nee
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