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User Guide.book - Hot Rod Handbooks

1. 41 Help 42 Dump 42 Diff 43 Xlate 43 Link 44 Link CaIRx 44 Link RamRx 45 Link CalTx 45 List Menu 46 List Load 46 List Def ult 2 4 2 24 22 ee ee es 46 List View 47 List Capture 47 List Play 48 List Read 48 List Save 48 List Load 49 Tist Default e ei doni pos musid ern e ed 49 List View 50 List Capture 50 List Play 50 List Read 51 List Save hi ene ep Sage eee eck at e hes ee 51 Function Menu 51 Function Load 52 Function Variable 52 Function Discrete 53 Function Clear DTC 54 Gauge Menu 54 Gauge Load 55 Gauge View 55 Plot Menu seen ee ee 55 Plot HPGL 56 Plot PostScript 57 Plot Text
2. 75 Alternating Double Fire double channel 75 Sequential multi channel 75 Sequential Staged multi channel 76 Central Fuel Injection CFI or CMFI 76 Base Pulse Constant 76 Injector Flow Rate 78 Sensors 2222 eee 81 O2 Sensor Positioning 81 Leaded open loop 81 Knock Sensor 82 Vehicle Speed Sensor 83 Wiring Information 85 ECM Terminals 85 Terminal Listings 86 ECM Terminal Descriptions 88 ALDL Connector 95 Distributor Interface 97 Non GM Distributors 97 Distributor Interface lt 97 Ignition Module Operation 99 Voll Chapter 8 KalMaker Street Pro 3 Variables 103 Variable Types 103 Zero Dimensional Variables 103 One Dimensional Variables 104 Two Dimensional variables 104 Three Dimensional variables 104 Variable Naming Convention 104 Variable Groups 105 General Variables 106 Internal Variables 107 Spark Variables
3. 216 Vol 1 Table 34 List Of Fuel Injectors 24 5 255 1 7 yellow ND orange 24 5 290 13 8 green ND 24 5 290 13 8 violet ND 24 5 255 13 8 brown ND 24 5 290 13 8 violet ND 25 25 25 25 25 1 39 2 Bosch 280150422 25 3 Blue MP Methano Green 25 6 43 5 MP Bosch 280150001 25 6 43 5 MP Bosch 280150002 25 6 43 5 Yellow MP Bosch 280150009 26 300 Bosch 0 280 150 001 26 300 Bosch 0 280 150 002 26 300 Bosch 0 280 150 009 27 50 12 15 MP Rochest 17121909 er 27 50 12 15 MP Rochest 17124251 er 27 50 12 15 MP Rochest 17124289 er 27 55 MP 27 55 MP 27 4 43 5 MP Bosch 280150802 Vol 1 217 Table 34 List Of Fuel Injectors 27 6 290 13 8 light ND green 27 6 290 13 8 violet ND 27 8 300 Bosch 0 280 150 802 28 7 55 1 MP 28 8 50 8 MP Bosch 280150811 28 9 255 2 7 yellow ND 28 9 255 1 6 pink ND 28 9 255 13 8 green ND 29 43 5 HIZ MP Bosch 280150151 29 43 5 MP Bosch 280150200 29 43 5 MP Bosch 280150335 29 43 5 MP Bosch 280150355 29 43 5 MP Bosch 280150357 29 2 350 Bosch 0 280 150 811 29 4 300 Bosch 0 280 150 200 29 4 300 Bosch 0 280 150 335 29 4 red Bosch 0 280 150 945 brown 29 8 45 MP Bosch 280150218 30 MP Rochest 17090844 er 30 MP Rochest 17121882 I er 30 Gre
4. sub groups e SPK STU Engine Run Flags 41 44 e SPK IPS Idle Proportional Spark 52 57 e SPK BAS Base Spark and Corrections 45 51 e SPK ESC Electronic Spark Control 71 78 e SPK DSR Driveline Spark Retard e SPK PND PKN DRV Transition Spark 62 63 e SPK DFC DFCO Spark 58 59 e SPK DGN Diagnostic Spark 60 61 e SPK TOM Torque Management Spark e SPK LOG 79 84 e SPK OUT Spark Output 64 70 Table 24 Spark SPK Variable List 44 SPK STU AFRUNPER run fuel refcounts 43 SPK STU AFRUNRPM run fuel rom 42 SPK STU RUNPER run spark refcounts 41 SPK STU RUNRPM run spark rpm SPK STU LPGRML Ipg stall mode lo rpm 03 SPK STU LPGRMD Ipg stall mode rpm hysteresis 03 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 109 Variable Groups Table 24 Spark SPK Variable List 52 SPK IPS RPMQ idle desrpm filter coefficient DB FB 53 SPK IPS PSCLT propspark ch threshold DB FB 56 SPK IPS RPMERR propspark max underspeed rpmerr DB FB 55 SPK IPS PSNEG propspark underspeed spark factor DB FB 54 SPK IPS PSPOS propspark overspeed spark factor DB FB 57 SPK IPS PSMAX max absolute propspark DB FB 47 SPK BAS IACADV map base idle mode spark 48 SPK BAS RUNADV map rpm base run mode spark SPK BAS RPMRAT hirpm spark factor 45 SPK BAS CLTOFS cltcrn offset 50 SPK BAS CLTCRN map ct spark clt co
5. The Function facility can be viewed as a stand alone subsystem within KalMaker It relies on information contained in a function script which is automatically loaded with a calibration script The function script contains input and output variable names units and conversion information as well as the commands necessary to override them Function Load The Load option enables a function script to be loaded manually The script may be loaded without any calibrations being present This allows KalMaker to be used to override functions in a standard ECM In order that the correct script is loaded the user should be aware of the program being used by the calibration in the ECM or PCM The way to determine this is as follows e Load Buffer1 or Buffer2 with the calibration e Select Buffer Info e The calibration script name and a brief description of the program is displayed e The function script has the same file name as the calibration script but a different extension Function Variable The Variable option enables continuous variables to be selected and transmitted to the ECM The actual variables can vary from calibration to calibration The variables transmitted by the Variable command are of two types e A sensor or counter input eg map clt e An internal variable eg advance The variables transmitted by the Variable command are of two formats e Absolute the variable replaces an Input or Internal value e Relative
6. 109 Fuel Variables 113 Idle Air Control Variables 117 Engine Trouble Codes 120 Output Variables 123 Kalmaker Switch Variables 125 Chapter 9 Pre Calibration Checks 127 Connecting the PC to the ECM 129 Chapter 10 Opening Loading and Saving a Calibration 131 Opening a Calibration from File 131 Opening a Calibration from Floppy Disc 133 Opening a Calibration from SRAM 133 Loading a Calibration To Calibrate in Real Time 133 Saving a Calibration 134 Writing a Calibration 135 EPROM Specifications 135 Chapter 11 Pre Calibration Settings 137 Linking to the ECM 137 Custom Calibration First Steps 137 Knock Sensor ON 139 Knock Sensor OFF 139 Vehicle Speed Sensor 139 TPS Voltage 140 Chapter 12 Getting Idle Right 145 Set Idle Speed 145 Hunting at Idle 148 Lumpy Camshaft 148 Setting idle speed for lumpy cams 149 Stalling Stumbling Deceleration 150 Throttle Stop Screw Adjustments 151 Vol 1 Chapter 13 Chapter 14 Chapter 15 Get
7. E1208 Script file timed out dd mm yyyy for file In applications where a timer is required the timer button date for the calibration script has expired E1209 Incompatible Calibrations The program information does not match that contained in the security script E1210 Can t open script for file A file open error occurred while opening the calibration script file for reading E1211 file is not a Calibration Script scrnam The calibration script file does not have the required header string E1212 Header bad for file The calibration script file header information is inconsistent E1213 Can t allocate input buffer for file An error has occurred while allocating memory required for processing the calibration script file E1214 Can t allocate output buffer for file An error has occurred while allocating memory required for processing the calibration script file E1215 Authorisation device not present The program cannot find the authorisation device required by the security script on any of the parallel ports at addresses 378h 278h or 3BCh E1216 Decompression failure for file An error has occurred while decompressing the calibration script 184 Vol 1 KalMaker Application Errors E1217 file is corrupted The decompressed calibration script information is not internally consistent E1218 Can t load Script file for file A general error has occurred while ope
8. 14 2 255 2 4 light ND green 14 2 255 2 4 green ND 14 3 300 Bosch 0 280 150 211 14 4 300 Lucas 5206003 14 4 270 Lucas 5207007 14 4 43 5 MP Bosch 280150703 14 4 43 5 MP Bosch 280150715 Voll 211 Table 34 List Of Fuel Injectors 14 6 300 Bosch 0 280 150 715 15 2 290 13 8 red ND dark blue 15 2 290 13 8 violet ND 15 2 290 13 8 sky blue ND 15 2 290 13 8 violet ND 16 1 300 Lucas 5207003 16 1 250 Lucas 5208006 16 1 36 3 MP Bosch 280150204 16 1 36 3 Bosch 280150206 16 1 36 3 MP Bosch 280150209 16 1 36 3 MP Bosch 280150217 16 1 36 3 MP Bosch 280150219 16 4 36 3 MP Bosch 280150205 16 4 43 5 Bosch 280150704 16 4 36 3 MP Bosch 280150725 16 7 300 Bosch 0 280 150 704 17 2 Bosch 280150121 17 3 300 Bosch 0 280 150 209 17 3 290 13 8 light ND green 17 3 290 13 8 grey ND 17 5 Bosch 0 280 150 121 17 8 255 2 dark ND grey 17 8 255 2 4 grey ND 212 Vol 1 Table 34 List Of Fuel Injectors 17 9 43 5 Bosch 280150100 17 9 Bosch 280150114 17 9 Bosch 280150116 17 9 43 5 Bosch 280150214 18 1 43 Gray MP Bosch 280150105 18 1 300 Bosch 0 280 150 100 18 1 Bosch 0 280 150 114 18 1 Bosch 0 280 150 116 18 1 Bosch 0 280 150 203 18 2 MP Bosch 280150125
9. 95 100 100 Table 10 50 percent Margin Low BreakPoint High 20 20 30 Vol 1 Chapter 3 Kalmaker Editor Menu Commands 33 Menu Functions Table 10 50 percent Margin continuea 30 40 50 50 60 70 70 80 90 90 100 100 The normal value for Margin is 50 percent which is the maximum At 50 percent margin an indicator is always highlighted However the system may also be interpolating from a neighbouring indicator and so if the indicator were to change by say 10 units the system may only see a 5 unit change If the margin is set to a small value an indicator normally does not stay highlighted long enough to be changed If the tracking variable exceeds the minimum or maximum breakpoint the minimum or maximum breakpoint is highlighted Edit3 3D variables are edited as a set of 2D arrays This means that all components of the variable are not shown on the screen at once The variables can be stepped through along either the X axis or the Y axis row wise or column wise editing A 3D variable name is of the form GRP SUB NAME x y where X and y are the two independent variables The Edit3 screen consists of a row of indicators which show the values of the current row or column depending upon the editing mode of the Local Buffer together with a keypad The currently selected indicator is highlighted There is also an area which displays the value of the highlighted indica
10. CCO Crank Cut Off CLT Engine Coolant Temperature DATA Constant values read by a controller used to calibrate it or modify its behavior The data is contained on the EPROM soldered into the Memcal DE Deceleration Enleanment DELTA Change in Variable usually time DFCO Deceleration Fuel Cut Off DMAP Delta Manifold Absolute Pressure DTPS Delta Throttle Position Switch DYNAMIC A type of memory which has to be constantly refreshed for it to store data 224 Vol 1 Chapter 17 Glossary Glossary Table 36 ECM Engine Control Module The engine control computer The same computer is used for all Camira Astra and Commodore models to VQ The MEMCAL is used to calibrate the computer for each model ECU Electronic Control Unit EEPROM Electrically Erasable Programmable Read Only Memory A chip which can be programmed and erased in situ They are typically smaller and more expensive than EPROM s EPROM Erasable Programmable Read Only Memory A chip which can be programmed by an EPROM programmer and erased with ultra violet light They are easily recognised by the quartz window used to erase them ESC Electronic Spark Control EST Electronic Spark Timing EXECUTABLE A binary file which can be loaded by the command processor and run FLAG A bit or byte similar to a mask When turned on it signifies that an event has occurred or something has been set FLA
11. SPK TQM RPM tqmspk rpm threshold DB FB SPK TQM KPHMIN tqmspk kph threshold DB FB SPK TQM KPH tqmspk kph threshold DB FB Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups Table 24 Spark SPK Variable List SPK TQM MAXADV tamspk max spark advance DB FB Fuel Variables The Fuel FUL groups describe fuel equations transient fuelling modes and fuel cutoff There are eleven sub groups e FUL CRK Crank Fuel e FUL AFR Air Fuel Ratio e FUL OUT Output Fuel Calculation e FUL BLM Block Learn Multiplier e FUL CLP Closed Loop Correction e FUL CCO Crank Fuel Cutoff e FUL CUT Speed Fuel Cutoff e FUL TRA Transient Map Variables e FUL TAE Transient Accel Enrichment e FUL TIDE Transient Decel Enleanment e FUL DFC Decel Fuel Cutoff Table 25 Fuel FUL Variable List 88 FUL CRK CFLTPS clear flood tps percent 89 FUL CRK CFLAD clear flood tps voltage 91 FUL CRK CFLBPW clear flood pulsewidth 85 FUL CRK TIM1 stage1 crank pulsewidth refcts 5D 86 FUL CRK TIM2 stage2 crank pulsewidth refcts 87 FUL CRK TIM3 stage3 crank decay interval refcts 90 FUL CRK BPWDEC crank decay delta 92 FUL CRK BPW1 clt stage1 crank output pulsewidth 5D 93 FUL CRK BPW2 clt stage2 crank output pulsewidth FUL CRK LPGDLY initial lpg crank delay 03 FUL CRK LPGCLT lpg inject coolant threshold 03 Vol 1
12. 276 291 305 320 335 349 364 378 393 407 422 436 451 465 480 495 509 284 305 327 349 371 393 415 436 458 480 502 524 545 567 589 611 633 655 676 698 720 742 764 378 407 436 465 495 524 553 582 611 640 669 698 727 756 785 815 844 873 902 931 960 989 1018 There are 454 grams to 1 pound so a 24lb hr injector 10896 grams hr Dividing by 60 gives you 181 6 grams minute Dividing by 60 again gives you 3 026 grams per second To find how many seconds it takes to flow 1 gram of fuel we divide 1 by 3 026 giving us 330 seconds for 1 gram of fuel to flow out the injector In this example enter a value of 330 for the variable No 111 See FUL OUT INJRAT on page 167 and enter the cylinder size for the variable 112 See FUL OUT CYLSIZ on page 167 See Injector Size Base Pulse Constant on page 138 and Mapping Fuel on page 163 Vol 1 Chapter 5 Injection Modes and Injectors 79 Base Pulse Constant 80 Vol 1 Chapter 5 Injection Modes and Injectors Sensors Sensors O2 Sensor Positioning If installing an 02 sensor in a non standard application note the following e The o2 sensor should be located close to the exhaust port unless using an internally heated 4 wire sensor The closer the sensor is to the port the faster it heats up and the slower it cools down e It should be located in a region of continuous flow If reversion occurs
13. 57 Plot Screen 57 View menu 57 Dump Files 57 Diff Files teure soe ersten Beer aie rk amp 58 Other Files Sys See eee et eS 58 QuitMenu 58 Working Without a Mouse 58 Chapter A Vehicle Modifications and Kalmaker 61 Different Tyre Diameter 61 Vol 1 Chapter 5 Chapter 6 Chapter 7 Different Final Drive 62 Engine has been bored or stroked but nothing else has changed 62 Changes to intake cam or exhaust system 63 Different Engine 64 Transplanted engine no changes 65 02 Sensor Positioning 66 Knock Sensor oe 67 Vehicle Speed Sensor 67 Fuel Pump and Fuel Pressure 68 Adjusting the TPS Throttle Position Sensor 68 MAP pressure sensors 69 MAT CTS sensors 69 Kalmaker Switch oe 70 Injection Modes and Injectors 73 Synchronous and Asynchronous Injection 73 Synchronous Injection Modes 74 Single Channel Throttle Body Mode 74 Two Channel Throttle Body Mode 74 Simultaneous Double Fire single channel 74 Simultaneous Single Fire single channel 74 Alternating Single Fire double channel
14. Bosch 280150157 20 7 36 3 Bosch 280150215 20 7 36 3 Bosch 280150216 20 7 36 3 MP Bosch 280150706 20 7 36 3 MP Bosch 280150712 20 7 36 3 MP Bosch 280150744 20 7 43 5 MP Bosch 280150762 20 9 290 13 8 sky blue ND 20 9 290 13 8 beige ND 20 9 290 13 8 yellow ND 21 250 Bosch 0 280 150 157 21 250 Bosch 0 280 150 706 21 250 Bosch 0 280 150 712 21 300 Bosch 0 280 150 762 21 1 50 12 15 MP Rochest 17120254 I er 21 1 50 12 15 MP Rochest 17121068 er 21 1 50 12 15 MP Rochest 17124248 I er 21 4 300 Lucas 5207011 21 5 36 16 15 MP Bosch 280150223 Vol 1 215 Table 34 List Of Fuel Injectors 21 5 36 16 15 MP Bosch 280150239 21 8 39 2 14 5 MP Bosch 280150759 22 43 5 12 4 MP Rochest 5235357 I er 22 43 5 12 4 MP Rochest 5235366 I er 22 43 5 12 4 MP Rochest 5235451 I er 22 43 5 12 4 MP Rochest 17069647 I er 22 43 5 12 4 MP Rochest 17069648 I er 22 43 5 12 4 MP Rochest 17109952 er 22 43 5 12 4 MP Rochest 17109953 er 22 2 MP Bosch 280150152 22 5 Bosch 0 280 150152 22 8 43 5 Dark MP Bosch 280150201 Gray 23 2 4 Black MP Bosch 23 1 250 Lucas 5208004 23 1 250 Lucas 5208005 23 1 300 Bosch 0 280 150 201 23 5 Bosch 0 280 150 151 23 6 43 24 43 14 5 Light MP Bosch 280150728 Blue 24 43 5 MP 24 11 to 18 Light MP Blue
15. Chapter 8 KalMaker Street Pro 3 Variables 113 Variable Groups Table 25 Fuel FUL Variable List FUL CRK LPGTMC lpg fuel inject time not running cold 03 FUL CRK LPGTMW lpg fuel inject time not running warm 03 FUL CRK LPGTMR lpg fuel inject time running 03 97 FUL AFR AFTMUL timout airfuel decay multiplier 98 FUL AFR AFTDCY clt initial timout airfuel 99 FUL AFR AFTDLY elt timout airfuel interval FUL AFR STOICAF stoichiometric airfuel ratio FUL AFR IAFTIM closed loop fuel idle time drv 5D A5 B1 DB 100 FUL AFR IAFTMD closed loop fuel idle time drv FB 101 FUL AFR IAFTMP closed loop fuel idle time pkn FB 102 FUL AFR IAFCLT idle airfuel ratio clt threshold 103 FUL AFR IACAFR clt idle airfuel ratio FUL AFR RUNCLT cold warm airfuel clt threshold 104 FUL AFR CLTAFR map clt cold run airfuel ratio 105 FUL AFR RUNAFR map rp warm run airfuel ratio m 111 FUL OUT INJRAT this injector rate multiplied by cylinder size gives base pulse constant 112 FUL OUT CYLSIZ see above FUL OUT EGRCRN vac rp egr base pulse correction m 124 FUL OUT VE map rpm volumetric efficiency 121 FUL OUT VEQ idle ve filter constant 122 FUL OUT VEQRPM idle ve filter rom 120 FUL OUT SAGRPM idle sag multiplier rom deadband 118 FUL OUT SAGFAC idle sag bpw factor 119 FUL OUT SAGFMX idle sag max bpw multiplier 114 Vol 1 Chapter 8 KalMaker Stree
16. If View Other files is selected a list of diff files is generated from the KalMaker Output directory list Any text file can be viewed Quit Menu Exits the program confirm Yes No If you have made any changes you are prompted to save them Working Without a Mouse All mouse operations can be emulated from the keyboard These require that either the left or right SHIFT key be held down throughout and the particular shift key indicates whether the mouse event employs the left button or right button The following shifted keys are interpreted as indicated Note that the cursor keys do not need mouse button qualification so for these keys the particular shift key held down determines the movement delta This is 8 pixels for the left shift key and 1 pixel for the right shift key Table 15 Left Shift Held Down KEY INTERPRETATION Up Cursor Move mouse cursor position up 8 pixels Down Cursor Move mouse cursor position down 8 pixels Left Cursor Move mouse cursor position left 8 pixels Right Cursor Move mouse cursor position right 8 pixels Page Down Left Button Press Page Up Left Button Release ENTER Left Button Press and immediate release Vol 1 Chapter 3 Kalmaker Editor Menu Commands Working Without a Mouse Table 16 Right Shift Held Down KEY INTERPRETATION Up Cursor Move mouse cursor position up 1 pixel Down Cursor Move mouse cursor position down 1 pixel
17. If the data list displays frames at around 10 per second then communication with the ECM is OK Link Cable The cable normally connects to the PC parallel port through the dongle However the cable can fail through a bad connection or if it is disconnected while KalMaker is displaying data Cables are checked before dispatch so they can be assumed to be good Check the following e PC parallel port DB25 connector is physically OK These can wear out with only moderate use e Ifthe cable terminator is soldered to ECM board make sure it is connected to the right terminal e If cable terminator is connected through the ECM plug likewise make sure the right terminal is used ECM In order for KalMaker to communicate with the ECM the ECM CPU must be operating If the CPU is not operating and backup resistors are installed the vehicle will start and run with backup fuel and spark the fan will also switch on where connected The ignition must be on AND an RT102 or Memcal installed for the ECM to link To check the ECM is operating properly start and run engine If the fan is on and check engine light remains on then ECM is most likely in backup Note Ifa Street Pro program is run without a security device then similar symptoms will occur The difference is that the ECM program will be running and KalMaker can link If the above check is indeterminate place ECM in diagnostic mode ground diagnostic terminal The check e
18. Left Cursor Move mouse cursor position left 1 pixel Right Cursor Move mouse cursor position right 1 pixel Page Down Right Button Press Page Up Right Button Release ENTER Right Button Press and immediate release Vol 1 Chapter 3 Kalmaker Editor Menu Commands 59 Working Without a Mouse 60 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Vehicle Modifications and Kalmaker 61 Chapter 4 Vehicle Modifications and Kalmaker KALMAKER CEE EEE EEN Garner tor Dern Where Kalmaker excels is in the area of engine vehicle modification High performance cars cannot be tamed by the factory calibrations unless you are satisfied with what comes off the factory floor Hot Rods Street Machines Customs and competition cars do not fall into this category so after the car and the engine has been modified the engine management system must follow The following areas are described in detail e Different Tyre Diameter Different Final Drive e Engine has been bored or stroked but nothing else has changed e Changes to intake cam or exhaust system e Different Engine e Transplanted engine no changes Different Tyre Diameter The different tyre diameter alters the number of pulses the ECM reads per kilometer via the Vehicle Speed Sensor A larger diameter tyre will go around fewer times per kilometer consequently the speed sensor constant should be decreased From the factory calibration du
19. Manual Gear Determination Variables e VAR KPH Roadspeed Variables 37 39 e VAR TRP Trip Computer Variables 40 Table 23 Internal VAR Variables List 30 VAR RPM IACHIQ idle rpm filter coefficient overspeed 29 VAR RPM IACLOQ idle rpm filter coefficient underspeed 31 VAR CLT CLTQ clt filter coefficient 32 VAR CAT CATFAC ma charge air temp coefficients p rpm 33 VAR CAT INVCAT cat inverse charge air 28 VAR TPS OFSQ tps offset filter constant 27 VAR TPS GAIN tps gain 26 VAR TPS TPSCT closed throttle tps VAR TPS EGRTIM egr enable throttle open time VAR MAP MAPQ map filter coefficient 25 VAR BAP PDF tps rpm baro throttle blade pressure drop factor 24 VAR BAP PDX maximum baro pressure drop 23 VAR BAP DEFBAP default baro pressure 35 VAR O2S LOVOLTS 02 ready lo volts FB 34 VAR O2S HIVOLTS 02 ready hi volts FB 36 VAR O2S RDYTIM 02 ready timer FB VAR NVR GxRAT gearx select nvratio VAR NVR GxERR gearx select rpm tolerance 108 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups Table 23 Internal VAR Variables List 38 VAR KPH KPHQ roadspeed filter constant 37 VAR KPH PPK vss pulses per kilometer 39 VAR KPH IDLKPH idle mode kph 40 VAR TRP LPHFAC trip computer duty cycle fuel VAR TRP LPKFAC oe computer p100k constant A5 B1 DB Spark Variables The Spark SPK groups describe ignition timing calculations of advances and retards used in EST and ESC There are ten
20. Mapping VE 174 How To Use VE Update 175 Comparing and Storing VE Update Calculations 175 Setting Closed Loop VE Table Manually 176 Tuning Open Loop VE Tables Manually 178 Tuning A F ratios for Economy 178 Turning On Lean Cruise Mode 179 Tuning A F ratios for Power 179 KalMaker Error Messages Descriptions 181 Menu System Errors Mn Sys Err 181 KalMaker Application Errors 181 Troubleshooting 197 Data Conversion Anomalies 197 Vol 1 Chapter 16 Chapter 17 KalMaker Link Trouble Shooting 198 PC or Laptop 198 KalMaker Program 198 Link Cable fern a he tee Se Se ee See E 199 ECM ege Ste eet en re ae 199 Parallel Port or Serial Port 201 Using the Diagnostic Functions 201 Common Engine Problems 202 Misfiring 202 Pinging 202 Excessive Fast Idle when Warm 202 Trouble Codes 205 ALDL Modes 205 Diagnostic Mode 206 Trouble Code Listing 207 Glossary 223 Vol 1 Introduction 9 Chapter 1 Introduction KALMAKER foe eee u na Garner tor Den This User Guide describes the installation
21. Some suggestions have been made to the possible cause and remedy of the Trouble Code The individual service manuals provide extensive detailed diagnostic procedures for further troubleshooting the problem areas indicated by the following codes These are only a general guide and are not intended as a trouble shooting tool Table 32 Trouble codes listed numerically Code Explanation 12 Indicates the ECM is ON and is not receiving any reference pulses from the distributor This is a normal code with the ignition ON and the engine not running and is used for verification of ECM operation during the Diagnostic Circuit Check Code 12 is not stored in the ECMs memory and will only flash when ALDL terminal B is jumpered to ground ALDL terminal A with the ignition ON and the engine not running Additional trouble codes stored in the ECM will appear after this code has flashed three times 13 Oxygen sensor output remained at 35 55 volts for more than one minute after warmup Possible open circuit or a possible defective oxygen sensor unit A sticky or misadjusted Throttle Position Sensor will also cause this Trouble Code 14 Coolant sensor indicated a temperature above 130C for 3 seconds after engine ran for 20 seconds Probably an overheating problem which must be rectified before continuing A defective coolant temperature sensor or a short to ground in the CTS circuit may also be a cause Check wiring and connections first 15 Coola
22. dcl sec An error has occurred while allocating memory required for processing the security file E1008 Can t allocate output buffer for sup port dcl sec An error has occurred while allocating memory required for processing the security file E1009 Decompression failure for support dcl sec An error occurred while decompressing the security file E1010 support dcl sec is corrupted The decompressed security file information is not internally consistent E1011 Can t load Security Script Support dcl sec A general error has occurred while opening and processing the security file E1100 Can t locate font file s The named font files are not on the support path the program executable path nor the 182 Vol 1 KalMaker Application Errors current path They must be on one of these paths in order to be loaded E1101 Restart to effect changes This is not an error but is included for completeness The capture buffer is allocated on startup to reduce memory fragmentation If it is changed the program must be restarted for the change to be effected E1102 Can t open support cfg for writing A file open error has occured while trying to open the configuration file E1103 Can t write to support cfg A file write error has occured while writing to the configuration file E1104 Serial Link disabled The serial link has been disabled because no parallel port has been selected in the config
23. the throttle blade is open too far throttle stop screw turned in the IAC even if fully closed won t be able to slow the idle speed down Note If your throttle body makes a lot of hissing sucking noises at idle it s probably because Vol 1 Chapter 12 Getting Idle Right 151 Getting in the Ballpark there s too small an air gap for air bypassing the IAC In other words the throttle blade is closed too far You need to adjust the throttle stop screw in so that it opens the blade a little more which will allow the IAC to close a slightly but only enough to quieten it down Observe the IAC gauge on the Gauges Screen If the idle steps are zero close the throttle blades by backing off the idle stop screw If the idle steps are high greater than 20 open the throttle blades by screwing the throttle stop screw in Adjust the screw to achieve approx 20 steps at idle Once this has been achieved fine tune the steps for a good strong idle Getting in the Ballpark The following procedure is recommended for those occasions when you are having trouble determining how far out the fuel map is at idle 1 2 3 ONO Scroll to 103 FUL AFR IACAFR Make sure you have the RTIME button selected Select TRACK This will highlight the Engine Temperature bar Rais ing or lowering this highlighted bar will immediately effect engine idle speed Use the up or down arrow to raise lower engine speed until you ac
24. 0 62 volts 4 Tighten screws then recheck reading to ensure adjustment has not changed Note Ifthe TPS was removed for any reason it should be adjusted BEFORE starting the engine for the first time and will then have to be READJUSTED AFTER the Minimum Idle Speed adjustment is made MAP pressure sensors There are three MAP sensors from GM vehicles that can be used e 7 bar Good for Naturally Aspirated engines they measure from 0 vacuum to approximately atmospheric pressure e 2bar Good for 15 PSI of boost e 3 bar Good for 30 psi of boost and a barometric pressure sensor For more info on Supercharger Turbocharger Calibrations See Supercharge Turbocharger Calibration Editor Chap 1 Vol 3 page 1 They all share a common pinout although the connector keying may be different e Pin A Ground e Pin B Sensor output e Pin C 5 volts MAT CTS sensors Manifold Air Temperature MAT sometimes called Inlet Air Temperature IAT and Coolant Temperature Sensors CTS provide a variable resistance according to temperature Table 17 MAT CTS Resistance Temperature C Temperature F IAT resistance CTS resistance 100 210 185 K 90 194 241 80 176 332 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker 69 Kalmaker Switch Table 17 MAT CTS Resistance 70 158 450 467 60 140 667 50 122 973 40 104 1800 1 459 30 86 2 238 20 68 3400 3 520 10 50 5 670 0 32 7500 9 420 10 14 13 500 1
25. 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups Table 25 Fuel FUL Variable List 137 FUL TDE DELTPS tpsde delta tps threshold 138 FUL TDE TPSFACG tpsde pulse term 139 FUL TDE TPSDEC tpsde decay factor 143 FUL TDE CLTFAC clt tpsde clt multiplier 140 FUL TDE DELMAP mapde delta tramap threshold 141 FUL TDE MAPFAC map mapde pulse term 142 FUL TDE MAPDEC clt mapde decay factor 144 FUL DFC LOCLT dfco enable clt 145 FUL DFC HIRPM dfco enable hi rpm 146 FUL DFC LORPM dfco enable lo rpm FUL DFC MAPTH dfco enable map 5D 148 FUL DFC MAPTHA dfco enable map auto trans A5 B1 DB FB 149 FUL DFC MAPTHM dfco enable map man trans A5 B1 DB FB 150 FUL DFC LOKPH dfco enable kph 147 FUL DFC LOTPS dfco enable tps 151 FUL DFC BPWSF dfco base pulse width multiplier 152 FUL DFC BPWMUL dfco exit async multiplier Idle Air Control Variables The Idle Air Control IAC groups describe idle initialisation transient idle and idle control There are seven sub groups e IAC RST IAC Reset e IAC DMP Desired Motor Position e IAC DES Desired Engine Speed e TAC CTL Idle Control e TAC WUP Warmup Base Term e TIAC TRA Transient Idle Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 117 Variable Groups e TAC SAG Idle RPM Sag Table 26 Idle Air Control
26. 111 FUL OUT INJRAT this injector rate multiplied by cylinder size gives base pulse constant 112 FUL OUT CYLSIZ see above See Injection Modes and Injectors on page 73 123 FUL OUT VECT closed throttle VE fuel map Ignores MAP sensor VECT must be selected to enable Vol 1 Chapter 13 Calibrating 167 Diagnostics Table 30 Most Used Variables continued 124 FUL OUT VE This is the Main Fuel Map and is the most used map See How To Use VE Update on page 175 177 FUL CUT LORPMA is the rpm that the rev limit cuts back in usually 50 to 100rpm lower than cut out 178 FUL CUT HIRPMA is the actual rpm that the rev limit cuts fuel 215 TAC DES RPMDR is desired idle speed in Drive if auto See b 10 on page 87 216 TAC DES RPMPN is desired idle speed in Park or Neutral if auto 217 TAC DES RPMMT is desired idle speed if Manual Trans 233 TAC TRA BYTSTP adds steps to idle air control when decelerating to prevent stalling at idle 234 TAC TRA BYMMAP lift these if using bigger cams to enable bypass steps above 260 DTC MSK EOPT1 Use these 3 masks to flag trouble codes eg M43 knock sensor M24 speed sensor 261 DTC MSK EOPT2 262 DTC MSK EOPT3 These are the most common Variables used and is all that is needed to tune even quite wild engines Diagnostics Most diagnostic variables don t need to be altered The dia
27. 18 3 43 5 Bosch 280150614 18 3 43 5 MP Bosch 280150702 18 4 250 Lucas 5204001 18 4 250 Lucas 5206002 18 4 250 Lucas 5207002 18 4 250 Lucas 5208001 18 4 250 Lucas 5208003 18 4 250 Lucas 5208007 18 4 Bosch 0 280 150 125 18 5 300 Bosch 0 280 150 614 18 8 39 2 MP Bosch 280150203 18 8 43 5 15 MP Bosch 280150901 18 9 47 9 MP Bosch 280150775 19 32 16 2 Yellow MP Bosch 280150718 Orange Voll 213 Table 34 List Of Fuel Injectors 19 40 2 25 White MP Bosch 19 33 16 2 Yellow MP Bosch Orange 19 33 14 5 Yellow MP Bosch Orange DDK 19 11t0 18 Yellow MP Orange 19 3 36 3 MP Bosch 280150734 19 6 290 1 7 dark ND grey 19 6 290 1 7 beige ND 19 6 290 1 7 orange ND 19 6 290 1 7 brown ND 19 6 290 2 7 pink ND 19 6 290 13 8 dark ND blue 19 6 290 13 8 orange ND blue 19 6 290 13 8 brown ND 19 6 290 13 8 red ND 19 7 270 Lucas 5207013 20 2 50 12 15 MP Rochest 17087325 I er 20 2 50 12 15 MP Rochest 17121947 er 20 6 255 2 4 blue ND 20 7 MP Rochest 5235301 I er 20 7 MP Rochest 5235302 I er 20 7 MP Rochest 5235434 er 214 Vol 1 Table 34 List Of Fuel Injectors 20 7 MP Rochest 5235435 I er 20 7 MP Rochest 5235436 er 20 7 MP Rochest 5235437 er 20 7 36 3 MP
28. 280 150 024 37 3 300 Bosch 0 280 150 026 37 3 300 Bosch 0 280 150 036 37 3 300 Bosch 0 280 150 043 37 6 300 Bosch 0 280 150 814 37 7 39 2 HIZ Green MP Bosch 280150803 38 3 43 5 MP Bosch 280150834 Methano 38 3 43 5 MP Bosch 280150835 38 6 MP Bosch 280150045 38 9 300 Bosch 0 280 150 834 220 Vol 1 Table 34 List Of Fuel Injectors 38 9 300 Bosch 0 280 150 835 41 9 MP Bosch 280410144 42 2 255 2 9 black ND 42 5 300 Bosch R 280 410 144 42 6 36 3 CFI Bosch 280150608 42 8 300 Bosch 0 280 150 400 42 8 300 Bosch 0 280 150 401 46 1 33 2 00 Blue CFI Bosch 280150400 2 40 DDK 46 3 36 3 2 5 MP Bosch 280150036 46 3 43 5 2 5 MP Bosch 280150041 47 1 300 Bosch 0 280 150 041 49 3 300 0 5 blue Bosch 0 280 150 403 52 4 32 2 25 Gray CFI Bosch 54 1 39 2 HI Z Black MP Bosch 280150351 55 6 16 1 4 Blue CFI Bosch 280150054 56 57 9 36 3 MP Bosch 280410153 63 5 16 1 4 Green CFI Bosch 280150056 72 2 MP Rochest 17104988 I er 77 2 72 5 MP Bosch 280410153 77 2 36 3 MP Bosch 280412911 80 MP Bosch 280411911 82 45 Low Z Red Bendix 25500139 Vol 1 221 Table 34 List Of Fuel Injectors 108 72 5 MP Bosch 280412911 1 180 45 Low Z White Bendix Methano 222 Vol 1 Gl
29. 56 volts The ideal TPS voltage at zero throttle is approximately 0 5 volts but it is not critical provided that is is within the range that is allowed You can alter these thresholds slightly to suit a TPS that is out of range but it is not recommended Instead it is better to change it mechanically Vol 1 Chapter 11 Pre Calibration Settings 141 Custom Calibration First Steps When using standard GM throttle bodies you shouldn t have this problem To check your TPS voltage at closed throttle proceed as follows 1 Goto List View Diagnostics 2 Check the reading against TPSSIG FIGURE 20 TPSSIG Voltage in Diagnostics 3 Ifthe TPSSIG reading exceeds the value in 280 ETC M22 TPSTH adjust the mounting position of either the body of the TPS or the activating blade that is attached to the throttle shaft 4 Check that the TPSSIG voltage falls below the threshold 142 Vol 1 Chapter 11 Pre Calibration Settings Custom Calibration First Steps 5 If it is not possible to adjust the TPS to the factory value click Buffer 1 Edit and scroll to 280 ETC M22 TPSTH 6 Enter a value that is slightly higher than the TPSSIG voltage Once this has been set the ECM will quickly learn the new zero throttle position To set the Fuel mixtures at idle Set Idle Speed on page 145 Vol 1 Chapter 11 Pre Calibration Settings 143 Custom Calibration First Steps 144 Vol 1 Chapter 11 Pre Calib
30. Chapter 16 Trouble Codes 205 ALDL Modes between pins A and B of the ALDL connector This mode is used when sensor information is lost or corrupted Note Grounding the Diagnostic terminal with the engine running puts the ECM into the Field Service Mode In the Field Service Mode the Check Engine Service Engine Soon light will show whether the system is in open or closed loop In open loop the Check Engine Service Engine Soon light flashes 2 5 times per second in closed loop it flashes once per second Data is output at pin A 5 of the ECM pin E on the ALDL connector In Diagnostic Mode the data is a 12Volt switching signal that flashes the Check Engine Lamp CEL also called the Service Engine Soon SES lamp In the Vehicle Service Mode the data stream is at 160 bits per second or BPS also called baud and the check engine light flickers dimly in this mode While very expensive scan tools are available to read the data stream from the ALDL connector it is very easy to create your own ALDL interface This interface allows the vehicle s ALDL data stream to be displayed in real time on a PC using simple software available on the internet See http www techedge com au and http www makinterface de for a starting point Note Weare only concerned with the operation in Normal Mode and Dlagnostic Mode Diagnostic Mode In the diagnostic mode the ECM will display a code 12 by flashing the Check Engine Service Engine Soo
31. E1912 Incompatible Clip xxx xxx xxxxxx The clip variable differs with the current script variable in either the translation equation number of bytes number of columns or number of rows therefore they cannot be interchanged E1913 Xxx xxx Xxxxxx not found The indicated clip variable name is not in the current script 194 Vol 1 KalMaker Application Errors E1914 Incompatible Row Size xxx xxx xxxxxx The 3D clip variable has a different row size from that of the current script variable therefore they cannot be interchanged E1915 Incompatible Col Size xxx xxx xxxxxx The 3D clip variable has a different column size from that of the current script variable therefore they cannot be interchanged E2000 Serial Update disabled If AutoLoad has been selected the modified variable is automatically transmitted to the ECM or PCM whenever a Save is selected If a link error has occurred or if no parallel port has been selected then the update cannot occur and this message is displayed E2001 Bad keypad value A non hex or non decimal keypad value has been entered E2002 Key Pad Conversion Error An error occurred while converting from the keypad value to computer units E2003 Serial Link failure A serial message has been sent to the ECM or PCM and the return message has either not been received or is incorrect E2004 No write access for this variable There is no write access for the indicated variable in t
32. Fuel FUL Variable List 169 FUL IVU LOCLT ve update lo clt 170 FUL IVU HICLT ve update hi clt 171 FUL IVU RPMWIN ve update rpm axis window 172 FUL IVU MAPWIN ve update map axis window 175 FUL IVU INTWIN ve update integrator limit 173 FUL IVU VEMIN ve min updated value 176 FUL IVU UPDTIM ve cell update time 182 FUL CCO LOCRANK crank fuel cutoff crank voltage 183 FUL CCO HIRPM crank fuel cutoff rpm 184 FUL CCO HICLT crank fuel cutoff clt 177 FUL CUT LORPM fuel cutoff lo rom 178 FUL CUT HIRPM fuel cutoff hi rom FUL CUT LOKPH fuel cutoff lo kph FUL CUT HIKPH fuel cutoff hi kph 181 FUL CUT CUTTIM fuel cutoff duration 129 FUL TRA MAPFAG tramap factor FUL TRA POSQ increasing tramap filter coefficient FUL TRA NEGQ decreasing tramap filter coefficient 130 FUL TAE DELTPS tpsae delta tps threshold 131 FUL TAE IACPW tpsae iac contribution FUL TAE TPSFAC tpsae pulse term 5D A5 B1 DB 132 FUL TAE TPSFAC rpm tpsae pulse term FB 136 FUL TAE CLTFAC clt tpsae cht multiplier 133 FUL TAE DELMAP mapae delta tramap threshold 5D B1 DB FB FUL TAE DELMAPC mapae delta tramap threshold A5 134 FUL TAE MAPFAC mapae pulse term 135 FUL TAE MAPDEC clt mapae decay factor 116 Vol
33. IAC Variable List IAC RST RPM startup base reset rpm IAC RST RBPW iac base reset limit wup 5D A5 B1 DB IAC RST RBPD iac base reset limit drv FB IAC RST RBPP iac base reset limit okn FB IAC RST RACD iac base reset limit acc delta FB IAC RST BASPOS iac base reset position IAC RST BASACD iac base reset position acc delta IAC RST DWYDEL iac base drive away term IAC DMP DPXDLY drv pkn transition base select delay IAC DMP PRKSTPC stepper park and reset position IAC DMP PRKSTPW stepper reset position hot IAC DMP PRKCLT reset clt threshold IAC DMP CLPSTP despos closed loop airfuel delta IAC DMP FAN1STP despos fan1 enable delta IAC DMP FAN2STP despos fan2 enable delta A5 B1 DB FB IAC DMP MAXSTP max cmd stepper position FB IAC WUP INIDLY warmup step keyon decay period IAC WUP INIPOSIcIt warmup step term keyon value IAC WUP DECFAC warmup step decay multiplier IAC WUP RUNDLY clt warmup step decay period running IAC TRA FAN2STP fan2 transient steps FB IAC TRA FAN2DLY fan2 step decay delay FB IAC TRA FANDEC fan decay steps FB IAC TRA STUSTP keyon transient step value IAC TRA STUDLY keyon decay delay IAC TRA STUDEC keyon and fan decay steps 118 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups Table 26 Idle Ai
34. Located on the RT Board in the ECM Opening a Calibration from File When developing a new calibration you must start from a base calibration Choose a calibration that suits your application and number of cylinders See Calibration List Chap 16 Vol 2 page 115 most GM Holden calibrations are included in the Kalmaker software Open your Calibration in Buffer 1 Once the KalMaker software is installed on your PC or laptop and a Real Time or modified ECM is installed in the vehicle it is then possible to program the Delco in Real Time by altering variables To find the Variable List you must first load a Calibration into Kalmaker and link the PC Laptop to the ECM It is asumed that their is sufficient fuel pressure all instruments are working the distributor is locked and statically timed To open a Calibration proceed as follows 1 Plug the dongle into the PC and connect the Cable to the ECM 2 Run KalMaker on the PC Vol 1 Chapter 10 Opening Loading and Saving a Calibration 131 Opening a Calibration from File 3 Turn the ignition in the vehicle to ON 4 Goto the Pull down menu BUFFER 1 FIGURE 18 Buffer 1 5 Select Read 6 Choose one of the included factory calibrations that most closely matches the application you are working on See Calibration List Chap 16 Vol 2 page 115 This will make a good starting point as opposed to starting from scratch IMPORTANT DO NOT attempt to load ca
35. Once the View option has been selected the mouse cursor is hidden to improve performance Pressing the SpaceBar or Escape key exits the display and enables the mouse cursor The View option discards the data once it has been displayed List Capture The Capture facility is similar in all respects to the View option above the only difference being in the destination of the displayed data Data displayed to the screen using List Capture is written to a Capture buffer which is allocated when KalMaker starts up The user can specify the size of this buffer it can capture several hours of data if there is memory available The data is displayed at approximately 10 frames per second and can fill a small Capture buffer quickly The user can exit Capture by pressing the SpaceBar or Escape key as in View List Capture is automatically exited whenever the Capture buffer is full Once the data is in the Capture buffer the user may select List Play to play the data back or may save desired frames of the Capture buffer to a file which may be played back later Data from successive Captures overwrites data held in the Capture buffer from a previous capture The user is prompted to save the Capture buffer before a List Capture However a List View will not modify the Capture buffer Vol 1 Chapter 3 Kalmaker Editor Menu Commands 47 Menu Functions List Play The Play facility displays the contents of the Capture buffer on the screen The
36. Port then changes are automatically transmitted to the ECM whenever changes are Saved to the Global Buffer If the variable is a 3D variable for example all values in that variable are transmitted to the ECM Edit Clip The Clip facility provides a means for transferring one or more variables from one calibration to another The variables can be saved from the Clip Buffer to a file and loaded from a file to the Clip Buffer The Clip Buffer is a temporary storage area where the variable value name rows columns dimension and conversion information called a variable structure are stored In order for a Clip variable to be copied from Clip to a Local or Global Buffer the variable structure must be compatible Note that if say 3D variable row and column sizes have changed from one calibration to another they are incompatible The Clip is normally used to transfer a group of variables from one calibration to another They may be a commonly used list of related variables such as the changes made when injectors or manifolds are changed Important The Clip buffer is intended for the transfer of small groups of variables Although it is quite large it will not hold a complete calibration The Buffer Xlate option is 28 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions used for a complete transfer of variables from one calibration to another Edit Clip Add Clip item The Clip Add command copies the cur
37. Save option the Local Buffer is written to the Global Buffer and also to the Undo Buffer e On exit the Local Buffer is compared with the Undo buffer If they differ the user is prompted to Save the Local Buffer to the Global Buffer Whenever the Edit screen is exited KalMaker compares the value of the variable on exit with the copy which has been saved on entry If they differ the user is prompted to Save the changes In the case of 1D 2D and 3D variables changes to the Local Buffer may be made in one of two ways e By indicator The indicator reflects the current value of Local Buffer If the mouse cursor falls within the indicator area and a mouse button is pressed the indicator will update the position of the mouse cursor This method may be too coarse for some variables By keypad To use the keypad first press a mouse button on the indicator you wish to change 2D and 3D only The keypad changes the highlighted indicator The indicator will change to reflect the position of the mouse cursor Keying in the desired value on the keypad and pressing keypad Enter will update the indicator Values greater than the maximum Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions for the variable are truncated to the maximum likewise minimum values FIGURE 6 Buffer Edit Note that sometimes an indicator won t extend to the maximum value displayed on an axis as the variable maximum is not necessarily t
38. TURBO SUPERCHARGED e Change the VE table If you don t have an engine or chassis dyno skip this step You can get an idea of the accuracy of the VE by looking at the block learn values See Comparing and Storing VE Update Calculations on page 175 Changes to intake cam or exhaust system Changes to the intake or exhaust system alter the volumetric efficiency and spark requirements of the engine If you have a calibration from an existing similar setup most of your work has been done for you Otherwise the procedure is going to have to be repeated several times due to the interaction between fuel and spark The first thing to get right is the spark It is best to do a little homework in this area So you have an idea of spark sensitivity Alter the existing spark values according to your estimation if you don t know ASK an experienced engine tuner or according to similar calibrations Take out more than is required if you are not 100 sure to avoid the engine running advanced and lean The sensitive spark area is around maximum torque and most effort should be directed here If the inlet system has changed radically the charge air table See VAR CAT CATFAC map rpm on page 108 ideally should be altered If you don t have a copy of a calibration from something similar the best thing to do is to leave it alone In order to calibrate this table you will need an engine Vol 1 Chapter 4 Vehicle Modifications and Kalmaker
39. To link to the ECM continue as follows 1 Goto Buffer 1 Link and select ECM lt PC 2 A progress bar is displayed indicating the progress of the linking operation If you get a message that says Link Identification Fail ure or Link Update Disabled you have not success fully linked to the ECM In this case refer to KalMaker Link Trouble Shooting on page 198 Custom Calibration First Steps You are now ready to edit variables in real time Assuming that you have successfully linked continue as follows 1 Select Buffer 1 Edit The Cal Variables List is displayed Note All Variables that end in A or B refer to Kalmaker Twin Tables Table A is default Table B will not work without Kalmaker Switch See Kalmaker Switch on page 70 Vol 1 Chapter 11 Pre Calibration Settings 137 Custom Calibration First Steps There are 413 Variables in Street Pro 3 See Kal Maker Street Pro 3 Variables on page 103 and they are separated into groups See Variable Groups on page 105 The following variables must be set up before you can start the engine and tune the calibra tion e Injector Size e Distributor Reference Angle e Knock Sensor e Vehicle Speed Sensor Note Almost all variables are edited in a similar manner Injector Size Base Pulse Constant 2 Scroll down your variable list to No 111 FUL OUT INJRAT and 112 FUL OUT CYLSIZ Note Ifyou are using injectors and the Base Pulse Constant is unknown sett
40. Undo The Undo copies the default transformation matrix saved on entry or since the last save to the top of the matrix stack This effectively restores the object to its previous orientation before last save Edit3 3D Export The Export option prompts the user for an output file name and dumps the current screen to the output file in pcx format This is a common bitmap format for which there are a number of editing programs Write The Write option enables the global buffer associated with either Buffer1 or Buffer2 to be saved to disk See Figure 3 KalMaker Buffer Operation When this option is selected the user is prompted depending upon the calibration size to save the calibration binary ina format to suit different EPROM s The files edited by KalMaker at present are one of three sizes The EPROM size does not necessarily have to be the same as the calibration size 40 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions Once the save size has been determined a file list of the directories listed in the Environment Output field is displayed in order together with the selection TYPE IT This enables the user to specify a save directory which is not part of the current configuration It defaults to the current directory The user is further prompted for an output filename once the output directory has been selected Once a valid file name has been entered it is opened and the contents of the global buffer
41. a certain rev range usually from approx 1800 to 2400 rpm at approximately 50 to 70 kpa MAP 178 Vol 1 Chapter 14 The Volumetric Efficiency Table Setting Closed Loop VE Table Manually Warning Before selecting this feature make sure your VE s are 14 7 1 at these load points Turning On Lean Cruise Mode The amount of Air Fuel Ratio you change is at FUL LNC DELAFR Do some fairly long runs at these points in this map and select Track See Edit2 Track on page 32 Familiarise yourself with these loadpoints and feel how much the engine is working Turn on Lean Cruise Mode by selecting GEN OPT EOPTCA and press LEAN CRUISE If you can feel a difference it is too lean You can have up to 3 points of Lean Cruise at the lesser load points but back it off to about 1 5 to 2 as the load increases You shouldn t be able to feel any difference between on and off Tuning A F ratios for Power There is no established optimum A F ratio that makes the most power every engine is different To squeeze every ounce of power you need the resources of a dyno with an A F meter then adjust A F and ignition for maximum power A F ratios of about 12 5 1 to 12 8 1 are usually a good place to start If your VE data is correct at the higher MAP readings the A F ratios should be reasonably accurate at these points If A F isn t showing 14 7 1 fuel is calculated by the A F ratio displayed multiplied by the VE If the VE isn t right then t
42. a file Stored data Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions lists may also be loaded into capture memory and played back off line FIGURE 8 List Save The List facility can be viewed as a stand alone subsystem within KalMaker It relies on information contained in a ram script which is automatically loaded with a calibration script The ram script contains data names units and conversion information List Load The Load option enables a ram script to be loaded manually The script may be loaded without any calibrations being present This allows KalMaker to be used to view and capture data lists transmitted by a standard ECM In order that the correct script is loaded the user should be aware of the program being used by the calibration in the ECM The way to determine this is as follows e Load Butter or Buffer2 with the calibration e Select Buffer Info e The calibration script name and a brief description of the program is displayed e The ram script has the same file name as the calibration script but a different extension List Default There are normally several data lists to choose from The data lists differ because they display different combinations of the same variables eg input and output functions They can also display say engine and transmission variables separately The List Default option enables one of these data lists to be used as the default Edit data list The B
43. are independently adjustable Edit3 Fwd The Fwd option selects the next 2D row of variables in increasing order of the current axis If the maximum axis value is reached the axis wraps to its minimum value Edit3 Bwd The Bwd option selects the next 2D row of variables in decreasing order of the current axis If the minimum axis value is reached the axis wraps to its maximum value Edit3 Xaxis A 3D variable may be viewed along the X axis as a series of 2D Y Z plots or along the Y axis as a series of 2D X Z plots The Xaxis option selects the X axis Variables are displayed in 2D order along the Y axis and are stepped through along the X axis ie the X axis is made the current axis Edit3 Yaxis A 3D variable may be viewed along the X axis as a series of 2D Y Z plots or along the Y axis as a series of 2D X Z plots The Yaxis option selects the Y axis Variables are displayed in 2D order along the X axis and are stepped through along the Y axis ie the Y axis is made the current axis Edit3 3D The 3D option is intended for display purposes only When selected a new screen appears and the 3D object is Vol 1 Chapter 3 Kalmaker Editor Menu Commands 37 Menu Functions drawn on the screen The object shown is the current edit buffer so any editing changes are reflected in the 3D object FIGURE 7 Edit 3D The orientation of each 3D object is described completely by a 4x4 matrix called the transformation matrix
44. are actually bit changes so the screen consists of eight independent buttons corresponding to options or masks If a button is pressed down the option corresponding to that button is set If a button is up the corresponding option is not set A OD variable name is of the form GRP SUB NAMEI There is no advantage to changing an EditO variable in real time so changes are transmitted to the ECM with the Edit Load Option Note The following numbers for example Edit1 Edit2 refer to 1D 2D or 3D maps but are not displayed as such For example Edit3 Track1 indicates that the tracking function is enabled on a 3D variable such as FUL OUT VE See Variable Types on page 103 Edit1 The Editi screen consists of a single indicator which shows the value of the Local Buffer together with a keypad Edit1 variables consist of single or double bytes A 1D variable name is of the form GRP SUB NAME Edit1 RTLink The RTLink option transmits the value of the indicator to the ECM as it is being changed either by keypad or indicator For the RTLink option to function the calibration must support RealTime updates and the Data Link must be enabled Edit2 The Edit2 screen consists of a row of indicators which show the values of the Local Buffer together with a keypad Edit2 variables consist of an array of single bytes There is also Vol 1 Chapter 3 Kalmaker Editor Menu Commands 31 Menu Functions an area which displays the va
45. complete for Disk 1 you WILL NOT be prompted to insert Disk 2 however you MUST install Disk 2 as this contains the scripts Failure to do this will render KalMaker inoperable Never install Disk 2 prior to Disk 1 KalMaker will not work 1 Insert KalMaker Disk 2 2 Type A INSTALL at the prompt Again it is recommended to let KalMaker install the components in their default locations 3 Press ENTER when KalMaker asks you any questions regarding the default directories for the components recommended Once the process is complete you will be able to run KalMaker At this time plug the dongle in the parallel port and 14 Vol 1 Chapter 2 KalMaker Installation Software Dongle test KalMaker to make sure that installation has been performed correctly and KalMaker is functional Software Dongle Disk 1 is a generic disk that is the SAME for all KalMaker programs Disk 2 is a unique disk that is tied to your particular dongle When you buy KalMaker the distributor keeps records of what unique dongle you have so that upgrades in the future or additional copies are tied to your dongle saving you the inconvenience of having to use another dongle every time you want a new program update Installation Problems The mechanics of the configuration file creation are as follows e The Disk1 installation procedure writes the file KCFG EXE to the KAL3 sub directory e Atthe finish of the Disk2 i
46. data in the Capture buffer can come from two sources e It may have been written directly to the Capture buffer by a List Capture e It may have been read into the buffer from a saved capture file using List Read The Play option enables the data to be displayed on the screen at a user selectable rate List Read The Read option reads a previously saved capture file and loads it into the Capture buffer The ram script associated with the capture file is also automatically loaded The List Read option does not require any calibrations to be loaded nor does KalMaker have to be linked to an ECM Once the capture data has been loaded into the Capture buffer it can be played back or saved again to disk List Save The Save option enables the user to write data from the capture buffer to a disk file The user can select the start and end frames to be saved and can also store a brief description Information about the program used by the ECM which generated the data is also stored This program information is then used when the file is loaded by a List Read to find the appropriate ram script There are no limitations on file names or extensions The capture file can be identified as such by KalMaker by its header The List option is available for all calibrations which use aram script It enables a data list to be specified by the user and viewed as text The data list can be captured as it is displayed for playback or can be written to
47. doesn t need changing Commanded AF Ratio can be described as the Targetted A F ratio Commanded A F ratio is used with BPC and VE to arrive at the actual A F ratio These 3 factors multiplied together determine the final Base Pulse Width Change any of these 3 factors and the BPW changes Once the Injector size is determined and the A F Ratio set only the VE remains to be adjusted The VE is constantly monitored and updated when in Closed Loop which is why stoich A F can be maintained in all kinds of driving conditions The Delco Engine Management System does this using the Integrator for short term adjustments and Block Learn for long term adjustments Integrator and Block Learn The Integrator and Block Learn work together to re tune the system to match any engine s charactersitics up to a practical limit Integrator The Short Term Fuel Trim STFT value is called the Integrator This is the value that maintains stoich 14 7 1 A Vol 1 Chapter 14 The Volumetric Efficiency Table 171 Integrator and Block Learn F in closed loop The value of the integrator varies above and below 100 128 for SP2 with 100 being no correction If the integrator the STFT reading exceeds 100 it means the ECM is adding fuel because the O2 sensor is reading a lean mixture If the STFT reading falls below 100 the ECM is removing fuel because the O2 sensor is reading a rich mixture Note In open loop the STFT will immediately ret
48. file 29 Edit Clip Write Clip file 29 Edit Clip cOpy all Clip 29 Edit Clip Undo all Clip 29 Edit Clip cLear All Clip 29 Edit Help 30 Edit Undo se 2 2 i een 30 Edit Save eee ee ee 30 Edit Next 31 Bot 22 2 lege evap esos ae cu Sus Ss 31 Edith et Sa e Sere ete ee Ee yt ee 31 B itl RTLnk 2 3 pos see ae ee re 3 chte Rer Ss een re ae 31 Edit RTk 228 2 ea nee 32 Edit2 Track HH een arten 32 Edit2 Margin 33 Edit 28 Sen ee a el eye ae Dene We er 34 Edit3 RTEink EE EE 34 Edit3 tracK 35 Edit3 Margin 36 Edit3 Fwd 37 Edit3 Bwd 37 Vol 1 Edit3 Xaxis 37 Edit3 Yaxis 22 GE a enee ee AED 37 EE 3D 2022732 oc ee ee ae a ee 37 Edit3 3D Ortho 39 Edit3 3D Translate 39 Edit3 3D Rotate 40 Edit3 3D Scale 40 Edit3 3D Config 40 Edit3 3D Saye se Se 2 2 Sie ee See eS 40 Edit3 3D Undo 40 Edit3 3D Export 40 Write yes beefs Ve SNe SNe Ses So selene Se ee 40 Registration 41 Info
49. file file An error occurred while opening the indicated dump file for writing When a dump to screen is selected the dump file is actually written to a temporary file in the tmp file directory displayed and then deleted E1703 Can t write dump file file An error occurred while writing to the indicated dump file When a dump to screen is selected the dump file is actually written to a temporary file in the tmp file directory displayed and then deleted The dump file can be several hundred kB in size so the tmp directory should be at least this size E1704 Can t open difference file file An error occurred while opening the indicated difference file for writing E1705 Can t write difference file file An error occurred while writing to the indicated difference file Vol 1 191 KalMaker Application Errors E1706 Can t open difference file file An error occurred while opening the indicated difference file for writing When a difference to screen is selected the difference file is actually written to a temporary file in the tmp file directory displayed and then deleted E1707 Can t write difference file file An error occurred while writing to the indicated difference file When a difference to screen is selected the difference file is actually written to a temporary file in the tmp file directory displayed and then deleted The difference file can be several hundred kB in size so the tmp dire
50. file The Engine All data list is played as the default Playback is also not yet available The Gauge viewing option is also presently only available from the main menu and not from an Edit screen The only displays available at present are gauges and lights 54 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions The Gauge facility can be viewed as a stand alone subsystem within KalMaker It relies on information contained in a gauge script which is automatically loaded with a calibration script The gauge script contains data names units and conversion information as well as gauge and light layouts Gauge Load The Load option enables a gauge script to be loaded manually The script may be loaded without any calibrations being present This allows KalMaker to be used to view data lists transmitted by a standard ECM In order that the correct script is loaded the user should be aware of the program being used by the calibration in the ECM The way to determine this is as follows e Load Buffer1 or Buffer2 with the calibration e Select Buffer Info e The calibration script name and a brief description of the program is displayed e The gauge script has the same file name as the calibration script but a different extension Gauge View The View option displays the default gauge data list as gauges and lights The actual information contained in the data list is calibration specific and is covered in the relev
51. fuel Note Not used in Kalmaker Simultaneous Double Fire single channel This mode is also called group batch or gang injection All injectors are fired in parallel once per crankshaft revolution twice per cycle This is the method most Delco systems use up to about 1995 when Sequential Injection was introduced Kalmaker Street Pro 3 and Workshop modules up to W30 use this mode Simultaneous Single Fire single channel When a system operating in double fire has a pulsewidth too small to deliver fuel reliably it can deliver it by doubling the pulsewidth every two revolutions hence twice as much fuel is injected half as often SSF is commonly used to deliver small pulsewidths 74 Vol 1 Chapter 5 Injection Modes and Injectors Synchronous Injection Modes Note This mode is used in Kalmaker and is used when using very large injectors at idle where large injectors are inclined to dribble It can be calibrated so that under a certain bpw it switches to Narrow Pulse Width See FUL OUT NPWH on page 115 and FUL OUT NPWL Alternating Single Fire double channel With ASF injection each group of injectors delivers fuel once per two revolutions It is also called semi sequential or banked injection Its advantage over SDF is that reduced fuel pressure fluctuations occur at idle as only half the injectors are open at one time Also if two O2 sensors are used the system can operate as two i
52. go much longer in duration than 230 degrees at 0 50 lift and keep lobe separation at least 110 degrees Idle Problems on Non GM Engines and Throttle Bodies A good idle can be difficult to achieve with tunnel rams stack injectors multiple throttle bodies and after market throttle bodies The most common problem is where the TPS not setup properly See Adjusting the TPS Throttle Position Sensor on page 68 and TPS Voltage on page 140 At Closed throttle you should have approx 0 5v At full throttle you must have approx 4v If you do not have these voltages set correctly you will never get a good idle The usual cause is the play in the shaft where it mates with the TPS It must have no play in it or the idle control will be erratic at best Even on a std V6 or V8 Commodore check to ensure that no one before you has fiddled with the shaft and forgotten to put the plastic sleeve back on the shaft The following procedures require the adjustment of many variables that normally don t require a change from the factory settings Before proceeding be aware of what your engine is telling you Keep your eye on your Gauges screen and List screen for tell tale signs 154 Vol 1 Chapter 12 Getting Idle Right Idle Problems on Non GM Engines and Throttle Bodies Trouble Codes and Default Maps For some applications particularly on non GM engines you may have a trouble code set and it is preventing you from setting up a
53. memory available The data is displayed at approximately 10 frames per second and can fill a small Capture buffer quickly The user can exit Capture by pressing the SpaceBar or Escape key as in View List Capture is automatically exited whenever the Capture buffer is full Once the data is in the Capture buffer the user may select List Play to play the data back or may save desired frames of the Capture buffer to a file which may be played back later Data from successive Captures overwrites data held in the Capture buffer from a previous capture The user is prompted to save the Capture buffer before a List Capture However a List View will not modify the Capture buffer List Play The Play facility displays the contents of the Capture buffer on the screen The data in the Capture buffer can come from two sources 50 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions e it may have been written directly to the Capture buffer by a List Capture e it may have been read into the buffer from a saved capture file using List Read The Play option enables the data to be displayed on the screen at a user selectable rate List Read The Read option reads a previously saved capture file and loads it into the Capture buffer The ram script associated with the capture file is also automatically loaded The List Read option does not require any calibrations to be loaded nor does KalMaker have to be linked to an ECM
54. much AFR decay on startup This is controlled in 98 FUL AFR AFTDCY clt and 99 FUL AFR AFTDLY Cranking Base Pulse Width You can also control the Base Pulse Width when cranking to start This procedure is NOT recommended and should only be used as a last resort The variables 92 FUL CRK BPWilclt and 93 FUL CRK BPW2 clt control BPW when cranking Add More Fuel at Start If you feel you need more fuel to start increase your AFTDCY 98 FUL AFR AFTDCY clt 158 Vol 1 Chapter 12 Getting Idle Right Idle Problems on Non GM Engines and Throttle Bodies Add IAC Steps on Warmup Finally there are extra IAC steps you can add on Warmup You don t normally need to touch these especially if the throttle body is hissing a lot an indication that the throttle is open anyway but when you have the fuel and spark right but just not enough air adjust 202 IAC WUP INIPOS clt and 201 IAC WUP INIDLY Vol 1 Chapter 12 Getting Idle Right 159 Idle Problems on Non GM Engines and Throttle Bodies 160 Vol 1 Chapter 12 Getting Idle Right Calibrating 161 Chapter13 Calibrating KALMAKER Pee ee ee m Garner tor Dern Engine calibration is the process of giving the ECM program the right data to manage engine operation correctly In order to obtain best fuel and spark it may be necessary to modify the data several times For example
55. not using an electric fan C 3 Circuit 444 IAC COIL B LO GA Circuit 443 IAC COIL B Hi C 5 Circuit 441 IAC COIL A HI C 6 Circuit 442 IAC COIL A LO These four wires run directly as a group to the 4 pin IAC unit connector It does this by sending voltage pulses referred to as counts to the proper motor winding to either activate the in or out operation of the valve CAUTION DO NOT under ANY circumstances apply 12V battery voltage across the IAC terminals Doing so will permanently damage the motor windings C 10 Circuit 410 COOLANT TEMPERATURE SIGNAL Connected to the coolant temperature sensor This circuit provides coolant temperature input to ECM C 12 Circuit 472 MAT SIGNAL Connected to the MAT sensor This circuit provides inlet air temperature input to the ECM C 13 Circuit 417 TPS SIGNAL Connected to terminal B of the 3 pin TPS connector This circuit provides a TPS input voltage to the ECM allowing the ECM to determine the amount of throttle opening since the input voltage signal changes relative to throttle opening C 14 Circuit 416 TPS 5V REFERENCE Connected to terminal C of the 3 pin TPS connector This circuit provides the 5V reference signal to the TPS C 16 Circuit 540 VN 240 12V BATTERY supply JE This terminal should be connected through a 20 amp fuse to a constant NON SWITCHED 12V source battery post on the starter motor maxi fuse for Painless Wiring systems BAT connec
56. of development you will have to purchase extra components including an EPROM programmer EPROM eraser and PALs Contact Injection Connection at tpiconn space net au EPROM Specifications The following data will be useful if you are going to use EPROMs for development Hint You can use equivalent EEPROMs if you wish provided your EPROM burner supports them This saves the cost of an eraser The EPROM size required is 16k 32k or 64k EPROMs are usually NMOS programming voltage usually 25V or CMOS programming voltage usually 12 5V Note Almost all EPROMs these days are CMOS EPROM speed should be 150ns or better This refers to the time required to address the EPROM and retrieve valid data When reading an EPROM into a buffer with an EPROM reader the buffer size will be 16K or 0 3FFF hex All EPROM s will have a notch on the pin1 end Don t put an EPROM in the wrong way around or it will die Table 29 EPROM Size Typical Application Calibration Size Eprom Size VN VP Manual Auto 16K 16384 bytes 270128 VR VS Manual 32K 32768 bytes 270256 VR V8 Auto 64K 65536 bytes 270512 Vol 1 Chapter 10 Opening Loading and Saving a Calibration 135 Writing a Calibration To run a standard Delco ECM with your own MEMCAL proceed as follows 1 2 A 8 Develop the program as you normally do using the Real Time ECM Read the calibration into Buffer 1 and EDIT any last minute change
57. pin ignition module plug At about 400 rpm this circuit applies 5V to the ignition module which switches timing control from module s internal calibration Module Mode to the ECM D 6 Circuit 150AA OXYGEN SENSOR GROUND Connected to the ganged common ground wire circuit together with ECM Terminals A 12 D 1 D 3 and D 10 refer SYSTEM GROUND on page 91 which are in turn connected to a 94 Vol 1 Chapter 6 Wiring Information Terminal Listings secure engine ground This circuit provides the ground for the Oxygen Sensor D 7 Circuit 412 OXYGEN SENSOR SIGNAL Connected to the Oxygen Sensor signal wire Ensure the connections for a heated O2 sensor are made correctly with the heater connection going to an ignition supply D 10 Circuit 450 SYSTEM GROUND Connected to the ganged common ground wire circuit along with ECM terminals A 12 D 1 D 3 and D 6 refer SYSTEM GROUND on page 91 which are in turn connected to a secure engine ground D 15 Circuit 467 INJ 1 3 5 7 Connected to Fuel Injectors 1 3 5 and 7 D 16 Circuit 467 INJ 2 46 8 Connected to Fuel Injectors 2 4 6 and 8 ALDL Connector The ALDL Assembly Line Data Link or Diagnostic Link connector comes in two different configurations e 12 pin Used in US vehicles and the JD JE Camira and LD Astra cars e 6 pin Used in VN to VL Commodores Later Commodores used a 16 pin OBD II style connector The following is a listing of the ALD
58. program which can display it to the screen and print it The PostScript plot file is in a format which can read by the AutoCad PSIN command It has layers specifically for AutoCad Once read into AutoCad it can be converted into a number of formats printed plotted or edited The default extension of all PostScript files is ps Plot Text The Text option writes the variable values to a text file This allows variable values to be printed raw or for example read into a spreadsheet for plotting Plot Screen The Screen option displays output on the screen as it would appear on the page The output is scaled for the screen aspect ratio View menu This menu is a simple text file viewer FIGURE 12 View Menu The View selection uses a general purpose file viewer to view the text files generated as KalMaker output These files are produced as output from the Buffer Dump File or Buffer Diff File options Dump Files If View Dump files is selected a list of dump files is generated from the KalMaker Output directory list Dump Vol 1 Chapter 3 Kalmaker Editor Menu Commands 57 Working Without a Mouse files are given an arbitrary dmp extension by KalMaker and are normal ascii text files Diff Files If View Diff files is selected a list of diff files is generated from the KalMaker Output directory list Dump files are given an arbitrary dif extension by KalMaker and are normal ascii text files Other Files
59. programmed for N 10 degrees of initial advance by the igntion module As soon as engine speed increases to 450 rpm the engine is assumed to be running and switches to Main Advance Go to No 48 SPK BAS RUNADVA Press Fwd to 800 rpm Set 50 60 amp 70 kpa to 28 degrees This allows a smooth transition from Main Advance to the Idle Advance map and vice versa Stalling Stumbling Deceleration The following variables are responsible for maintaining desired idle speed when engine RPM drops rapidly or when the engine is loaded up at idle from things such as power steering surges letting out the clutch or if it is not quite on tune 21 8 IAC SAG RPM2 21 9 IAC SAG STEP2 e 220 221 IAC SAG RDB1 IAC SAG STEP1 For factory or near factory standard engines the values in these variables will not need changing However a modified engine with a non factory camshaft may experience sag 150 Vol 1 Chapter 12 Getting Idle Right Set Idle Speed which is when the engine comes rapidly off idle from WOT Idle falls well below the desired speed for example less than 600 RPM and stumbles then stalls There are two levels of engine speed that the idle can fall to that will trigger the adding in of steps of the IAC to prevent stalling These two breakpoints are called deadbanas If engine speed drops by more than the first deadband 220 IAC SAG RDB1 some steps are added If en
60. that there are a number of menu items These may be activated by moving your mouse over the menu and clicking a mouse button Note No distinction is made between left and right mouse buttons The menu choices have one letter that is underlined This is the designated Shortcut Key associated with the menu choice The following table lists the Main Menu Hotkeys Table 1 Main Menu Hot Keys Shortcut to Key About A Setup S Buffer 1 1 Buffer 2 2 List L Func tion F Gauge G Plot P View V Quit Q Once a certain menu or function is selected either by the keyboard or the mouse the action may be cancelled by pushing the Esc Escape button on the keyboard Where changes are effected always select SAVE Menu Functions All of the Kalmaker Menu commands display several functions The main menu items are from left to right e About menu e Setup Menu e Buffer 1 amp 2 Menu 18 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions e List Menu e Function Menu e Gauge Menu e Plot Menu e View menu e Quit Menu About menu Selecting About has no direct function within KalMaker except to display the version of the KalMaker software and the details of the program distributor Setup Menu The Setup menu contains the following commands e Environment e Parallel Port e Clock Factor Capture Buffer e System Environment This command sets all read a
61. the 02 sensor can give a false lean reading Also note the following phenomenon regarding oxygen sensors e Silicon based products including silicon based lubricants and silastic will damage the sensor and it will be seen as a white coating on the oxygen sensor Always make sure when using this type of material that it is suitable for emission vehicles Symptoms may be surging rough running and idle problems e Rich mixtures These can cause a carbon coating to build up on the sensor causing the sensor to not work correctly e Old age These devices have a finite life span usually around 100 000 kilometers e Leaded fuel The oxygen sensor will be gradually and irrevocably damaged if it comes into contact with leaded fuel e Excessive heat Oxygen sensors have an operating range between 300 and 600 degrees celsius Temperatures in excess of 800 degrees will result in sensor damage e Testing with an ohm meter NEVER test the sensor with an ohm meter as this will feed several volts into the sensor and damage it Leaded open loop Before starting an accurate VE table should be obtained if possible Unless special O2 sensors are used this can only occur with unleaded fuel Vol 1 81 Knock Sensor Open loop can be forced by three methods e Change FUL RUN STOICAF to an improbable value say 10 1 or 20 1 e Change all stoichiometric values in the FUL RUN RUNAF table to be just above or below FUL RUN ST
62. the similarly coloured wire from ECM Terminal C 16 as is indicated by the same Circuit 540 VN 240 JE Also connected to this same 12V source should be fuel pump relay Terminal 30 and one side of the oil pressure activated fuel pump backup switch if fitted B 3 Circuit 453 Crankshaft Distributor REFERENCE Connected to one of the four wires which run as a group to the 4 pin distributor plug This circuit provides a reference ground between the ECM and the distributor ignition module to assure there is no voltage drop between these two components B 5 Circuit 430 DISTRIBUTOR REFERENCE Connected to one of the four wires which run as a group to the 4 pin distributor plug This circuit provides the ECM with rpm and crankshaft position input Should this circuit become open or grounded the engine will not run because the ECM will not pulse the injectors B 8 Circuit 449 A C SIGNAL Connected to the positive terminal of the AC compressor clutch wiring plug Connected in this manner this circuit will provide a 12V input to the ECM to inform it that the AC Vol 1 Chapter 6 Wiring Information 91 Terminal Listings compressor clutch is engaged and the ECM will then proceed to adjust the idle speed by controlling the IAC unit to compensate for AC compressor clutch engagement Note DELETE if not using an air conditioning system Note B 9 Kalmaker Switch See Kalmaker Switch on page 70 B 10 Circuit 434 PAR
63. the variable increases or decreases an Input or Internal value 52 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions In all cases the procedure is Move the indicator to the desired value Transmit the value via the Load option or Input the desired value via the keypad Transmit the value via the Enter option The variable can be transmitted as it is updated by selecting the RTLink option and altering the indicator The Enter or Load option used above first selects the variable it sends a select message and then sends its value Bl oe e The variable may be viewed via the List option Note that in the absence of further communication with the ECM the modification is only temporary Selecting the List option establishes communication with the ECM and the modification stays in effect while the data list is being viewed The current variable may be deselected via the Deselect option The ECM then uses the normal input or internal variable value The Clear option clears all variable modifications and deselects all variables Function Discrete The Discrete option enables discrete variables to be selected and transmitted to the ECM The actual variables can vary from calibration to calibration The discrete functions are listed according to function They may be e Discrete output overrides e Internal state flags e Reset or clear flags The procedure in all cases is as follows e A button press ind
64. time OUT TCC TPSHYST tcc unlock tps hysteresis OUT FPR HIMAT fpr mat threshold OUT FPR LOBAT fpr bat threshold OUT FPR LOTPS fpr lotps threshold OUT FPR HITPS fpr hitps threshold OUT FPR TIME fpr engine runtime OUT FPR BATMUL fpr fuelcalc reduction factor Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Kalmaker Switch Variables Table 28 Output OUT Variable List OUT FPC LPGRTM fuelpump Ipg disable runtime 03 Kalmaker Switch Variables All Variables that end in A or B refer to Kalmaker Twin Tables Table A is the default mapping of the A variables and by default is identical to Table B In default mode not connected the Kalmaker runs all A variables and B variables are disregarded You can switch between the two instantaneously See Kalmaker Switch on page 70 Note There are quite a few A amp B maps in the Gen Opt variables Spark Fuel IAC etc Any Variable with either an A or B at the end of it identifies it as a twin maps variable Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 125 Kalmaker Switch Variables 126 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Pre Calibration Checks 127 Chapter 9 Pre Calibration Checks KALMAKER CEE EEE EEN Garner tor Den This section contains some tips which may be of help when modifying calibrations e Your work may have already been done for you If you intend adapti
65. we be reading this A F ratio 179 Is FUL RUN VE the same as FUL OUT VE 177 Is this a dongle If so describe it 10 Is this command only applicable to SP2 Is it possible to use SP3 with a parallel port to link 20 Is this the Percentage reading in the FUL RUN VE on Fig 31 Fuel Map 177 Isn t this the authorisation device We re getting mixed up between the DOngle and the PAL 129 M Manual Gear Determination Variables 108 N Need to expand on these fatcory calibrations What do they all mean What s BAYA NOI N02 N03 for example 132 Nore on Setup menu 19 Not very clear with regard to using unkown injectors Please clarify this 78 R Reset Idle Mode not clear on this point 149 S Serial cable 131 Some info on cylinder select required Include text or a link to appro priate info on Resistor Pack Backup Risitors 132 Vol 1 235 SPK BAS RPMRAT 110 DFC DFCADV 110 DSR 109 LOG 109 OUT MAXADV 111 STU LPGRMD 109 LPGRML 109 TQM 109 T There is not enough info here to demonstrate how to tune for max power Update it or delete it 179 Torque Management Spark 109 What s this mean 25 U Using a non realtime factory program will cause a link error even if the ECM is operating properly 200 V SPK BAS ALTCRN 110 EGRADV 110 VAR MAP MAPQ 108 NVR 108 GxERR 108 GxRAT 108 TPS EGRTIM 108 TRP LPKFAC 109 W What do we adjust the bar on the VE table to Do we adjust to STFT of 128 What does the read
66. 04 Vol 1 Chapter 15 Troubleshooting Trouble Codes 205 Chapter 16 Trouble Codes KALMAKER CEE EEE EEN Garner tor Den The ECM and sensors provide a diagnostic service in the event of a failure of the system Any problems encountered by the ECM cause a Trouble Code to be stored in the Computer s memory This Trouble Code causes the Check Engine Soon light to go on if fitted which alerts you to a fault in one of the sensor circuits or the ECM itself To retrieve this information from the computer s memory the ECM must be put into the Diagnostic Mode The following sections describe the diagnostic procedures in detail highlighting those areas which are monitored by the ECM Diagnostic facility ALDL Modes Nothing is normally connected to the ALDL connector and the ECM runs in Normal mode There are three other modes available and to put the ECM in a particular mode a resistor is placed between pins A and B The value of this resistor determines the voltage at pin A 9 of the ECM e Diagnostic mode or the flashing error mode Short circuit for example a paper clip This mode generates a simple human readable diagnostic code sometimes called an Error Code or Trouble Code See Trouble Code Listing on page 207 e Vehicle Service Mode A 10K resistor between pins A and B of the ALDL connector This mode generates a computer readable dump of the EPROM e Backup Mode or Limp Home Mode A 3 9K resistor Vol 1
67. 1 Chapter 1 Introduction 9 Copy Protection should it be found that in the opinion of the distributor there is no fault with the software or associated hardware or where the fault has been caused by failure to strictly adhere with the information contained within If you are not confident with the modification of any hardware you are advised not to attempt them and to contact the KalMaker distributor to arrange the modification for you at extra cost Copy Protection Kalmaker Street Pro 3 software is copy protected by a Software Dongle See Software Dongle on page 15 Street Pro 3 will not run without the dongle installed in the parallel port All KalMaker programs generated by Street Pro 3 are copy protected by the Security Device known as a Programmable Array Logic PAL See Developing Multiple Calibrations Chap 4 Vol 2 page 15 If the Security Device is not detected the program behaves as follows e If the program is on an RT102 board it will run for 60 minutes before selecting backup fuel and spark If the program is on an EPROM backup fuel and spark will be selected after 60 minutes run time or next key on This 60 minute delay allows development without a security device e Once back up fuel and spark have been set power must be removed from the ECM to restore normal operation Note Ifa program has been developed on the SRAM RT 102 board it cannot be copied directly onto an EPROM It must be saved
68. 1 it will differ from the original calibration C1 The translation is meant to be a labour saving first step only and the user should look at the results carefully There is no guarantee that the result will be a useable calibration unless all variables translated exist on the other calibration that is there are no variables unique to either calibration If the calibrations are very different a more useful method of transfer is to copy the required variables from calibration C1 to clip and then copy them to calibration C2 Link The Buffer Link option is available only on Buffer1 Link CalRx The Link CalRx option enables calibration data to be transmitted to KalMaker The ECM reads the data variables 44 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions and transmits them via the serial link in response to a KalMaker request Note that in order for the transfer to occur a calibration must be loaded into Buffer1 The calibration must use the same program as that in the ECM The ECM program information is sent before any data is transmitted KalMaker proceeds with the transfer if the data is consistent with the program data contained in the calibration script An indicator bar displays the progress of the transfer The mouse cursor is hidden during the transfer in order to improve performance The Link CalRx data transfer is available only with RealTime programs Link RamRx The Link RamRx option is similar
69. 1313 Can t allocate Translate Buffers xxxx bytes An error occurred while allocating memory for the data translate buffers These are required for high speed translation of the data received from the ECM or PCM E1314 Can t allocate Display Buffers xxxx bytes An error occurred while allocating memory for the data display buffers These are required for high speed dispaly of the data received from the ECM or PCM 186 Vol 1 KalMaker Application Errors E1315 Can t allocate Trouble Code Buffers xxxx bytes An error occurred while allocating memory for the trouble code display buffers These are required for high speed dispaly of the data received from the ECM or PCM E1316 Can t allocate Data List Descriptors An error occurred while allocating memory for the list of data list descriptors E1317 Can t open file An error occurred while opening the data capture file file The usual cause is that the file path or drive does not exist E1318 file is nota SCANPRO binary The data capture file file does not have the required header string E1319 file is corrupted The data capture file header is the wrong size E1320 file corrupted at frame xx of xx The data capture file size is smaller than indicated by the header information The program attempts to read the number of frames indicated by the header This error occurs if an end of file occurs before all frames are read E1321 Can t open
70. 146 Vol 1 Chapter 12 Getting Idle Right Set Idle Speed 7 If no Knock Sensor is present adjust the timing until the detonation stops then continue from Step 5 until idle speed and quality is good 8 Go to 123 FUL OUT VET 9 The load points in this variable are defaulted at 50 which is usually too rich Drop them to 35 45 10 Go to the Gauges screen Hint Press g then v 11 Refer to the rolling graph on the Gauge View screen 5 E R gt 16 CIE Za Z Daa 7 40 MAT degC SPKRTD deg The Red line indicates 02 voltage and this should oscillate between EL RR RK 400 mv and 800 mv STFT percent LTFT percent 025 mY ACCEL MODE LEARN ENABLE RICH LEAN FUEL CONTROL ASYNC FUEL 02S READY FIGURE 21 Rolling O2 Graph on Gauges screen Note At higher rom this will should switch up and down very quickly whereas at idle it is almost a straight line 12 As the red line drops A F goes lean As it rises it goes rich In this example the idle mixture is slightly rich In this case 13 Note engine speed and MAP Kpa Go to 123 FUL OUT VET and drop the values for the load points closest to the engine speed and MAP 14 Switch back to Gauges and re check the rolling graph 15 Repeat the process until the red line is close to the centre green line Note When you have this correct you should make the same load points in the main VE map the same Vol 1 Chapter 12 Getting Idle R
71. 192 baud so for all standard computers the clock factor is set at 1193180 8192 146 If the clock factor needs adjustment the computer should be Vol 1 Chapter 3 Kalmaker Editor Menu Commands 21 Menu Functions connected with a functioning ECM and the slider bar adjusted until communications are established Table 5 Exit Key Functions Clock Factor ExitKey Function Cancel Exit any changes made are lost OK Exit any changes made take effect immediately for the duration of the current session but are not saved to disk Save Any changes made take effect on exit and are saved to the config file kal2 cfg Capture Buffer The capture buffer option enables the size of the data capture buffer to be set The size of this buffer should be proportional to the amount of memory available Normal use may require say five minutes of data capture but there may be instances where much longer is required The buffer size is adjusted by moving the slider to the required time or memory size The time conversion assumes a standard frame of 64 bytes some messages are shorter than this and the capture time may be greater than shown The program must be restarted in order for capture buffer changes to take effect Table 6 Exit Keys Capture Buffer ExitKey Function Cancel Exit any changes made are lost OK Exit any changes made and saved take effect next startup Save Current buffer size is sav
72. 25 mat threshold ETC M25 RUNTIM m25 runtime enable ETC MAT DEFMAT default mat ETC M21 TPSTH m21 tps threshold ETC M21 DETTIM m21 determination time ETC M22 TPSTH m22 tps threshold ETC TPS DEFTPS rpm default tps ETC M33 BAPFAC m33 baro multiplier ETC M33 TPSTH m33 tps threshold ETC M33 DETTIM m33 determination time ETC M34 MAPTH m34 map threshold ETC M34 RPMTH m34 rpm threshold ETC M34 TPSTH m34 tps threshold ETC M34 DETTIM m34 determination time ETC MAP DEFMAP defmap engine not running ETC MAP MAPOFS defmap offset engine running ETC MAP RPMFAC defmap rpm term factor FB Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 121 Variable Groups Table 27 Engine Trouble Code ETC Variable List ETC MAP RPMOFS defmap rpm term offset FB ETC MAP TPSFAG defmap tps term factor FB ETC MAP TPSOFS defmap tps term offset FB ETC MAP MINSTEP defmap iac term threshold FB ETC MAP STEPMUL defmap iac term factor FB ETC MAP ACMAP defmap delta acc on ETC MAP DRMAP defmap delta auto in drive ETC MAP DEFMIN minimum defmap FB ETC MAP INCMAPQ filter constant defmap increasing FB ETC MAP DECMAPQ filter constant defmap decreasing FB ETC M13 RUNTIM m13 runtime enable ETC M13 02LO m13 02 lo threshold ETC M13 02H
73. 4K address spaces and a jumper selects which is used This is done at the factory and it is not recommended that any alterations are made to the SRAM YOU SHOULD NEVER REMOVE THE SRAM FROM THE BOARD THIS WILL VOID THE WARRANTY Using a non realtime factory program will cause a link error even if the ECM is operating properly 200 Vol 1 Chapter 15 Troubleshooting Using the Diagnostic Functions Also note the following e The ECM only needs power and ground in order to run and link No sensors need to be installed e Ifthe incorrect backup resistors are installed the vehicle will start and run but will deliver fuel incorrectly The backup resistors among other things mode the hardware for the number of engine cylinders Parallel Port or Serial Port Many later laptops will load and display Kalmaker perfectly but will not Link to ecm pcm because the Comm Ports have been changed from software controlled to hardware controlled Some will link using the Parallel Port others have no Serial Port and have switched to USB Usually these will not work and you will have to change the settings in the Bios Note Ifusing the Parallel port you must run a Link Test in Kalmaker to determine the most suitable clock speed and delay Enter these figures and Save Something that often upsets the Serial Port is the Infra Red Disable infra red as follows 1 Right click on My Computer 2 Choose Properties Device Manager Infr
74. 6 180 20 4 25 000 28 680 30 22 52 700 40 40 100 700 100 700 Kalmaker Switch Kalmaker can be deployed with two different fuel and ignition maps on the same calibration so that you can switch between two modes of operation such as using different fuels or gas running a different map for drag racing uncorked headers etc All Variables that end in A or B refer to Kalmaker Twin Tables See KalMaker Street Pro 3 Variables on page 103 Table A is the default mapping of the A variables and by default is identical to Table B In default mode not connected the Kalmaker runs all A variables and B variables are disregarded You can calibrate the B maps differently to the A maps To enable the B maps add a terminal and wire to pinout B9 on the ECM plug and connect it to one side of a switch in the dashboard Connect the other pole of the switch to ECM ground ie terminals D3 D10 With the switch OFF not grounded the A maps are enabled by default With the switch ON ground B9 B maps are enabled instantaneously even with the engine running Note A amp B variables are part of same calibration and are nothing to do with Buffer 1 or 2 With the switch OFF not grounded the A maps are enabled by default With the switch ON ground B9 B maps are enabled instantaneously even with the engine running 70 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker Kalmaker Switch Note The twin tables are all stored
75. 63 Vehicle Modifications and Kalmaker dyno and an engine instrumented for air temperature coolant temperature and manifold temperature The system uses these temperature inputs to estimate air mass Errors caused by wrong values should in theory be small An idea of the changes required for the VE table can be obtained from inspection of block learn values See The Volumetric Efficiency Table on page 171 If the idle quality has deteriorated such as with the installation of a different camshaft See A Note on Cam Choice on page 153 the desired idle speed should be altered See TAC DES RPMDR on page 168 IAC DES RPMPN on page 168 or TAC DES RPMMT on page 168 Increase the bar on the screen to increase the idle speed Note As you can see in KalMaker there are quite a number of variables associated with idle that may be altered However it is generally advisable that idle speed is the main thing that is altered when seeking to cure a poor idle problem with a large camshaft Alteration of the transient or sag variables should be done with caution and patience as getting the values wrong will result in erratic control of idle or the engine will hunt at idle If engine speed change does not help try altering IAC transient decay variables IAC TRA DEFDEC and IAC TRA BYPDEC on page 119 Different Engine When adapting the Delco and KalMaker to an engine from a non GM manufacturer use a calibration from a simi
76. A blue screen is displayed 2 From the main menu choose File Open A drop down list is displayed 3 From the drop down list choose KAL3 TFG 4 Click OK Another blue screen is displayed Scroll down to the grafix entry The default value is Gfx God ve 20 5 Change the default value 20 to the number that works for you for example 33 6 Choose Save then exit 16 Vol 1 Chapter 2 KalMaker Installation Kalmaker Editor Menu Commands 17 Chapter 3 Kalmaker Editor Menu Commands Garner tor Denn This section describes the operation of the KalMaker editor and outlines the function of the various on screen menus commands and Hot Keys When you run KalMaker on your machine provided you have the software dongle connected you will see the disclaimer box Read the disclaimer and if you agree click on the box to continue Calibration changes made with bees product may affect sehe raliabilii y and satuti They frag cauta denge to or Gorrtosp the Barvice liia st migis and dr ieetzain Ein pararta By centins sg prog om operation past this disclaimer tie usar atcepte reapassibility for the comsequences of any modifications Foci litated Su aaa of thia product This predent ie mot Intorgded to be user on any vehicle sugject bo amission legislation FIGURE 2 Disclaimer Vol 1 Chapter 3 Kalmaker Editor Menu Commands 17 Main Menu Main Menu Working from left to right on the screen you will see
77. EC steps sec to kick in when decellerating however it does happen 3 Ifthe throttle body is hissing loudly it means the IAC is open too far Screw in the throttle stop to open the throttle slightly and start again You should be able to get the engine to idle at near zero steps if you give it the correct amount of fuel it likes and idle advance is set to what the engine can handle before pinging Note If you have made several changes but find that after a while no amount of adjustment seems to be making a difference unplug the ECM and start again Idle Proportional Spark Spark has a huge effect on idle Idle Proportional Spark IPS compensates for idle rpm fluctuations by adding or substracting advance to steady up these fluctuations This is very effective if setup correctly You can adjust the Coolant Temperature that IPS cuts in at 53 SPK IPS PSCLT You can turn it off by raising the temperature Try it and see what happens The Maximum Advance that IPS will perform is set by 57 SPK IPS PSMAX It is usually 5 degrees either way Drop this to 2 degrees or increase to 8 and see what happens Finally there is Positive and Negative RPM increase factor 54 SPK IPS PSPOS and 55 SPK IPS PSNEG Check out V8 and V6 differences Play with these and see what happens Different engines like different settings Idle Sag Settings When using warm hot cams it may be a good idea to change the Idle Sag setti
78. Garner tor Dern Non GM Distributors Some info on non GM or GM disssys from non EFI engines MSD Crane ProComp type modules Reference angl is basically the delay factor between TDC and the point at which the ignition trigger switches It only needs to be changed when using another type of engine and or distributor crank trigger which is not suited to the calibration you are using Distributor Interface The Delco ECM uses a standard 4 wire interface to communicate with the ignition controller Ignition controllers can be any of the following e TBI ignition module as used on many US engines and local Vol 1 Chapter 7 Distributor Interface 97 Distributor Interface 1 8 and 2 0 Camira The TBI module uses a reluctor input FIGURE 15 TBI Ignbition Module Factory and Aftermarket e Bosch Module all 8 cylinder uses a Hall Effect input e Coil Pack all 6 cylinder uses a Hall Effect input It is important to note that the ECM does not know which device it is connected to All devices use the 4 wire interface The 4 wire interface is as follows e Reference high e Reference low ground e EST output ECM to ignition controller e Bypass control All ignition controllers operate in three modes e Backup Mode also called Module Mode This is the mode that is used to start the engine When the engine is cranking spark advance is fixed at 10 degrees The computer has no control over t
79. I m13 o2 hi threshold ETC M13 CLTTH m13 clt threshold ETC M13 TPSTH m13 tps threshold ETC M13 DETTIM m13 enable time ETC M51 CHKSUM program checksum ETC M51 PROGID program id ETC M24 MAPTH m24 map threshold ETC M24 RPMLO m24 lo rpm threshold ETC M24 RPMHI m24 hi rom threshold ETC M24 DETTIM m24 determination time ETC M43 ADLO m43 low dc voltage threshold ETC M43 ADHI m43 high dc voltage threshold ETC M43 DEFRTD m43 default retard ETC M43 DETTIM m43 determination time ETC M35 DETTIM m35 determination time Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups Table 27 Engine Trouble Code ETC Variable List ETC M35 RPMERR m35 rpm error threshold ETC M35 RSTCTS m35 reset threshold FB ETC M41 BATTH m41 bat threshold ETC M41 VACTH m41 vacuum threshold ETC M41 DETTIM m41 determination time Output Variables The output OUT groups describe ancilliary functions such as air conditioner clutch and fan There are seven sub groups e OUT GEN Output Control e OUT ACC Air Conditioner Clutch e OUT FAN Fan e OUT TCC Torque Converter Clutch e OUT LIT Economy Lite e OUT FPR Fuel Pressure Regulator Solenoid e OUT FPC Fuel Pump Control Table 28 Output OUT Variable List OUT GEN DELAY output disable delay OUT ACC DE
80. Integrator returns to a value of 100 the BLM will stop moving and remain at that value permanently That means the VE table has been re tuned at this engine operating condition The only thing that will return the BLM value to 100 is removing power from the ECM or retuning the VE table manually In reality the BLM does not remain at a fixed value It constantly alternates around the 14 7 A F 172 Vol 1 Chapter 14 The Volumetric Efficiency Table The VE Map Hint In general if your BLM values are all significantly low then you probably have your BPC set too high and vice versa if your BLMs are high Adjust FUL OUT INJRAT and FUL OUT CYLSIZ on page 114 accordingly If the BLMs are both above and below 100 but within a reasonable limit say 90 and 110 your VE table is probably reasonably close If you are outside of these limits the calibration is probably significantly off and needs to be manually corrected The VE Map The VE map FUL OUT VE on page 168 stands for Volumetric Efficiency Often referred to as the fuel map it is more accurate to refer to it as the VE Map The Volumetric Efficiency table has two functions e it tells the program how full the cylinder is of air e itis a final fudge factor used to calibrate the system The Delco system runs in Closed Loop once a few parameters have been met Closed loop means it is in self learning tuning mode and is controlled by the O2 Oxygen sensor as described u
81. K NEUTRAL SIGNAL Connected to the park neutral switch connector Grounded in Park or Neutral When the transmission selector lever is placed in the park or neutral position this switch completes the circuit from this terminal to ground B 11 Circuit 815 KNOCK SENSOR INPUT The wire that connects the knock sensor to the ECM connects at terminal B 11 on the ECM See Knock Sensor on page 67 C 1 Circuit 304 VN 404 FAN RELAY CONTROL JE Connected to Terminal 85 of the fan control relay This circuit allows the ECM to control the operation of the engine cooling fan relay by grounding this terminal thus providing ECM control of the electric cooling fan operation You should conncet this circuit up when an electric fan is used Note If you are using an electric engine cooling fan in your installation it should also be wired to run whenever the AC compressor clutch is engaged This can be most easily accomplished by adding a second fan control relay to the system This second relay should be activated by the same circuit Terminal B8 which provides the ECM with the AC on signal A second relay is required for this application because the stock fan relay is activated by supplying a ground whereas the AC on signal is a 12V input thus requiring the use of a second relay to allow either circuit to independently control the fan operation 92 Vol 1 Chapter 6 Wiring Information Terminal Listings Note DELETE if
82. Knock Sensor OFF on page 139 Note If the system is used on non GMH engine a knock filter from a engine of similar cylinder bore diameter should be used There are many US systems for which Memcals can be obtained Vehicle Speed Sensor It is important to run a VSS but not essential There are several reasons why you should run a VSS The main function of this sensor is to control all Transient Fuel and Transient Steps Transient functions are those that occur between stages for example decelerating Controlling transient stages by delivering extra or less Fuel Spark and Idle Control Steps gives a high degree of drivability and Idle Control Without this Vol 1 Chapter 4 Vehicle Modifications and Kalmaker 67 Fuel Pump and Fuel Pressure sensor many engines stall when slowing to a stop See Vehicle Speed Sensor on page 139 The VSS also controls the Lockup Converter speeds Hint Aftermarket Speed Sensors are available that screw into the Transmission where the speedometer cable usually goes The speedometer cable piggy backs onto the VSS unit allowing the use of cable driven speedos Fuel Pump and Fuel Pressure If you are using a fuel pump other than a stock GM in tank style pump be sure to properly mount it utilising rubber insulators to avoid noise and vibration The Fuel Pump must supply sufficient fuel flow and maintain the required pressure for the application The appropriate vacuum controlled Fuel Pressure Regula
83. L connector terminal locations and the circuits to which they are connected Table 21 ALDL Connector Wiring ALDL Terminal Circuit Description TERMINAL A GROUND Connected to common ground circuit from ECM terminals A 12 D 1 D 3 D 6 and D 10 refer SYSTEM GROUND on page 91 which are in turn connected to a secure engine ground TERMINAL B DIAGNOSTIC Connected to ECM Terminal A 9 TERMINAL E CheckEngine Connected to ECM Terminal A 5 Soon lamp Vol 1 Chapter 6 Wiring Information 95 Terminal Listings Table 21 ALDL Connector Wiring TERMINAL F TCC Connected to ECM Terminal A 7 See A 7 on page 90 if utilising an ECM controlled TCC system TERMINAL G FUEL PUMP Connected to fuel pump relay Terminal 87 TEST TERMINAL H 12V Battery Voltage Note Because of the use of different intermediate plugs and harnesses between the ECM and the ALDL connector on different make and year vehicles the colour codes on the wires attached to the ALDL terminals will not always match the codes on the appropriate wires from the ECM Double check the connections to ensure the proper circuits go to the proper terminals TERM AL IDENTIFICATION DPI SERIAL DATA DACSkSTIC IESSEN AL TEGIP EIN ALR OP UZEL FUEL PUMP F USEC SERVICE BH OHE S000 LAMP JF EEL SERIAL DATA OF USET FIGURE 14 ALDL Connector Vol 1 Chapter 6 Wiring Information Distributor Interface 97 Chapter 7 Distributor Interface KALMAKER
84. LAY acc request delay OUT ACC LORPM acc enable lorpm OUT ACC HIRPM acc enable hirpm OUT ACC HITPS acc enable tps OUT FAN LOCLT1 fan1 enable locit threshold OUT FAN HICLT 1 fan1 enable hiclt threshold OUT FAN LOKPH1 fan1 enable lokph OUT FAN LOCLT2 fan2 enable loclt threshold OUT FAN HICLT2 fan2 enable hiclt threshold OUT FAN HIKPH2 fan2 enable hikph OUT FAN DELAY fan2 enable delay FB Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 123 Variable Groups Table 28 Output OUT Variable List OUT LIT DELGR1 upshift enable time g1 OUT LIT DELGR2 5 upshift enable time g2 5 OUT LIT RPMTHRI tps elite enable hirpm OUT LIT SHFRPMx gearx elite enable lorpm OUT LIT SHFMAPx gearx elite enable map OUT TCC LOCLTLIM tcc lock enable ch OUT TCC LOKKPH tcc lock lokph OUT TCC ULKKPH tcc lock hikph OUT TCC NEGDELTPS tcc lock neg delta tps limit OUT TCC POSDELTPS tcc lock pos delta tps limit OUT TCC ULKTPSA kph tcc lock hitps limit OUT TCC LOKTPSA kph tcc lock lotps limit OUT TCC ULKTPSBIkph tcc lock hitps limit 5D OUT TCC LOKTPSB kph tcc lock lotps limit 5D OUT TCC LOKDEL tcc lock enable time OUT TCC HIKPH unlock kph test threshold OUT TCC TPSLO tcc unlock lotps threshold OUT TCC TPSHI tcc unlock hitps threshold OUT TCC ULKDELLO tec unlock lokph time OUT TCC ULKDELHI tec unlock hikph
85. M GROUND d 4 WHITE Circuit 151 Engine Ground d 5 TAN BLACK Circuit 424 DFV HEI Bypass Control d 6 Black Circuit 150AA OXYGEN SENSOR GROUND d 7 PURPLE Circuit 412 OXYGEN SENSOR SIGNAL d 8 not used d 9 not used d 10 BLACK Circuit 150 SYSTEM GROUND d 11 H20 d 12 H20 Injection d 13 not used not used d 14 not used not used d 15 LIGHT BLUE or BLACK PINK Circuit 467 Injector Control d 16 LIGHT GREEN or BLACK Circuit 467 Injector Control GREEN ECM Terminal Descriptions Each ECM Terminal is dealt with in the following text Those terminals not in use are not shown here Where necessary reference is made to specific year models and differences between wiring harnesses are indicated Every attempt has been made to cover all models but factory alterations accessory installations and customizing techniques may cause different wiring source and destination locations than that which appears here Always check carefully any ambiguous differences A 1 Circuit 465 FUEL PUMP RELAY CONTROL 88 Vol 1 Chapter 6 Wiring Information Terminal Listings Connected to Terminal 86 of the fuel pump relay This circuit allows the ECM to activate the fuel pump relay by supplying 12V through this terminal The fuel pump power circuit is provided by a connection to relay Terminal 30 of the 12V wire directly from the Battery Fuse In addition Terminal 85 of the fuel pump relay should be connected to the common ganged groun
86. OICAF e Change the closed loop temperature limits In any case the system won t be in open loop if there is no O2 sensor DGN MSK MASK1 and DGN MSK MASK3 should be altered to mask out malfunction codes m13 m44 and m45 Some or all of these will be flagged with no O2 sensor present With O2 sensor present if the air fuel ratio is not equal to FUL RUN STOICAF then the system runs in open loop Inspection of the factory calibration dumps will reveal that the engine runs open loop at high map values The reason for this is that these regions are calibrated rich for maximum power Once the system in running open loop closed loop terms and block learn terms become inoperative You should have a reasonable idea of how much spark the engine requires If you don t have an accurate VE substitute one from something similar and run one or two percent richer than normal for safety As stressed before one thing to be avoided is lean fuel and a lot of spark advance The final fuel and spark values will have to be iterated because of the interaction between the two Knock Sensor There are 2 parts to the knock sensor system e The Knock Sensor screws into the engine block e The Knock Filter which is attached inside the Memcal See The MEMCAL Chap 4 Vol 2 page 20 The wire that connects the knock sensor to the ECM connects at terminal B 11 on the ECM The ESC logic and the M43 diagnostic logic are separate
87. Once the capture data has been loaded into the Capture buffer it can be played back or saved again to disk List Save The Save option enables the user to write data from the capture buffer to a disk file The user can select the start and end frames to be saved and can also store a brief description Information about the program used by the ECM which generated the data is also stored This program information is then used when the file is loaded by a List Read to find the appropriate ram script There are no limitations on file names or extensions The capture file can be identified as such by KalMaker by its header Function Menu This menu controls the ECM over ride facility available on VR VS only The ECM can be temporarily contolled by KalMaker for diagnostic purposes Changes revert after 4 minutes FIGURE 9 Function Menu The Function option is available for all calibrations which use a function script It enables ECM or PCM inputs and outputs to be overidden The alternative sensor input values may be entered by the user and outputs may be forced to user Vol 1 Chapter 3 Kalmaker Editor Menu Commands 51 Menu Functions defined states The altered inputs and outputs can then be viewed in a data list The List Function facility can alter engine operation as can Buffer Edit but alters internal ram or scratchpad memory not calibration memory The changes are temporary and are intended for diagnostic use
88. PMDR on page 168 and IAC DES RPMPN on page 168 b 11 White Red VN 815 Knock Sensor Input Connected to the knock sensor which is standard in the V6 and HSV V8 This is optional on std V8 The knock sensor is screwed into the water jacket drain plug on drivers side of engine bank To function a knock filter SNEF must be fitted either to Kalmaker Real time Board or in the Memcal b 12 c 1 Blue White VN Dark Blue JE Circuit 304 VN FAN RELAY CONTROL 404 JE c 2 Lt Green Black VN Light Blue circuit 366 A C Relay Control JE c 3 IAC It green black Circuit 444 iac coil B LO c 4 IAC Lt green white Circuit 443 iac coil B Hi c 5 IAC It blue white Circuit 441 iac coil A HI Vol 1 Chapter 6 Wiring Information 87 Terminal Listings Table 20 ECM Connector Table continued c 6 IAC It blue black Circuit 442 iac coil A LO c 7 Lt Blue VN Circuit 446 4th Gear O Drive Temp c 8 Not Used c 9 Not Used c 10 YELLOW Circuit 410 COOLANT TEMPERATURE SIGNAL c 11 Lt Green 432 MAP Sensor Input c 12 TAN Circuit 472 MAT SIGNAL c 13 DARK BLUE Circuit 417 TPS SIGNAL c 14 GRAY Circuit 416 TPS 5V REFERENCE c 15 c 16 ORANGE Black VN Orange Circuit 540 VN 12V BATTERY supply JE 240 JE d 1 BLACK Circuit 151 SYSTEM GROUND d 2 BLACK Circuit 452 TPS CTS MAT Ground d 3 BLACK VN Circuit 450 SYSTE
89. SH RAM Similar to an EEPROM but larger and faster Can be programmed and erased in situ FLOATING POINT A data format 4 or 8 bytes in length used to represent numbers with a decimal point Floating point calculations are usually much slower than integer calculations HEX Base 16 0 9 A F It is very easy to represent binary base 2 numbers in hex and vice versa hence its widespread use INT Integrator INTEGER A data format 2 or 4 bytes in length used to represent whole numbers KB Kilobyte or 1024 bytes 210 MAP Manifold Absolute Pressure MASK A byte where the value of each bit turns an option or piece of code on or off Vol 1 Chapter 17 Glossary 225 Glossary Table 36 MAT Manifold Absolute Temperature MB Megabyte 1024 1024 bytes 220 Sometimes used for 106 bytes MEMCAL The name for the replaceable cartridge containing among other devices an EPROM This EPROM contains the program and data read by the ECM MPI Multi Point Fuel Injection NIBBLE The upper or lower half of a byte 4 bits NON VOLATILE A type of memory which retains data when power is removed NVRAM Non Volatile Ram 02 Oxygen Sensor Voltage PC Personal Computer PCM Power train Control Module PFI Petrol Fuel Injection same as MPI PROGRAM Data read by a controller interpreted by it as machine instructions then used to control the controller RAM R
90. See any good text on 3D Computer Graphics for an explanation These matrices are stored in a transform file in the directory from which the calibration script was loaded If this file isn t found default transforms are used Making transformations is straightforward e Use the Ortho option to scale the object to a suitable size e Rotate it around suitable axes until it appears in a convenient viewing position try X then Z e Fine tune by scaling and translating Once the object is in a suitable position the transform matrix can be saved and the object will appear in the same position when next viewed The buttons on the 3D View screen are divided into 3 groups The top group of four move the variable on the screen The 38 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions operations Translate Rotate and Scale can occur on any of the three axes X Y or Z the next group The operations occur on a mouse press A left mouse press operates in one direction a right mouse press moves in the opposite direction There is no keyboard equivalent to this While the mesh is moved around the screen it is wireframed as PC computer graphics are not fast enough to fill it in real time When the object is no longer being moved via a mouse press it is filled and labelled On slower PCs this operation can take a few seconds Edit3 3D Ortho The Ortho option sets the view volume an imaginary cube drawn around the obje
91. Transferring an untried Vol 1 Chapter 3 Kalmaker Editor Menu Commands 45 Menu Functions calibration or one which is very different to that already existing may cause erratic engine behavior and is not recommended The erratic behavior is not caused by the transfer itself but by the new calibration values Important Transferring a calibration via Link CalTx while the vehicle is being driven on a road may cause unsafe or erratic vehicle operation List Menu The List option is available for all calibrations which use a ram script It enables a data list to be specified by the user and viewed as text The data list can be captured as it is displayed for playback or can be written to a file Stored data lists may also be loaded into capture memory and played back off line The List facility can be viewed as a stand alone subsystem within KalMaker It relies on information contained in a ram script which is automatically loaded with a calibration script The ram script contains data names units and conversion information List Load The Load option enables a ram script to be loaded manually The script may be loaded without any calibrations being present This allows KalMaker to be used to view and capture data lists transmitted by a standard ECM In order that the correct script is loaded the user should be aware of the program being used by the calibration in the ECM The way to determine this is as follows e loa
92. Trouble Codes DTC and ETC groups describe the engine trouble codes These groups should be read in conjunction with the factory workshop manual See Trouble Codes on page 205 e DTC MSK Diagnostic Masks e DTC DTC MSK Diagnostic Masks e DTC LOG Trouble Code Logging e ETC M13 O2S Slow e ETC M14 CLT High Signal Low e ETC M15 CLT Low Signal High e ETC CLT Default Coolant e ETC M21 TPS Signal High e ETC M22 TPS Signal Low e ETC TPS Default TPS e ETC M23 MAT Low Signal High e ETC M24 Vehicle Speed Sensor e ETC M25 MAT High Signal Low e ETC MAT Default MAT e ETC M33 MAP Signal High e ETC M34 MAP Signal Lo e ETC MAP Default MAP e ETC M35 Idle Speed Error e ETC M41 No Crank Refpulses e ETC M42 EST or Bypass Fault e ETC M43 Knock Sensor e ETC ESC Default Retard e ETC M44 O2S Lean e ETC M45 O2S Rich e ETC M51 Eprom Bad 120 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups e ETC M55 AD Error Table 27 Engine Trouble Code ETC Variable List DTC MSK EOPTX diagnostic option mask DTC LOG NOMCNT successive powerups with no malfs ETC M14 CLTTH m14 clt threshold ETC M14 RUNTIM m14 runtime enable ETC M15 CLTTH m15 clt threshold ETC M15 RUNTIM m15 runtime enable ETC CLT DEFCLT max default clt ETC M23 MATTH m23 mat threshold ETC M23 RUNTIM m23 runtime enable ETC M25 MATTH m
93. Volume 1 Kalmaker Street Pro 3 User Guide KALMAKER Garner tor Den Vol 1 Kalmaker Street Pro 3 User Guide 1 Vol 1 Kalmaker Street Pro 3 User Guide Chapter 1 Chapter 2 Chapter 3 Introduction ee ee e a ee ee Copy Protection 10 Kit Contents 10 PC or Lap Top Specifications 1 KalMaker Installation 13 Pre installation Issues and Checks 13 Installing the Software onthe PC 14 Software Dongle 15 Installation Problems 15 Configuring Laptop Screen Resolution 16 Kalmaker Editor Menu Commands 17 Main Menn 18 Menu Functions 18 About menu 19 Setup Menu 19 Environment 19 Parallel Port 20 Glock Factor ee een Sins Soe eee ae 21 Capture Buffer 22 System 22 Buffer 1 amp 2 Menu 22 Read 25 Edit 25 Edit View 27 Edit Load ee 28 Edit Clip 28 Edit Clip Add Clip item 29 Edit Clip Delete Clip item 29 Edit Clip Copy Clip item 29 Edit Clip Read Clip
94. a Red and Disable it Using the Diagnostic Functions Once the PC has been connected to the ECM you can use the diagnostic functions within KalMaker as follows 1 Run KalMaker by entering c KAL3 KAL3 2 From the LIST menu choose LOAD 3 Click OK 4 Select N03 RS Note This procedure only applies if you have not yet opened a calibration 5 Click OK 6 From the LIST menu select VIEW The following choices are available e Engine inputs e Outputs Vol 1 Chapter 15 Troubleshooting 201 Common Engine Problems e All e Diagnostic 7 Select Diagnostic The diagnostic screen is displayed You can now see the output of the sensors etc To use the datalog function e Select List Capture See List Capture on page 47 Hint You can save the capture for later viewing Open your saved capture files with the commands on the LIST menu To view the outputs from the sensors only 8 From the GAUGE menu select LOAD 9 Load the N03 GS file 10 From the GAUGE menu select VIEW To exit this screen press the ESC key on the key board Common Engine Problems Misfiring Engine misfiring may be caused by a number of things for example ignition module distributor coil and plug leads Another cause may be an overly rich mixture The A F ratio on the meter may actually indicate a ean condition due to the increase in unburned fuel in the exhaust gas Misfiring can also cause catalytic converter overheating and da
95. a very different VECT value than at the same spot in the main VE map at say 1200 or 1400 rpm Note If this option is not selected the idle fuel load points will be operated in the original main fuel map 124 FUL OUT VE inthe same manner as the factory software Very accurate idling can be achieved even with large cams It is assumed that you have a calibration loaded in accordance with Loading a Calibration To Calibrate in Real Time on page 133 and Pre Calibration Settings on page 137 1 Start the engine 2 Select Buffer 1 Edit Hint Press 1 then e 3 Scroll down to 11 GEN OPT EOPTCA 4 Click to enable the Vect Enable button 5 Once the engine is running adjust idle speed with the variable IAC DES RPMMT for manual trans or IAC DES RPMPN for auto Adjusting this variable should cause the idle speed to move up and down accordingly If idle quality is poor increase Base Idle Advance SPK BAS IACADV on page 167 If the engine is hunting up and down usually caused by acam change See Hunting at Idle on page 148 6 If the engine is pinging detonation go to the Main Ignition Advance map SPK BAS RUNADVA on page 167 Note If the engine is fitted with a knock sensor watch the Retard guage to see if timing is being retarded due to detonation You can see exactly where it is happening so now you can make adjustments to the advance to correct it See Knock Sensor on page 67
96. ace 206 Alpha N 169 Auto Transmission Nuetral Safety Switch 92 Torque Converter Clutch control wiring 90 B Backup Mode 98 205 Backup resistors 199 200 banked injection 75 Base Specific Fuel Consumption 78 batch injection 74 Battery Supply 91 93 Common Connections to 91 Block Learn 171 Block Learn Cell 172 Block Learn Table 173 Block Learn term 172 Block Learn value 172 breakpoints 151 CG Check Engine Soon Light 89 Vol 1 229 clock factor 21 198 Closed Loop 206 207 Correction 173 idle 145 Closed Loop Correction Terms 161 Closed Throttle Fuel map 145 Code 21 155 Common Ground 90 91 94 95 configuration file create 15 Coolant Temperature Fan Control relay aignal cesses Sensor reference signal SIENA 45 res Trouble Code 207 Counts pulses 93 cylinder select 64 D datalog function 202 Deadband 145 deadbands 151 Deceleration enleanment 65 fuel cutoff 65 Default TPS 141 155 DGN 105 DGN MSK MASKx 168 Diagnostic mode 205 diagnostic mode 206 Diagnostic Mode 98 Distributor Reference Signal 91 Dongle 10 dongle 14 15 129 dual plane manifold 74 duty cycle 74 E Electronic Control Module Air Conditioning Reference 91 ALDL diagnostic 95 Connectors 85 86 Terminal Descriptions Control of EST 94 Crankshaft Location Reference 91 Engine Speed Reference 91 230 Vol 1 Fan Control 92 Field Service Mode 206 Manifold Air Temp Reference 93 T
97. aker e Scripts Several scripts are loaded into Kalmaker when the program starts It is important to know what role these scripts play For detailed technical information on the Kalmaker Environment refer to Volume 2 Chapter 3 Kalmaker Environment on page 5 Vol 1 Chapter 2 KalMaker Installation 13 Installing the Software on the PC Installing the Software on the PC The installation of KalMaker on the PC is a straight forward procedure However you MUST adhere to the following instructions EXACTLY 1 Write Protect the original disks Hint Itis a good idea to make a backup of the original Si disks at this time and store the originals in a safe place Insert the KalMaker Disk 1 into the 3 5 disk drive Log on to that drive eg lt cd a gt Assuming you wish to install the program on the hard drive recommended at the prompt type INSTALL The installation process has now been initiated Follow the on screen instructions You are prompted for the name of the drive to install the program on During the installation process you will be also be prompted for numerous paths or direc tories as to where to install KalMaker and its compo nents It is recommend that you install KalMaker in the default locations For your reference the fol lowing outlines the suggested file organisation The installation process will take a minute or so Install the scripts on Disk 2 When the installation process is
98. an t open list file file If two or more 2D variables are required on a page the layout is specified with a list file An error occurred while opening the indicated list file E1802 The number of rows and columns can be specified in the list file by a line of the following format rows cols The list file argument begins with a and is not of the above form E1803 If the list file line is not of the above form it must consist of a single variable name per line This error is displayed if an error occurred while reading a list file argument E1804 The variable name specified in the list file cannot be found in the loaded calibration script E1805 Can t open output file file A plot file can be saved as a vector plot in either HPGL or Postscript format or saved as text An error occurred while opening the indicated plot output file for writing E1806 Can t open output file file When 3D variables are viewed as 3D objects the screen can be saved as a PCX paintbrush bitmap An error occurred while opening the indicated pcx output file for writing E1807 Can t write output file file When 3D variables are viewed as 3D objects the screen can be saved as a PCX paintbrush bitmap An error occurred while writing to the indicated PCX output file E1808 Error writing 3D config file The orientation of 3D variables when viewed as 3D objects can be saved to a file An error occurred while opening the indicated 3D con
99. andom Access Memory Memory which can be read from and written to It can be static or dynamic memory It can also mean memory that can be accessed in any order as opposed to sequential memory such as tapes Read Only Memory ROM An EPROM is an example of ROM but typically a ROM refers to a masked ROM which cannot be erased SAE Society of Automotive Engineers STATIC Memory which doesn t need to be constantly refreshed to retain data TBI Throttle Body Injection also known as single point or low pressure injection TCC Torque Converter Clutch TCM Transmission Control Module TEXT When used to describe a file the same as an ASCII file TPS Throttle Position Switch VAC Vacuum baro map Vol 1 Chapter 17 Glossary Glossary Table 36 VATS Vehicle Anti Theft VOLATILE A type of memory which loses data when power is removed VSS Vehicle Speed Sensor WORD A unit of data two bytes 16 bits in length Vol 1 Chapter 17 Glossary 227 Glossary 228 Vol 1 Chapter 17 Glossary Numerics 290 ETC MAP DEFMAP 155 3D maps 104 A AC on Signal 92 acceleration enrichment 65 adapting a calibration 127 Advanced Variables 103 AFR Timeout 158 Air Conditioning Compressor clutch on reference air intake temperature 128 ALDL Diagnostic Terminal 90 fuel pump circuit 96 TCC circuit 96 terminals 95 ALDL data stream 206 ALDL interf
100. ant Program Reference Once the View option has been selected the mouse cursor is hidden to improve performance Pressing the SpaceBar or Escape key exits the display and enables the mouse cursor The View option discards the data once it has been displayed Plot Menu This menu facilitates plotting in several formats FIGURE 11 Plot Menu The Plot Facility enables either a single 3D or one or more 2D variables to be dumped as text or viewed as line plots Output Vol 1 Chapter 3 Kalmaker Editor Menu Commands 55 Menu Functions is either to screen or to a plot file which can be one of two common formats The plot file is intended to be read by a third party plotting program such as a CAD package or HPGL Plotter Emulator A single 3D variable 3D VAR x y is plotted as a number of 2D variables These plots can be of constant X or constant Y corresponding to different slices of a 3D plot The required 3D variable can be selected from a pick list The vector font file must be loaded for the Plot facility to work The method for selecting 2D variables is different to that used for 3D Normally several related 2D variables are plotted on the screen or page The variables names are read from a file containing one or more names together with formatting instructions The list file directory should be on the input path directory list The list file is a simple text file Its format is rows cols specifies the required l
101. are written to it If the file already exists the user is prompted to overwrite the existing file Registration The registration option allows the user to store a small amount of calibration and customer information together with the date inside the calibration in encrypted form When selected and if registration is enabled for the calibration which has been loaded an edit screen is displayed containing the date and relevant registration fields They may be edited with keyboard keys using TAB or the mouse to select new fields If the first key pressed in a field is nota RIGHT ARROW the field is cleared Table 14 Registration Exit Keys ExitKey Function Cancel Any changes made are lost Save Any changes made are saved to the global buffer The buffer must then be written to a disk file Info The info option enables the user to store several lines of information about a calibration in an information file The information is stored together with the calibration name in an info file with a standard name of kal inf one per binary directory If a record is not kept of the contents of each calibration the information can easily be forgotten especially when large numbers of files are generated The information which can be stored in a file name is limited especially with DOS naming conventions The info option is a simple and limited solution and if more is required than simple storage of information the user
102. as been set the Undo variables are transmitted to the ECM This enables the effect of a group of changes on engine operation to be gauged Edit Clip cLear All Clip The Clip Clear option clears all buffers used by the Clip facility Vol 1 Chapter 3 Kalmaker Editor Menu Commands 29 Menu Functions Edit Help The Help option displays a screen of information about the current variable Included in the help are the minimum and maximum units that the variable may take and references to related variables The Buffer Help option allows the user to navigate through help screens whereas the Edit Help option is intended to give only information on the current variable Edit Undo The Undo option copies the Undo Buffer to the Local Buffer The Undo Buffer contains the same value as the Global Buffer at all times Whenever an Edit screen is entered a copy of the calibration variable is read from the Global Buffer and saved to the Undo Buffer This can be a single value or a complete 2D or 3D map If the user then Edits and changes the variable and then requires the variable to be set to the value it had before the changes the Undo function copies the Undo Buffer to the Local Buffer Whenever the Local Buffer is Saved the Undo Buffer is updated with the same value This means that an Undo operation can only restore the variable to the value it had at the last Save With 3D Edit screens the user is prompted to Undo the current r
103. ation name Select Buffer 1 Write This will overwrite the VE table FUL OUT VE To check that the updated calibration has successfully been written to Buffer 1 1 Open the calibration in Buffer 7 Both Buffer 1 and Buffer 2 calibrations should have the same name Select Buffer 1 Diff To Screen Both Buffer 1 and Buffer 2 calibrations should have the same name verifying that you now have the new data in your current calibration in Buffer 1 Note Once you have set VE Update you will most likely still need to do some manual adjustments Setting Closed Loop VE Table Manually You can tell if the VE isn t correct in Closed Loop by watching the Short Term Fuel Trim gauge STFT on the Gauges Screen If it reads under 100 it is rich If it reads over 100 it 176 Vol 1 Chapter 14 The Volumetric Efficiency Table Setting Closed Loop VE Table Manually is lean at that load point and can be corrected by sliding the appropriate VE bar up or down at that load point Slide the bar up to richen the VE or down to lean it out The aim is to set the VE s at all these load points in Closed Loop to achieve actual 14 7 This is very difficult to get exactly right however within a couple of points is considered close enough Note In Open Loop WOT if the VE s are wrong you have no way of knowing unless you use a Wide Band Oxygen meter Just because the commanded A F Ratio says 12 8 1 it doesn t mean to say t
104. auses the ECM to enter the Diagnostic Mode A 10 Circuit 437 VSS SIGNAL Connected to the Vehicle Speed Sensor VSS Input from the VSS provides a reference to the ECM which it uses to control the TCC and other functions If the VSS is not used See Vehicle Speed Sensor on page 67 ECM Terminal B 10 the park neutral switch connection should be grounded to the ECMs ganged common ground wire circuit refer SYSTEM GROUND on page 91 which is in turn connected to a secure engine ground With B 10 grounded the VSS systems self diagnostics will not set a trouble code to indicate a VSS problem A 11 Circuit 476 or ANALOG GROUND Connected to Terminal B of the MAT and MAP sensors 90 Vol 1 Chapter 6 Wiring Information Terminal Listings This circuit provides the analog ground for the MAT and MAP sensors Note DO NOT connect to common engine chassis ground A 12 Circuit 150 SYSTEM GROUND Connected to Terminal 85 of the fuel pump relay and should also be connected to the ganged common ground wire circuit from ECM Terminals D 1 D 3 D 6 and D 10 which are in turn connected to a secure engine ground B 1 Circuit 540 vn 12V BATTERY supply 240 JE This terminal should be connected through a 20 amp fuse to a constant NON SWITCHED 12V source battery post on the starter motor maxi fuse for Painless Wiring systems BAT connection on ignition switch etc The wire from this terminal can be ganged with
105. ayout GRP SUB VARO x variable name 1 GRP SUB VAR1 x variable name 2 GRP SUB VARNIx variable name N The first line is optional and is used ifthe user wants a different layout from the default It specifies the number of columns and rows used in the layout The layout line must be the first line if it is used Plot HPGL HPGL Hewlett Packard Graphics Language is a commonly used plot language which can be read directly by a HPGL plotter The language typically consists of pen select pen movement pen up and pen down commands If printer output is required the HPGL file can be read by an HPGL emulator which converts the plotter commands to printer commands HPGL plotter emulator programs typically enable the user to scale and rotate the plot as well as specify pen widths The default extension of all HPGL plots is plt A typical HPGL plot can use from 1 to 8 pens The pens used in the HPGL plot generated by KalMaker are 56 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions e Pen 1 Axes and Labels e Pen 2 Background Grid e Pen 3 Plot values Plot PostScript The PostScript language is a page description language commonly used by desktop publishing programs It can also be used as a plotting language and as a general purpose file transfer language by CAD packages such as AutoCAD PostScript format files can be edited with a text file to alter scaling or can be read by a PostScript interpreter
106. ble ECM Wire Color Circuit Number Description a 1 DARK GREEN WHITE Circuit 465 FUEL PUMP RELAY CONTROL a 2 Yellow Black VN Dk Green JE Circuit 463 VN Trip Computer VN JE 48 JE a 3 Not Used VN JE a 4 Not Used VN JE 86 Vol 1 Chapter 6 Wiring Information Terminal Listings Table 20 ECM Connector Table continued a 5 BROWN WHITE Circuit 419 CHECK ENGINE SERVICE ENGINE SOON LIGHT CONTROL a 6 PINK VN JE Circuit 439 VN 12V IGNITION supply 639 JE a 7 TAN BLACK JE Grey Red VN Circuit 422 Automatic Trans TCC CONTROL Circuit 422 Manual Transmission O D CONTROL Circuit 456 Manual Transmission SHIFT LIGHT CONTROL a 8 Not Used a 9 WHITE BLACK Circuit 451 DIAGNOSTIC TERMINAL a 10 BROWN YELLOW VN White Circuit 437 VN VSS SIGNAL JE 921 JE a 11 BLACK Circuit 469 MAP MAT Ground a 12 BLACK Circuit 150 SYSTEM GROUND b 1 ORANGE JE Orange Black Circuit 540 vn 12V BATTERY supply VN 240 JE b 2 TAN WHITE VN Circuit 33 VN Cranking Signal Input b 3 BLACK RED VN Black JE Circuit 453 EST REFERENCE b 4 not used b 5 PURPLE WHITE Circuit 430 DISTRIBUTOR REFERENCE b 6 b 7 b 8 Brown CIRCUIT 449 A C Request Input b 9 Kalmaker switch See Kalmaker Switch on page 70 b 10 Grey VN ORANGE BLACK Circuit 434 PARK NEUTRAL SIGNAL See JE IAC DES R
107. butor Interface KalMaker Street Pro 3 Variables 103 Chapter 8 KalMaker Street Pro 3 Variables KALMAKER CEE EEE EEN Garner tor Den Calibration variables can be broadly divided into the following three categories e Static Variables This covers the main spark fuel and volumetric efficiency tables These are variables which can be obtained on an engine dynamometer e Transient Variables Control of transient events such as AE DE and DFCO These are variables which can be obtained on a chassis dynamometer or by road testing e Advanced Variables The following variables are not essential to understand the system and should be initially turned off or calibrated out e High Resolution Block Learn e Twin Table Parameters Variable Types In addition there are four different types of variables ina calibration Zero Dimensional Variables These variables can be option bytes or mask bytes in which each bit means something The bits may turn certain pieces of code off or on or tell the program something about the drive train it is controlling For example bits can signify how many cylinders an engine has or whether there is a manual or auto transmission installed The program reads the option byte determines that an auto transmission is installed and performs say Torque Converter Clutch logic If a manual transmission is installed it would do Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 103 Variable Typ
108. calibration For example if you have a Code 21 or 22 the ECM switches to Default TPS which is assumed from RPM and MAP values See Code 22 on page 208 Always regularly check for trouble codes in List View If you have a trouble Code FIX IT The Default TPS map 291 ETC MAP DEFMAP tps rpm and the Default MAP 290 ETC MAP DEFMAP can be calibrated quite accurately if you take the time These are the maps used when Code 21 or 22 are set and we are running in Default TPS mode If you are running in Default TPS the TPS gauge will be jumping all over the place even at idle You cannot tune when in this mode To get out of Default TPS mode you must change the position of your TPS on your throttle body Make sure the plastic shaft bush is in place and for after market or home made throttle bodies one of these bushes may be the answer to taking out any play If there is too much play you may be able to get the correct voltage at idle but you might not get 4v at WOT It may be the case that at WOT the ECM will only see 50 TPS If this is the case you will lose throttle resolution which affects low speed driving and idle For example you can be cruising at 1800rpm At this speed TPS might normally be 7 but with all the slop in the shaft it is showing 2 This means you would still be in Idle Mode meaning you would only be getting Idle Spark 47 SPK BAS IACADV map With VECT enabled this is w
109. can also decrease the timout airfuel interval FUL AFR AFTDLY and the Closed Loop Fuel Idle Time variables FUL AFR IAF TMD for Drive and FUL AFR IAFTMP for Park Neutral Problems with Large Injectors For idle problems because of very large injectors you can adjust the variables FUL OUT NPWH and FUL OUT NPWL to force the injectors to single fire when the BPC is between these figues A Note on Cam Choice The idling part of the calibration can be the trickiest part to get right You can use a big cam and run a MAP sensor engine without dampening filtering the signal VAR MAP MAPQ A MAP sensor can only handle cam duration up to a certain size after which you may have to run the computer in TPS throttle position mode that is fixed fuel and fixed spark Vol 1 Chapter 12 Getting Idle Right 153 Idle Problems on Non GM Engines and Throttle Bodies relative to throttle position Street Pro 3 however has an optional feature in its software so that you can run a MAP sensor until engine speed reaches a set value below which it switches to TPS mode We have run a Crane 300 solid cam 264 268 degrees 050 with over 600 lift and Crane 288 solid in 5 7L V8 using a MAP sensor and both idled at 1200 rpm very well Most factory EFI intake systems are designed for torque as opposed to horsepower so installing a big cam will sacrifice low and midrange torque Choose a cam with high lift and don t
110. cessive heat Oxygen sensors have an operating range between 300 and 600 degrees celsius Temperatures in 66 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker Knock Sensor excess of 800 degrees will result in sensor damage e Testing with an ohm meter NEVER test the sensor with an ohm meter as this will feed several volts into the sensor and damage it Knock Sensor Including a Knock Sensor will provide your engine with some protection against engine detonation due to bad fuel elevation hot running labouring or a combination of any of these problems There are 2 parts to the knock sensor system e The Knock Sensor screws into the engine block and transmits a signal to the ECM when engine detonation occurs e The Knock Filter which is attached inside the Memcal See The MEMCAL Chap 4 Vol 2 page 20 The Knock Filter eliminates the noise that the Knock Sensor picks up allowing the detonation signal only if present to pass through to the ECM The wire that connects the knock sensor to the ECM connects at terminal B 11 on the ECM The ESC logic and the M43 diagnostic logic are separately enabled If you use a calibration set up for a knock sensor ina vehicle which doesn t have one then you must disable both ESC and M43 logic If no knock filter is installed and the system expects one it will get a continuous knock signal and pull out full retard even if M43 is masked See Knock Sensor ON on page 139 or See
111. correct If the fuel is not kept up to the engine the A F ratios become lean which can lead to detonation This must be kept in mind when adjusting the fuel settings ignition timing and boost pressures Clearly an engine under boost does not need excessive ignition advance as this will make the detonation problem worse Rich dense charges burn quicker less advance needed e The air intake temperature must also be considered Generally increased boost is equated with increased air intake temperatures which leads to a decrease in the intake charge density or its ability to carry oxygen and atomise with the fuel for a given volume As the air intake temperature rises so does the likelihood of detonation The magnitude of the effect of this temperature increase will be proportional to the efficiency of the intercooling setup i e 128 Vol 1 Chapter 9 Pre Calibration Checks Connecting the PC to the ECM the better the intercooler the lower the air intake temperature the less effect this will have Again keep this in mind when setting boost pressure fuel and ignition e Another useful indicator of mixtures is the exhaust gas temperature As the A F ratio becomes lean the exhaust gas temperature increases Suitable gauges are available from the supplier Connecting the PC to the ECM A Serial Port cable included in SP3 kit is used to connect to the serial port of your PC or laptop to the ECM SP2 used a Parallel cabl
112. covered by this reference 11 GEN OPT EOPTCIcriveline Spark retard enabled for smoother driveline spark engagement FB 11 GEN OPT EOPTC trqmgt This option limits spark advance for torque spark reduction DB FB 11 GEN OPT EOPTC two fan If this option is not set fan1 is software option controlled If set fani can be switch controlled hi freon pressure Fan2 is software controlled A5 B1 DB FB 11 GEN OPT EOPTC disable The block learn multiplier is used in the fuel blmcrn equation even if closed loop fuel mode is disabled This option disables the effects of block learn correction by setting the lookup value to 100 It does not stop the block learn cell from being updated A5 B1 DB FB 11 GEN OPT EOPTC Ipg This option together with the Ipg switch option enables Ipg spark crank and fuel control 03 Internal Variables The internal VAR groups describe the calculation of internal engine variables from input sensor values There are ten sub groups e VAR RPM Engine Speed Variables 29 30 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 107 Variable Groups e VAR CLT Engine Coolant Temperature Variables31 e VAR CAT Charge Air Temperature 32 33 e VAR TPS Throttle Position Switch Variables 26 28 e VAR MAP Manifold Absolute Pressure Variables15 22 e VAR BAP Barometric Pressure 23 25 e VAR O2S Oxygen Sensor Variables 34 36 e VAR NVR
113. ct Pressing the ortho button will turn the 3D view into a 2D mesh as it is positioned along the Z axis This operation is always the first to be performed if a new translation matrix is to be created All 3D objects use a default matrix which the user can change if desired Normally this option is not used unless the user wishes to create a new transformation matrix for the variable It has the effect of scaling the variable A large view volume will mean the size of the variable on the screen is reduced It always leaves the object positioned down the Z axis Rotation around the X axis then the Z axis is required to position the object in a suitable orientation It is a good idea not to make the view volume too small If the object is manouvered out of the view volume off the screen the fill algorithm can become confused and the object will be filled in the wrong order If this occurs just press the Undo option This will restore the object to its position when last saved by copying the original transform matrix to the one being used for display Normally the only options required will be to rotate the object around the Z axis To do this press the Rotate option the Z axis button The object will rotate on left or right mouse presses until the required orientation occurs Edit3 3D Translate This option will move the mesh along one of the three axes For this to occur an Axis button needs to be pressed after the Translate button A lef
114. ctor data needed is the seconds of injector opening per gram of fuel injected sec gram which is the slope of the fuel delivery curve Note The value is the size of ONE injector in seconds per gram of flow that is the amount of time it takes for the injector to flow one gram of fuel The non linear properties are second order and can be ignored To obtain this slope the injectors have to be tested at a minimum of two points in their linear range Note Most injector data uses the static or wide open flow rate based on horsepower per injector or 76 Vol 1 Chapter 5 Injection Modes and Injectors Base Pulse Constant volume per time for constant flow which is useless for calibration purposes If the injector constant is not correct the whole calibration will be out One of the benefits of a correct calibration is that pieces of it can be used again in other calibrations In this sense it is a description of certain engine parameters If it has been based on incorrect data it is useless except for the vehicle which runs it Injector constant increases with increasing engine size and decreases with increasing injector size In the following table Table 18 njector Table the left column is the injector type The next two columns are the data used in Street Pro 3 to calculate BPC which is Injector Rate x Cylinder Size BPC The remaining columns are the Base Pulse Constants of these injectors matched to the en
115. ctory should be at least this size E1708 Can t open translate report file file An error occurred while opening the indicated report file for writing E1709 Can t open translate binary file file An error occurred while opening the indicated binary file for writing E1710 Can t allocate translate buffer 1 An error occurred while allocating a buffer for the first binary calibration E1711 Can t allocate translate buffer 2 An error occurred while allocating a buffer for the second binary calibration E1712 Can t write translate report file file An error occurred while writing to the indicated report file E1713 Can t write translate binary file file An error occurred while writing to the indicated binary file E1714 Error reading info file file If an info file is found in the current calibration directory it is opened and read This error is displayed if the file is not the correct size or a file read error occurs E1715 Can t open info file file If an info file does not exist in the current calibration directory one is opened if data is to be saved This error is displayed if an error occurred while opening the info file E1716 Error writing to info file file An error occurred while writing to the indicated info file 192 Vol 1 KalMaker Application Errors E1800 Vector font file not loaded A stroked or vector font must be loaded for plot and 3D routines E1801 C
116. cylinder volume has changed so more fuel is needed Therefore in this example you would e Increase the base pulse constant The most important thing to do is to increase the base pulse constant so that the right amount of fuel is injected The following example illustrates the technique Say we have a 304 cubic inch engine which has been stroked to 355 cubic inches then FUL RUN BPC FUL RUN BPC 355 304 This works because the fuel injectors have been developed to have linear characteristics in their working range If the cylinder volume is so large that the injectors can t inject 62 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker Vehicle Modifications and Kalmaker sufficient fuel then the solution is to use larger injec tors NOT to increase the base pulse constant e Alter the main advance table Before altering anything you should have a good idea of how much spark the engine can tolerate If you don t look at a few calibrations or ask an experienced engine tuner The maximum torque area is most sensitive and if this has changed the spark values will need alteration The best approach is to take out more spark than is needed so that no detonation occurs then add it in small areas until detonation occurs Note Once an engine has detonated it should be allowed to cool as the detonation threshold is reduced and detonation will reoccur easily BE VERY CAREFUL WITH DETONATION IN ANY ENGINE ESPECIALLY
117. d Butter or Buffer2 with the calibration e select Buffer Info e the calibration script name and a brief description of the program is displayed e the ram script has the same file name as the calibration script but a different extension List Default There are normally several data lists to choose from The data lists differ because they display different combinations of the same variables eg input and output functions They can also display say engine and transmission variables separately The List Default option enables one of these data lists to be used as the default Edit data list 46 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions The Buffer Edit View option displays the default data list from within the Edit screen The data list is not selected from within Buffer Edit because the data list is viewed frequently and a default select option here would be a hindrance The default data list is saved together with tracking information to a track file by selecting Edit Margin Save The track file has the same file name as its associated ram script but a different extension The track file is automatically loaded with a ram script if it exists List View The View option enables the user to select one of the available data lists for display to the screen as text The actual information contained in the data list is calibration specific and is covered in the relevant Engine or Transmission Reference
118. d circuit from ECM connector Terminals A 12 D 1 D 3 D 6 and D 10 which is in turn connected to a secure engine ground See SYSTEM GROUND on page 91 A wire should be connected from the fuel pump relay Terminal 87 to the fuel pump positive terminal and also to Terminal G of the ALDL connector This connection will allow you to power up the fuel pump by supplying 12V to this terminal of the ALDL connector for test purposes A 2 Circuit 463 VN 48 Trip Computer JE Connected to the Trip Computer Connector Yellow Black VN Dk Green JE Note DELETE if not using a trip computer A 5 Circuit 419 CHECK ENGINE SERVICE ENGINE SOON LIGHT CONTROL Connected to the Check Engine Service Engine Soon light This circuit allows the ECM to provide a ground to the Check Engine Service Engine Soon Light thus illuminating the light to alert the driver to possible problems with the ECM individual sensors or wiring Power for this light should be provided from the gauges supply WE STRONGLY RECOMMEND THE INCLUSION OF THIS CIRCUIT in the re wiring process as this light is an important part of the systems self diagnostics A 6 Circuit 439 VN 639 12V IGNITION circuit Connected to a switched 12V source This circuit provides power to the ECM from a 12V switched source the ignition switch protected by a 10 amp fuse Power should be available at this terminal when the ignition key is in the run and start positions Depending on
119. d name are found along the help search paths E1601 Invalid help data file The help data file does not have the required header string E1602 Can t allocate help buffer The help data file is read into allocated memory where various operations are performed on it Caused by a memory allocation error E1603 Can t open help index file When a calibration binary is loaded the system searches the calibration script paths for the required script Once the script is loaded help 190 Vol 1 KalMaker Application Errors files of the same name but with different extensions are searched for along the help paths This error is displayed if no help files of the required name are found along the help search paths E1604 Can t allocate help index buffer The help data file is read into allocated memory Caused by a memory allocation error E1605 No help available This message is displayed if no help buffer memory has been allocated This could be caused by an unsuccessful search for either the help data file or the help index file or memory allocation errors in loading these E1606 Help decompression failure An error occurred when the help data for the current variable was decompressed E1700 Can t open dump file file An error occurred while opening the indicated dump file for writing E1701 Can t write dump file file An error occurred while writing to the indicated dump file E1702 Can t open dump
120. djusting the TPS Throttle Position Sensor on page 68 When the ignition key is turned on the ECM assumes the throttle is closed The ECM registers this position as 0 of throttle position It does this at every start up Note Throttle position is read as a percentage Zero equals zero throttle and 100 is full throttle To check for correct Throttle Position proceed as follows 1 Switch to the Gauges screen by selecting Gauge View Hint Use the keyboard shortcut keys G then V 140 Vol 1 Chapter 11 Pre Calibration Settings Custom Calibration First Steps 2 Check that the TPS percent is at 0 for closed throttle and 100 for WOT PS percent VEHSPD kph 6 T TPS should read 0 0 for closed throttle 100 for WOT FIGURE 19 Throttle Position in Gauges Screen At 0 the output voltage from the TPS to the ECM must fall within a set range in the ECM known as threshold points lf the TPS is outside of the threshold for a set time a trouble code is set which lights the SES light Service Engine Soon if fitted If a Code 21 or 22 is set the ECM will revert to Default TPS which affects engine idle The TPS reading will most likely be jumping all over the place when you attempt to tune the engine The threshold points for factory calibrations can be found in Kalmaker at Variable 280 ETC M22 TPSTH Low Threshold point set at 0 16 volts and variable 276 ETC M21 TPSTH High Threshold point set at 2
121. e Note Always make sure both the PC and the vehicle are OFF when connecting or disconnecting the cable Failure to do this will result in damage to the cable which will render your system inoperative and is not covered by the warranty Once plugged into the ECM connect it to the PC Serial Port Plug the dongle software protection device into the parallel port and then you can run the KalMaker program at the c gt prompt type cD KAL3 then KAL3 You are now ready to make some changes in Real Time or perform diagnostic functions with KalMaker Note As the automotive environment is very noisy electromagnetically always use genuine shielded KalMaker Cables as supplied in Kit to ensure reliable operation of the KalMaker Program KalMaker can be used as a Programming tool or a scan diagnostic tool as KalMaker Scan Pro is incorporated into the Street Pro Packages Vol 1 Chapter 9 Pre Calibration Checks 129 Connecting the PC to the ECM 130 Vol 1 Chapter 9 Pre Calibration Checks Chapter 10 KALMAKER CEE EEE EEN Garner tor Den Opening Loading and Saving a Calibration 131 Opening Loading and Saving a Calibration A Calibration can be opened form one of three sources e From file Calibrations can come from the files stored in the default Path List or calibrations you have saved and stored From floppy disc A disc that has a calibration saved on it in Kalmaker format e From SRAM
122. e Mode on page 162 and maximum power See Power Enrichment Mode on page 162 can take ratios down to 12 1 Thus stoich air fuel is a compromise It is too rich for maximum economy and too lean for maximum power see Table 31 Air Fuel Ratio Set on page 174 Open loop calibrations on the other hand don t need converters or O2 sensors to run The system reads the VE table value calculates the air in the cylinder looks up the air fuel ratio table and calculates the fuel pulse width If these aren t right the system has no way of knowing Thus a drawback of open loop is that the calibration must be correct or err on the rich side for safety There are two other modes of operation that should be understood before proceeding They are e Power Enrichment Mode e Lean Cruise Mode Power Enrichment Mode The ECM switches to Power Enrichment mode at wide open throttle as determined by the throttle position sensor when it moves past a certain point for example 60 throttle opening In this mode the ECM ignores the O2 sensor and commands a richer than 14 7 A F This is because engines develop more power with a slightly richer mixture but not too rich This is the area of tuning that interests hot rodders the most this is where the fuel delivery for all out power is determined Lean Cruise Mode In this mode the ECM commands a leaner A F than stoic 14 7 This is quite OK at light loads when the vehicle speed is above a cer
123. e calibration file file for reading E1404 Can t open Gauge Script file An error occurred while opening the gauge script file for reading This error occurs if a gauge script is loaded manually E1405 Can t allocate memory for file The gauge script is read into allocated memory where various operations are performed on it Caused by a memory allocation error E1406 file is not a Gauge Script The gauge script file does not have the required header string E1407 file is corrupted The gauge script file header information is inconsistent E1408 Can t load Gauge Script file for file A general error has occurred while opening and processing the gauge script file required for the loaded calibration binary E1409 Can t allocate gauge coordinates An error occurred while allocating memory for the gauge needle coordinate buffers These are required for high speed translation of the data received from the ECM or PCM E1410 Can t allocate lite coordinates An error occurred while allocating memory for the gauge lite buffers E1500 Can t find file A DOS critical error has occurred while creating a list of function script files for reading Usually caused by searching for a directory or drive which is not ready or doesn t exist E1501 No files found that match path No files have been found which match the function filelist wildcard E1502 Out of memory allocating file list An error occurred wh
124. e if it falls within a breakpoint plus or minus the margin The margin is the percentage difference between one breakpoint and the next It is not always constant as sometimes breakpoints are unevenly spaced Table 11 10 percent Margin Low BreakPoint High 20 20 22 38 40 42 58 60 62 78 80 82 98 100 100 Table 12 25 percent Margin Low BreakPoint High 20 20 25 35 40 45 55 60 65 75 80 85 95 100 100 Table 13 50 percent Margin Low BreakPoint High 20 20 30 30 40 50 50 60 70 70 80 90 36 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions Table 13 50 percent Margin continuea 90 100 100 The normal value for Margin is 50 percent which is the maximum At 50 percent margin an indicator is always highlighted However the system may also be interpolating from a neighbouring indicator and so if the indicator were to change by say 10 units the system may only see a 5 unit change If the margin is set to a small value an indicator normally does not stay highlighted long enough to be changed If the tracking variable exceeds the minimum or maximum breakpoint the minimum or maximum breakpoint is highlighted Note that tracking occurs on only one of the two independent variables and the user must select the other However a margin applies to both The X axis and Y axis margins
125. e programmed idle speed of 700 rpm the Idle Air Control motor IAC tries to reduce engine speed which reduces load and manifold pressure to say 30 kpa as the engine slows down At the same time fuel leans out and the engine begins to labour engine load and manifold pressure increases to say 90kpa as engine speed drops to say 400 rpm This calls for a large injection of fuel so if the engine doesn t stall it will suddenly shoot up to say 1000 rpm Meanwhile the Ignition Advance map is changing at its load points so as the IAC closes fuel drops off and the process repeats itself 148 Vol 1 Chapter 12 Getting Idle Right Set Idle Speed WARNING The views expressed below are the opinion of the author and there is no guarantee of accuracy Altering calibrations will effect exhaust emissions For Off Road Purposes Only To check to see that the problem is due to excessive overlap proceed as follows 1 You should have the laptop connected and linked to the ECM 2 Start and run the engine at idle 3 Click Gauge View to display the Gauges screen Hint Just press G and V 4 Check the BPW gauge and the Advance gauge 5 If they are both fluctuating the hunting is being caused by the camshaft 6 Determine which one is fluctuating the most and therefore having the most effect 7 If possible check the engine speed required for a decent idle and note the MAP kpa reading for that speed Hint You
126. e running closed loop Look at the transient fuel acceleration enrichment deceleration enleanment and deceleration fuel cutoff if necessary If you are running a catalytic converter keep in mind that if it is run too lean it can overheat Also if deceleration fuel is not working properly heavy decelerations can load the converter with fuel and overheat it Transplanted engine no changes When fitting a GM engine originally fitted with a Delco it is assumed that the original sensors wiring harness fuel pump etc are being used The following points should be noted Map sensor should be located above the vacuum take off otherwise the sensor hose may fill with fuel and response could be sluggish The sensor hose should not be too long for the same reason If a different radiator is being used make sure the engine runs at normal temperature If the engine is always cold closed loop won t be entered and the Air Fuel ratio will be obtained from the FUL RUN COLDAF table If extractors or twin converters are used the converters will take longer to light off and startup emissions may increase All exhaust pipe to the converter s should be stainless steel See the discussion above for changed inlet and Vol 1 Chapter 4 Vehicle Modifications and Kalmaker 65 O2 Sensor Positioning exhaust system e Be careful where you route the distributor wires Any wires carrying pulses may be susceptible to Electro Magnetic Int
127. e two sub groups e GEN IDN Calibration Identification 6 8 e GEN OPT Engine Options 9 14 Table 22 General GEN Variable List 9 GEN OPT EOPTA cco Enables fuel cutoff on a crank no crank transition This reduces the potential of a backfire 9 GEN OPT EOPTA invert The crank cutoff logic uses a crank input cco input which may be high or low when cranking occurs depending on where it is tapped This option inverts the crank input level 9 GEN OPT EOPTA lorpm Forces backup spark in a potential stall backup spk Backup spark is fixed to crank position and is more stable than est spark at very low engine speeds 9 GEN OPT EOPTAJlotps Forces backup spark if closed tps mode is backup spk set Backup spark is fixed to crank position and is more stable than est spark at very low engine speeds 9 GEN OPT EOPTA lookup Enables a variable commanded airfuel ratio run af obtained by table lookup If this option is not set commanded airfuel ratio is set to a fixed value AFR STOICAF 9 GEN OPT EOPTA idle blm If blm update has been disabled enable blm update if idle control is active and idle 02s reading indicates lean airfuel 10 GEN OPT EOPTB clt Allows an AC coolant sensor to be used sensor instead of the factory Bosch sensor 10 GEN OPT EOPTBjive int The ve update option is applicable only to update real time applications using a static ram The ve table value is updated according to the curren
128. ed to config file kal2 cfg System exits to DOS Type EXIT to return to KalMaker Buffer 1 amp 2 Menu These menus facilitate the comparison of two separate calibrations The idea is to load one calibration into one buffer and another into the second or make changes in one buffer and have the original in the second and note differences at a glance between the two Buffer 1 is intended for real time or main editing Buffer 2 is intended to evaluate differencing and facilitate copying 22 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions It is important to understand the data flow between these buffers FIGURE 3 KalMaker Data Flow A Buffer Read loads a calibration binary into the global buffer where it can be altered by edit commands Data is also transmitted to and from the global buffer and the ECM by Vol 1 Chapter 3 Kalmaker Editor Menu Commands 23 Menu Functions Cal Receive or Cal Transmit commands A Buffer Write writes the global buffer to disk FIGURE 4 KalMaker Buffer Operation There are two global buffers one associated with Buffer1 and one with Buffer2 Only the global buffer associated with Buffer 1 is used for communication with the ECM If Buffer Edit is selected and a variable edited the relevant variable is copied from the global buffer to a local display buffer This allows changes to be made and subsequently abandoned without altering the global buf
129. eing rich and gradually lean them off until the desired A F ratio is reached Always factor in a margin of safety to account for certain transient variables such as the occasional bad batch of fuel or high ambient temperatures that the vehicle may experience 174 Vol 1 Chapter 14 The Volumetric Efficiency Table How To Use VE Update Note False lean mixtures may be read on an A F meter due to several reasons One cause is camshafts with a high degree of overlap or Rotary engines with radical port timing Lean mixtures in this case are due to extra air being passed through the engine at low speeds How To Use VE Update This feature can only be used with the Kalmaker Real Time computer fitted with the RT102 board and Static Ram See Constructing a Real Time Computer Chap 4 Vol 2 page 13 1 Select the VE INT UPDATE button at GEN OPT EOPTCA on page 167 2 Select DISABLE BLM at the same location VE Update ignores block learn corrections but when you switch off VE Update there could be block learns there that will effect the Short Term Fuel Trim STFT on the Gauges Screen These will revert back to zero in due course but it may be confusing until it does The best option is to actually clear any block learns by disconnecting power to the ECM before using VE Update 3 Drive the car or run it on a Dyno 4 Hold engine speed as close to the load points as possible that is every 400 rom and every 10 kpa No
130. eliably delivered e For transient acceleration modes where fuel is required instantly and not at the next injection pulse Vol 1 Chapter 5 Injection Modes and Injectors 73 Synchronous Injection Modes In these cases fuel is injected asynchronously that is independent of reference pulses In asynchronous mode fuel is injected at a fixed rate usually 80 or 160 times per second Synchronous Injection Modes Single Channel Throttle Body Mode Single TBI injection TBI300 and TBI770 is used exclusively on 4 cylinder applications TBI injectors are usually bottom fed use low fuel pressure and are fired once per reference pulse This means that they only have one reference period to deliver fuel and consequently are very stiff deliver a large amount of fuel in a small amount of time Note This mode is switchable in Kalmaker Street Pro 3 and Workshop WO but the TBI programs are not available See GEN OPT EOPTBItbilpfi on page 107 Two Channel Throttle Body Mode Double TBI injection is used on V6 and V8 applications TBI 220 Two injectors in a dual plane manifold are are fired on alternate reference pulses The engine is effectively running as two x 3 or two x 4 cylinder units The two injectors are independent and may overlap both may be on at the same time Two injectors are used because the duty cycle is too severe for a single injector unlike a four cylinder which has more time between firings to deliver the
131. en Bar Bosch 280150024 b 218 Vol 1 Table 34 List Of Fuel Injectors 30 43 5 11 to 18 Red MP Bosch 280150756 30 43 5 11 to 18 Red MP Bosch 280150911 30 37 2 4 Green MP Bosch 30 37 2 35 Green MP DDK 30 55 MP 30 7 29 MP Bosch 280150035 30 9 290 13 8 pink ND 30 9 290 13 8 light ND green 31 43 5 11 to 18 Red MP Bosch 280150912 32 45 11 to 18 MP Rochest 15637677 I er 32 45 11t0 18 Red MP Bosch 280150756 32 55 MP Bosch 280150808 32 5 43 5 MP Bosch 280150804 32 8 Yellow MP Bosch 280150007 32 8 Black MP Bosch 280150044 32 8 39 2 MP Bosch 280155009 33 300 Bosch 0 280 150 804 33 1 300 Bosch 0 280 150 402 33 4 43 5 MP Bosch 280150951 33 9 300 Bosch 0 280 150 951 Vol 1 219 Table 34 List Of Fuel Injectors 33 9 300 Bosch 0 280 155 009 33 9 255 2 9 red ND orange 35 43 5 Blue MP Bosch 280150967 36 7 43 5 MP Bosch 280150003 36 7 43 5 MP Bosch 280150015 36 7 43 5 MP Bosch 280150024 36 7 43 5 MP Bosch 280150026 36 7 43 5 MP Bosch 280150043 37 40 2 0 Green CFI Bosch 280150402 2 25 DDK 37 1 43 5 Bosch 280150814 37 3 300 Bosch 0 280 150 003 37 3 300 Bosch 0 280 150 015 37 3 300 Bosch 0
132. erference EMI e The speed sensor constant should be changed if drive train parameters or tyre diameter have changed see e If the vehicle is much lighter or heavier than that the engine was originally calibrated for then you should look at transient fuel acceleration enrichment and deceleration enleanment variables O2 Sensor Positioning If installing an 02 sensor in a non standard application note the following e The 02 sensor should be located close to the exhaust port unless using an internally heated 4 wire sensor The closer the sensor is to the port the faster it heats up and the slower it cools down e It should be located in a region of continuous flow If reversion occurs the 02 sensor can give a false lean reading Also note the following phenomenon regarding oxygen sensors e Silicon based products including silicon based lubricants and silastic will damage the sensor and it will be seen as a white coating on the oxygen sensor Always make sure when using this type of material that it is suitable for emission vehicles Symptoms may be surging rough running and idle problems e Rich mixtures These can cause a carbon coating to build up on the sensor causing the sensor to not work correctly e Old age These devices have a finite life span usually around 100 000 kilometers e Leaded fuel The oxygen sensor will be gradually and irrevocably damaged if it comes into contact with leaded fuel e Ex
133. es Economy Light logic instead There are eight options per byte not all of which are always used One Dimensional Variables These single variables may be bytes or words two bytes They may represent anything e g counters delays air fuel ratios idle motor steps etc Two Dimensional variables These are also called ookup tables If you have ever written a computer program you will know that they are a sequence of bytes similar to a one dimensional array in a computer program Typical tables are motor steps vs rpm air fuel ratio vs time delay vs rpm etc Three Dimensional variables These are the 3D maps typically pictured in automotive literature They can also be thought of as an array of two dimensional arrays Typical tables are e air fuel ratio rom map e The dependent variable is air fuel ratio e The independent variables are rom and map e spark advance vs rpm and map e The dependent variable is spark advance e The independent variables are rom and map KalMaker Street Pro 3 can edit these tables on either axis Each variable in a calibration whether zero one two or three dimensional has a unique name by which it is identified Calibrations having different programs may have extra variables added while some variables may be omitted Variable Naming Convention KalMaker Street Pro 3 uses a consistent naming scheme which calls the same variables by the same names across different calibrations The
134. fer An Edit Save saves the local changes to the global buffer Important If RT Link is used the changes made to the local buffer are transmitted to the ECM In order for the global buffer to reflect the data in the ECM these changes must also be saved to the global buffer by an Edit Save If in doubt as to whether the ECM data is the same as that in the global buffer select Buffer Link CalRx to receive the ECM data and write it into the global buffer Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions The user is prompted to save data if on exit the local buffer differs from the global buffer FIGURE 5 Buffer 1 Menu Note The following options apply identically to Buffer1 and Buffer2 except where noted Buffer is identical in every way to Buffer2 except that it is used to transfer data to and from the ECM The purpose of Buffer2 is to enable calibration differences and translation but it can also be used to edit calibrations in exactly the same fashion as Buffer Read The Read option enables you to select the directory and file to load for subsequent editing and transfer to the ECM When this option is selected a file list of the directories listed in the Enviroment Cal field is displayed in order together with the selection TYPE IT You can specify a directory which is not part of the current configuration It defaults to the current directory Once a directory is selected a list of a
135. fig file for writing E1900 Can t open clip file file An error occurred while opening the indicated clip file for reading E1901 file is not a clip file The clip file does not have the required header string Vol 1 193 KalMaker Application Errors E1902 Can t allocate clip input buffer for file An error occurred while allocating memory required for processing the clip file E1903 Can t allocate clip output buffer for file An error occurred while allocating memory required for processing the clip file E1904 Error reading file An error occured while reading the indicated clip file E1905 Decompression failure for file An error occurred while decompressing the clip file E1906 Clip buffer full The maximum number of clip variables 256 has been reached E1907 Can t open output file file An error occurred while opening the indicated clip file for writing E1908 Can t allocate clip input buffer for file An error occurred while allocating memory required for processing the clip file E1909 Can t allocate clip output buffer for file An error occurred while allocating memory required for processing the clip file E1910 Can t write output file file An error occurred while writing to the indicated clip file E1911 No write access for xxx xxx Xxxxxx There is no write access for the indicated variable in the current script therefore it may not be altered
136. filter be used If you leave knock sensor switched on and you aren t running one the main advance will be retarded 6 to 12 degrees as soon as engine temperature reaches 50 degrees resulting in a very gutless engine The same thing happens if you install a MEMCAL with a knock filter in it but you don t have a knock sensor fitted Note Ifyou install a HSV 185 kw chip you must fit the knock sensor in the block and wire it to B 11 Vehicle Speed Sensor 7 If you are NOT using a VSS See Vehicle Speed Sensor on page 67 scroll down to No 260 DTC MSK EOPT1 and clear m24 These masks prevent the trouble code from coming on After you have altered each variable you will be prompted to save 8 Select Save if you wish to keep your changes or Discard if not Vol 1 Chapter 11 Pre Calibration Settings 139 Custom Calibration First Steps Fan operation Hi and Lo settings Idle mixture on Idle VE set to an amount that isn t so rich for non GM calibrations TPS Voltage Most brands of Throttle Position Sensors will provide an input to the ECM of 0 to 5 volts from fully closed to fully open This is great for engine swapping or using different throttle bodies It is one of the few sensors that usually doesn t need changing to a GM type If you are using an aftermarket non GM or modified GM throttle body however you must check the TPS voltage at closed throttle to ensure it is within an acceptable range See A
137. gine size above These figures are what we use in our Workshop software and the older version of Street Pro 2 Table 18 Injector Table Injector Injector Cylinder Tytpe Rate Size 2L 3 8L 5L 5 7L Std Black 219 x 500cc 1095 Std 206 x 633 1300 Std 235 X 625 1465 706 Cream 175x 625 1095 775 Blue 186 x 715 1335 945 Red 153 x 715 1095 As an example when using Street Pro 3 if you use a 5 7L Blue 775 injector in a5L choose the Injector Rate of 186 but change the cylinder size from 715cc to 625cc to suit the 5L Note Always use the Injector Rate matched to the particular injector If using Workshop or SP2 the Base Pulse Constant for the same engine would be 186 Inj Rate x 625 Cyl Size 1162 Vol 1 Chapter 5 Injection Modes and Injectors 77 Base Pulse Constant Note The Red 945 30 Ib Ford Motorsport injector rate is the estimated value we use Note how the bigger injector uses a lower Injector Rate figure If this bigger injector was installed without reducing the Injector Rate it would drown the cylinder with approx 25 more fuel Bigger Injectors need to be scaled down so that when at maximum torque the VE is approximately 80 to 90 See The Volumetric Efficiency Table on page 171 This the reason for the Injector Rate These figures are not critical and can be increased if you need a little more flow however it is recommended that you use the same figu
138. gine speed continues to drop and reaches the second deadband even more steps are added Usually the first deadband IAC SAG RDB1 is set at 150 rpm Therefore if your desired idle speed is 800 rpm See Setting idle speed for lumpy cams on page 149 engine speed can drop to 650 rpm 800 150 650 before steps set in TAC SAG STEP1 are added This is usually about 6 steps If engine speed drops further and reaches the second deadband 218 IAC SAG RPM2 then IAC SAG STEP2 steps are added usually 20 steps When running a bigger cam you often have to drop the deadband to bring the recovery into effect faster than if a standard cam was being used Exactly how much is a suck it and see approach but as a guide try dropping 220 TAC SAG RDB1 from 150 to 100 and add a few steps start with around ten steps to 221 IAC SAG STEP1 Note Make small adjustments to the steps to avoid the IAC adding the steps faster than it can decay them Similarly drop 218 IAC SAG RPM2 to 150 rpm Experiment with small increments and you will be able to achieve good idle with even the wildest of cams Throttle Stop Screw Adjustments The purpose of the throttle stop screw is to put the throttle blade in a position that allows the idle air control motor IAC to be effective If the throttle blade is closed too far throttle stop screw backed out the IAC even if fully opened will not pass enough air to idle If
139. gnostic codes can be turned on or off via the DGN MSK MASKx variable It is good practice to leave all codes on where applicable Open loop applications should disable the three O2 based codes M13 M44 and M45 Hint Note If the application is not running a knock sensor then M43 should be masked If the application is not using a speed sensor then M24 should be masked The mask does not entirely disable certain codes MAT CLT MAP and TPS codes are basic to the system operation If the codes are masked 168 Vol 1 Chapter 13 Calibrating Diagnostics they are still flagged internally and the system will use a default value For example if an M33 or M34 map code is set the system will calculate a default map based on TPS and RPM known as TPS Mode or Alpha N mode This may be necessary for engine with huge cams and or large bore throttle bodies multiple throttle bodies where the MAP sensor reading is erratic See Diagnostics Chap 14 Vol 2 page 103 Vol 1 Chapter 13 Calibrating 169 Diagnostics 170 Vol 1 Chapter 13 Calibrating The Volumetric Efficiency Table 171 Chapter 14 The Volumetric Efficiency Table KALMAKER CEE EEE EEN Garner tor Dern There are 3 parts to the fuel equation e The BPC INJ RAT x CYL SIZ See Base Pulse Constant on page 76 This is determined by injector size e VE percentage commanded Air Fuel Ratio This is preset and usually
140. grammable Array Logic 10 Protection Device 129 R reference pulse inputs 99 S Scan Pro 129 Security Device 10 semi sequential injection 75 Serial Port 129 cable 129 Service Engine Soon 141 206 SES light 141 Short Term Fuel Trim 161 171 Spark Advance 166 Retard 166 Sensitivity 166 SPK 105 Static Variables 103 stoichiometric 161 T TBI 220 74 TBI injectors 74 TBI300 and TBI770 74 TH 700 R4 90 three dimensional variables changing 128 threshold point 141 Throttle Position Sensor reference input signal refernce voltage Trouble Code nnise wiring connections throttle resolution 155 TOO MUCH SPARK ADVANCE 166 TPS Mode 169 291 ETC MAP DEFMAP 155 Transient acceleration modes 73 Vol 1 233 Idle 145 Variables 103 turbo supercharged engines 128 Twin Tables 70 125 137 V VAR 105 VAR KPH VSSCONST 61 Vehicle Service Mode 205 Vehicle Speed Sensor Disabling of 90 Wiring 90 Volumetric Efficiency 173 Z Ignition adjustments 166 234 Vol 1 D Driveline Spark Retard 109 F FUL LNC DELAFR is not in the list of variables Need to describe what you see here so that no mistakes are made when en abling Lean Cruise 179 G Get Commodore terminal listings These are TPI 88 H How do you read VE Tables from the ALDL connector 65 How do you save the current information you have made for the cali bration 176 I If A F isn t showing 14 7 1 Where should
141. hat s what it is With an A F meter and a dyno you can adjust the VE s until the A F meter shows the same as the Commanded A F Ratio FUL AFR RUNAFR Disable turn off the Block Learn Mode 1 GotoNo 11 GEN OPT EOPTCA 2 Select Disable BLM 3 Save This prevents the self tuning part from making any corrections Fnd a nice quiet piece of road You don t have to go fast but you need to drive at constant speeds Make a chart with the 10 20 30 etc kpa readings across the top then the rpm s down the left side in rows and columns Photocopy a bunch of them and have them on a clip board The Load Points in the VE maps See FUL OUT VE on page 168 are in increments of 400 rom and 10 kpa 4 Switch to the Gauges screen type G V 5 Hold the engine speed at each RPM and Kpa increment In other words hold engine speed steady at each load point so that the STFT can be read 6 Take note of the STFT at every MAP kpa load point and every RPM load point every 400 rpm 7 Ifthe STFT reads under 100 128 SP2 it is rich If it reads over 100 128 SP3 it is lean at that load point Vol 1 Chapter 14 The Volumetric Efficiency Table 177 Setting Closed Loop VE Table Manually 8 To adjust the STFT you must adjust the VE at that load point To do this switch to FUL OUT VE 9 Correct the VE by sliding the appropriate VE bar up or down at that load point Slide the bar up to richen the VE or down to lean it
142. he actual A F could be anything however there is no need for alarm provided the existing A F ratio isn t affecting performance the engine is not detonating and the Injector BPC is correct See Base Pulse Constant on page 76 If you have the luxury of an A F meter and it reads 13 1 but your gauge is showing 11 1 commanded it only means your VE is out You should correct this before making any further adjustments Note Oxygen sensors and A F meters are more accurate at lean ratios than rich that is ratios from 14 7 1 and higher are measured more accurately Vol 1 Chapter 14 The Volumetric Efficiency Table 179 Setting Closed Loop VE Table Manually 180 Vol 1 Chapter 14 The Volumetric Efficiency Table KalMaker Error Messages Descriptions KalMaker Error Messages Descriptions When you are using KalMaker you may come across various error messages The following guide describes the probable cause of the error message Menu System Errors Mn Sys Err 0106h A conventional memory allocation request failed The menu system automatically switches to the next available memory type if it exists 0107h An EMS operation failed or was invalid This will usually cause a switch to a different memory type 0108h There was an EMS save request but there was no installed EMS memory on this system 0109h Either all EMS pages are allocated or there are no free EMS handles 255 max 0202h An error occurred while
143. he Laptop as follows 1 Select Buffer 1 Link 2 Select All gt gt to PC Calibration Receive Note You can only do this in Buffer 1 3 The calibration is transferred to the PC and a progress bar is displayed indicating the rate of transfer 4 When complete the calibration in the laptop is the same as the calibration in the ECM Loading a Calibration To Calibrate in Real Time Once a calibration has been opened on the PC it must be transferred to the ECM The calibration is stored in the SRAM on the RT Board inside the ECM Note Each time we change to a different calibration in our Laptop we must Transfer it to the ECM if we want the engine to run on that calibration This process is known as Linking See Linking to the ECM on page 137 Vol 1 Chapter 10 Opening Loading and Saving a Calibration 133 Saving a Calibration Saving a Calibration If you make changes to an open calibration you will have to Save the changes or Discard them Note This procedure does not permanently save the calibration to a file on your laptop It only saves the calibration in the buffer To save the calibration to a file you must use the Buffer Write command If you try to exit or change to another calibration the message box Buffer has been modified Save or Discard is displayed If you wish to Save you will skip straight to Step 1 If you Discard all the changes are lost To save your changed calibration at any time
144. he axis maximum The axis maximum is normally chosen to be the nearest convenient value to the variable maximum The following keys can assist in editing indicators Table 7 Buffer Edit Keys Key Result F3 up F4 down F5 left F6 right The following topics apply for all Edit screens except where noted Edit View The View option displays the default data list see List Default Once the View option has been selected the Vol 1 Chapter 3 Kalmaker Editor Menu Commands 27 Menu Functions mouse cursor is hidden to improve performance Pressing the SpaceBar or Escape key exits the display and enables the mouse cursor The View option discards the data once it has been displayed The entry to and exit from the View screen are intended to be as easy as possible so that the user may toggle between Editing and Viewing the data list Edit Load The Load option transmits the current variable contained in the Local or Display Buffer see Fig 3 KalMaker Buffer Operation to the ECM For this option to be functional the loaded calibration must support Real Time operation and the data link to the ECM must be enabled The variable in the ECM corresponding to the variable being edited on the screen is updated with the current value Note that in order for the Global Buffer to be updated as well the changes made must be saved using the Save option If the AutoLoad option has been set see Setup Parallel
145. he current script therefore it may not be altered E2005 General Conversion Error An error occurred while converting from engineering to computer units E2100 No Emulator program loaded In order to transfer data only to the emulator with a PartTx both the program and data must have been previously transferred to the emulator via a Full Tx E2101 Buffer and Emulator programs differ The program which has been downloaded to the emulator differs from the program in the current buffer In order to download data from the buffer to the emulator the programs contained in each must be identical Vol 1 195 KalMaker Application Errors E2102 No printer port at xxx The program has been configured for an emulator at the displayed address but a valid printer port was not detected there E2103 EE08 not detected on Iptx xxxx The program has been configured for an emulator but none was detected at the port displayed E2104 EE08 not present The program has not been configured for an emulator E2105 Initialisation error on Iptx xxxx The emulator has been detected on the displayed address but has transmitted either no response or an incorrect response to initialisation E2106 Failure at EE08 offset xxxx The emulator program and the buffer program differ at offset xxxx 196 Vol 1 Troubleshooting 197 Chapter15 Troubleshooting KALMAKER CEE EEE EEN Garner tor Dern Data Conversion Anomalies You ma
146. here your VE will be coming from your Main VE Fuel map will have no effect because it switches out of Idle Mode at 3 1 Idle Fuel When tuning an engine you must first tune it to run right at normal operating temperature If you are running a colder than standard thermostat NOT RECOMMENDED then either change it to a 180F 82C or recalibrate your Charge Air Temp CAT tables nternal Variables on page 107 and VAR CAT CATFAC map rpm on page 108 otherwise it will Vol 1 Chapter 12 Getting Idle Right 155 Idle Problems on Non GM Engines and Throttle Bodies run lean one minute and rich the next depending on what temperature you tuned at and at what the temperature is at any given time If you tune your O2 voltage the red line in the STFT graph in Gauges View to be in the middle of graph you will be at approx 14 7 Depending on the quality of the MAP signal you are getting and you don t have too much cam overlap you can change your 103 FUL AFR IACAFR c1t allto 14 7 so that your Idle fuel will be in closed loop You can tune your engine to this idle setting within reason Note You can Clip Add this before you change it then Clip Copy it back Reset your 103 FUL AFR IACAFR clt back to the way it was The O2 voltage should now be higher that is somewhere in the top half of the STFT graph Experiment with these settings Generally give the engine the fuel it is happy with at idle also keepi
147. hieve a reasonable idle This will indicate the amount of fuel that is required to achieve a good idle Do NOT save this value Go to 11 GEN OPT EOPTCA Select VECT ENABLE Go to 123 FUL OUT VET Once again select the TRACK button and adjust idle quality When idle is good press the View button or go to the Gauge Screen and take note of the Oxygen Sensor value 152 Vol 1 Chapter 12 Getting Idle Right Getting in the Ballpark 10 Alter the VECT to achieve a voltage roughly in the middle 11 Go to 124 FUL OUT VE This is the main fuel map or the VE volumetric effi ciency map This is where the fuel is calculated 12 Press Fwd 13 Go to the 800 RPM map and select TRACK so you can see what KPA you are idling at 14 Make this value much the same as the VETmap and adjust neighbouring bars to similar values Note It is important to keep your maps smooth and hilly rather than mountainous At this stage you should select the VE UPDATE feature See How To Use VE Update on page 175 Running rich at idle when cold The variable FUL AFR IACAFR should handle cold starts adequately but you may notice on your Gauges screen at start up that the commanded AF AFR ratio is far richer than the values in FUL AFR IACAFR If this is the case you can change the timout airfuel decay FUL AFR AFTDCY Decrease the AFR vs Coolant temp values to see what affect they have You
148. his In theory you could unhook the computer and the engine would continue to run at 10 degrees if it had fuel e EST Mode When the engine reaches 450 rpm it is considered to be running and switches to EST Mode In EST Mode the computer controls the amount of advance e Diagnostic Mode This mode is mainly for setting timing and isalso controlled by the computer It should not be confused with Module Mode as it is just coincidental that it also fixes timing at 10 degrees Vol 1 Chapter 7 Distributor Interface Ignition Module Operation Diagnostic mode is activated by bridging the diagnostic link in the ALDL connector This switches the computer to a fixed timing output 10 degrees by default It can be changed in the software Ignition Module Operation The ECM determines engine rpm from the period between reference pulse inputs and outputs spark accordingly It effectively estimates engine speed from the last reference pulse At engine speeds below 400 rpm this scheme becomes inaccurate because of cycle to cycle fluctuations The ECM therefore starts with a fixed spark Backup Mode or Module Mode and switches control to the ECM EST Mode at engine speeds greater than 400 rpm Get info from source ref angle files and source ignition modules Distributor EST D4 Reference B5 Bypass D5 Ref Low B3 FIGURE 16 Ignition Module Figure 16 on page 99 illustrates the magnetic reluctor type ignition m
149. hrottle Position Signal 93 Electronic Spark Timing Control 94 Reference Signal 91 ESC logic 67 ESC logic 82 EST Mode 98 ETC M22 TPSTH 141 142 exhaust gas temperature 129 F factory calibrations 127 flashing error mode 205 Fuel Injectors Wiring Connections Pump alternatives to stock Backup Switch power supply 91 relay Control FUL 105 G gang injection 74 GEN 105 global buffer 25 group injection 74 l IAC Coil wiring connections 5 IAC 105 IAC SAG RDB1 150 IAC SAG RPM2 150 IAC SAG STEP1 150 IAC SAG STEP2 150 Idle Proportional Spark 157 Ignition Source 89 Vol 1 231 Inlet Air Temperature 69 Integrator 171 IPS 157 K KAL3 CFG 15 KAL3 TFG 15 KCFGEXE 15 knock filter 67 83 L Lean Cruise Mode 178 Limp Home Mode 205 Long Term Fuel Trim 172 lookup tables 104 M M13 168 M24 168 M33 169 M34 169 M43 diagnostic logic 67 82 M44 168 M45 168 main fuel tables 174 Manifold Air Temperature 69 Sensor reference signal 94 Trouble Code 208 mask bytes 103 Mass Air Flow Burnoff Relay supply voltage sseseneeeenn 91 Sensor analog ground urrun 90 power Supply ceseeeeeee ees 91 Mnifold Air Temperature Signal 93 Module Mode 94 98 N naming convention 104 O oil pressure activated fuel pump backup switch 91 Open Loop 206 option bytes 103 Oxygen Sensor 95 Ground 94 232 Vol 1 Trouble Code 207 P Pro
150. ibration effort should be directed at getting the VE table right The aim is to set the VE at each load point to a value that puts the STFT at 100 This translates to an actual A F ratio at or near stoic 14 7 1 at the exhaust pipe Note 124 FUL OUT VE is the main fuel map It is a 3D map consisting of RPM vs VE vs MAP Kpa Fuel Calculation There are three stages to the main fuel calculation e The mass of air in the cylinder is estimated assuming perfect conditions and adjusted for actual use with the VE table e The mass of fuel is then calculated by dividing the mass of air by the air fuel ratio e The injector pulse width is calculated from the mass of fuel multiplied by the injector constant Vol 1 Chapter 13 Calibrating 163 Mapping Fuel It is assumed that the engine starts and idles smoothly See Pre Calibration Settings on page 137 and Getting Idle Right on page 145 You can watch the effect the oxygen sensor has on the Short Term Fuel Trim guage STFT at different engine speeds and load points vacuum This gauge will tell you if it is too rich or too lean For example With the engine at normal operating temperature RPM 2000 MAP 40kpa and in Closed Loop meaning self learning tuning capability a STFT of 120 indicates a rich situation calculated by the oxygen sensor See ntegrator and Block Learn on page 171 so the VE map must be recalibrated Engine is ai normal operating fempersiuce ar
151. icates the discrete options desired e The Select option transmits a select message for these options e A button press now indicates the state of the selected options e The Override option now transits the state of the selected Vol 1 Chapter 3 Kalmaker Editor Menu Commands 53 Menu Functions options The discrete flags may be viewed via the List option Note that in the absence of further communication with the ECM or the modification is only temporary Selecting the List option establishes communication with the ECM and the modification stays in effect while the data list is being viewed The current discrete flags may be deselected via the Deselect option The ECM output or internal state takes its normally calculated value The Clear option clears and deselects all discrete flags Function Clear DTC The Function Clear DTC does two things e It clears the internal trouble codes e It clears logged trouble codes and the data associated with them It differs from the Discrete Clear DTC command which clears only the internal trouble codes Gauge Menu The Gauge option is available for all calibrations which use a gauge script It displays a data list in graphically using two basic displays gauges and lights Gauges display continuously variable outputs while lights display on off or discrete outputs FIGURE 10 Gauge Menu The displayed data list at present cannot be selected captured or written to a
152. ight 147 Set Idle Speed value See The Volumetric Efficiency Table on page 171 This can be very accurate depending on O2 sensor condition and location You should get the idle A F as close as possible to stoic before continuing If this is a new engine you can now run the cam in with VE Update on See The Volumetric Efficiency Table on page 171 On non GM engines and or modified engines however you may not be able to get a smooth idle The following paragraphs address several issues which cover most problems Hunting at Idle There are two causes for the engine hunting at idle e Lumpy Camshaft The standard calibration cannot resolve the MAP readings after the installation of a cam that has excessive overlap e Switching to and from the Default MAP This can be caused by a non GM or an aftermarket modified throttle body and or TPS See Stalling Stumbling Deceleration on page 150 Lumpy Camshaft After a change to a bigger cam the manifold vacuum will decrease With EFI manifold vacuum is measured in absolute pressure values Manifold Absolute Pressure which reads opposite to vacuum that is Zero vacuum is maximum pressure which is usually 100kpa With the stock cam the engine idled at approximately 40 kpa at 700 rpm With the bigger cam it is now trying to idle at 60 kpa The standard calibration s Fuel Map calls for more fuel at 60 kpa than 40 kpa which increases engine speed As engine speed increases above th
153. ile allocating memory for the function file list Vol 1 189 KalMaker Application Errors E1503 Can t open Function Script for file An error occurred while opening the function script required by the calibration file file for reading E1504 Can t open Function Script file An error occurred while opening the function script file for reading This error occurs if a function script is loaded manually E1505 Can t allocate memory for file The function script is read into allocated memory where various operations are performed on it Caused by a memory allocation error E1506 file is not a Function Script The function script file does not have the required header string E1507 file is corrupted The function script file header information is inconsistent E1508 Can t load Function Script file for file A general error has occurred while opening and processing the function script file required for the loaded calibration binary E1509 Serial Link failure A serial message has been sent to the ECM or PCM and the return message has either not been received or is incorrect E1600 Can t open help data file When a calibration binary is loaded the system searches the calibration script paths for the required script Once the script is loaded help files of the same name but with different extensions are searched for along the help paths This error is displayed if no help files of the require
154. in KalMaker then loaded into the EPROM using the EPROM burner software Kit Contents Contained within this KalMaker software package you will find the following e 3 5 Floppy Disks for an Intel PC Serial Port Interface Cable 10 Vol 1 Chapter 1 Introduction PC or Lap Top Specifications e Dongle e Kalmaker modified ECM fitted with RT102 SRAM EPROM one 1 Security Device PAL and Serial Port Interface FIGURE 1 Kalkmaker Street Pro 3 Note This document deals with the Street Pro 3 version of the Kalmaker software Where relevant references are made to older versions SP1 and SP2 and Workshop software PC or Lap Top Specifications As a general rule choose a reasonable brand Pentium 133 for use with Kalmaker Avoid using later models with USB ports only Kalmaker is still MS DOS based and will not work with Windows XP The following is the minimum specification for running Kalmaker e Your laptop must have a minimum screen resolution of 800 x 600 in DOS otherwise the screen can appear distorted or the page won t fit on the screen Some Kalmaker buttons may be inaccessible See Configuring Laptop Screen Resolution on page 16 e 8 Megabytes of RAM minimum 64Mb RAM is ideal the Vol 1 Chapter 1 Introduction 1 PC or Lap Top Specifications more the better e 3 5 Floppy Disk Drive e Hard Drive with at least 4 Mb of free space as a minimum Ideally start with a 4Gb hard d
155. ing on the VE table have to be 165 What do you do now How do you set up Injector Size in variable 111 138 What do you do with B10 when you are using a VSS and a non GM transission 92 What do you mean by reduce the spark 65 236 Vol 1 What do you mean TYPE IT 25 What has the ENgine Temp got to do with idle quality 152 What s a A F Meter 177 What s a SITE 128 What s AMBX 61 What s ESC Logic Waht s M43 Diagnostic Logic 67 82 What s the difference between Buffer 1 and A Buffer 23 Where can you read commanded AF ratio 177 Where is MAT correction variable in SP3 202 Which calibrations come with SP3 131 Why use a Baro sensor 69 Write line What is this 200 Y You can have up to 3 points of Lean Cruise at the lesser load points but back it off to about 1 5 to 2 as the load increases You shouldn t be able to feel any difference between on and off 179 Vol 1 237
156. ing the Base Pulse Constant will be difficult Set the BPC too low and the injector will reach its maximum flow but is capable of much higher flow rates Set it too high and the injector may reach its duty cycle too quickly If this happens you have to change the BPC and redo all of the VE table 3 Fill in the required data for your injectors See Base Pulse Constant on page 76 Distributor Reference Angle 4 Scroll down to No 64 SPK OUT REFANG 5 Double click this variable Different engine ignition modules have different Dis tributor Reference Angles You must ensure this varia ble is set for your combination Some of the common Ref Angles are e V8 Holden 60 degrees e V6 Holden 70 degrees e TPI Chev Camira 10 degrees e V8 Ford 70 degrees 138 Vol 1 Chapter 11 Pre Calibration Settings Custom Calibration First Steps See Distributor Interface on page 97 Knock Sensor 6 Turn Knock Sensor ON or OFF depending on whether you are using one or not See Knock Sensor on page 67 Knock Sensor ON e Scroll down to No 71 SPK ESC LOCLT and set to 50 degrees e Scroll down to No 262 DTC MSK EOPT3 and set button m43 Knock Sensor OFF e Scroll down to No 71 SPK ESC LOCLT and set to 152 degrees e Scroll down to No 262 DTC MSK EOPT3and clear button m43 Note Kalmaker does not come standard with a knock filter attached to the RT Board This is an option but generally we recommend that a knock
157. is section describes some details of the various electrical connections wiring components and related information to assist you in adapting a Delco ECM into a non GM or custom environment Every project is different so not all of this information may be relevant If you are using a complete factory wiring harness that has been removed intact from the donor vehicle you should find most of the connections listed in the following pages already in place This will substantially simplify the rewiring process and require you to merely thin out the wiring harness by removing unnecessary or unwanted wires and make the few connections necessary to wire in the Delco ECM into your vehicles existing wiring ECM Terminals The following information is a listing of the 56 terminal locations one 24 pin terminal and one 32 pin terminal in the two plastic connectors which attach the main wiring harness to the ECM The listings are based on the JE Camira VN Commodre V6 and V8 configurations Other GM models are similar Vol 1 Chapter 6 Wiring Information 85 Terminal Listings Back view of 32 Pin C D Connector Back view of 24 Pin A B Con FIGURE 13 ECM Connectors Note Remove the ECM from the wiring harness connectors before doing any circuit testing or modifications Terminal Listings Each terminal will be dealt with individually to show more clearly its role in the overall installation Table 20 ECM Connector Ta
158. ivalent That is single and double fire injectors have more time to deliver fuel and so have more control over it If the fuel inject period is greater than the inlet valve opening then sequential injection becomes equivalent to single fire injection all injectors firing simultaneously once per two revolutions Hint This is used on the Commodore VS Ecotech V6 and the VT V6 and V8 onwards Sequential Staged multi channel This was used on LT5 Corvettes which have four valves per cylinder and two separate inlet tracts It is the same as sequential injection except that two injectors are used instead of one above a certain engine load This enables two small injectors to be used instead of one large one for better atomisation and greater accuracy in fuel delivery Central Fuel Injection CFI or CMFI CFI is used on some US GM truck applications It uses a single injector together with individual cylinder delivery via nozzles and distribution block It is a cross between single point and multi point injection For further information on local and US GM hardware the GMSTG publication Fuel Injection is recommended See Factory Publications Chap 17 Vol 2 page 119 Base Pulse Constant The Base Pulse Constant BPC variable FUL RUN BPC is actually two constants in one It tells the system the cylinder size variable 112 See FUL OUT CYLSIZ on page 167 and the injector size variable 111 FUL OUT INJRAT on page 167 The inje
159. lar GM engine installed in a vehicle of similar weight and gearing You will have to install the GM distributor or timing pickup ignition module See Distributor Interface on page 97 The main steps are as follows e Get the injector constant right otherwise it will make it difficult to calibrate with any accuracy See Base Pulse Constant on page 76 e Set the number of cylinders to the right value Software cylinder select must match hardware 4 6 and 8 cylinder calibrations only work in 4 6 and 8 cylinder applications See Configuring the RT102 for the number of cylinders on 64 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker Vehicle Modifications and Kalmaker page 19 Try and use a fuel system fuel pump fuel filter fuel pressure regulator injectors from a vehicle that matches the reference calibrations to make things easier See Fuel Pump and Fuel Pressure on page 68 You should have an idea of the spark requirements of the engine you are calibrating This should allow you to estimate a spark table If you are unsure ask an experienced engine tuner Once the calibration has been set up See Pre Calibration Settings on page 137 start and run the engine If it backfires or detonates in certain areas load points reduce the spark and or increase the fuel in that area You can get an idea of accuracy of the VE tables by reading them from the Short Term Fuel Trim STFT on the Gauges screen assuming you ar
160. librations that are not included with the software package e g read the data straight from a Memcal or after market chip supplier KalMaker has a number of factory calibrations that have been converted to KalMaker format to make them suitable for Real Time calibration If you have a calibration that is not included in the list provided please call your distributor to arrange for it to be converted to KalMaker format to enable viewing comparison and editing You are now ready to link your PC Laptop to the ECM See Linking to the ECM on page 137 132 Vol 1 Chapter 10 Opening Loading and Saving a Calibration Opening a Calibration from Floppy Disc Opening a Calibration from Floppy Disc If you have saved a calibration on disc or have received a disc from another source proceed as follows Start Kalmaker in the usual way Insert the disc Select Buffer 1 Read Select TYPE IT from the Path List The Enter Path Specification box is displayed with C KAL3 by default 5 Overtype the default path with A A List of Contents of the disc is displayed 6 Select the appropriate file a gt Opening a Calibration from SRAM There are times when you may have to retrieve a calbration from your SRAM perhaps because you have mixed up experimental calibrations and you can t remember which one is which or you may have deleted your calibration from your Laptop You can upload the calibration in the SRAM back to t
161. ll files in that directory is displayed Choose a title from this list to load into the global buffer The default directory for read is prompted Click on this to select path and then O K Select calibration from list Edit The Edit option is the main feature of KalMaker It enables calibration variables to be viewed and edited On calibrations which support Real Time variables may be changed and transmitted to a running engine Variables may also be copied to a clip buffer and saved to a file Vol 1 Chapter 3 Kalmaker Editor Menu Commands 25 Menu Functions When Buffer Edit is selected a list of variables contained in the loaded calibration script is displayed The variables are displayed together with a number This number is the order of the variable in the script and is provided to assist navigation through the Edit variables When a variable is selected one of four Edit screens appears depending upon the dimension of the variable selected See KalMaker Street Pro 3 Variables on page 103 The term variable used below is applied to a variable of any dimension Whenever an Edit screen is entered the following occurs for all Edit variables e The calibration variable single variable or 2D or 3D map is copied from the Global buffer and written on entry to the Undo Buffer A copy of the calibration variable is also written to the Local Buffer e Any edit changes are made to the Local Buffer If the user selects the
162. loading a system font file 0204h An input device mouse error occurred This indicates that no mouse was found 0701h General memory allocation error 0704h General file read error 0705h General file write error 0801h File viewer could not allocate enough memory to read file KalMaker Application Errors E1000 DS1410 authorisation device not present The program cannot find the authorisation device required by the security script on any of the parallel ports at addresses 378h 278h or 3BCh Vol 1 181 KalMaker Application Errors E1001 DS1410 authorisation data corrupted The data read from the authorisation device is not internally consistent E1002 Can t load security file The security file cannot be found or an error occurred while loading the file E1003 DS1427 timer not present In applications where a timer is required the program cannot find a DS1427 timer button or the data read from the button is not internally consistent E1004 Program timed out dd mm yyyy In applications where a timer is required the timer button date for program execution has expired E1005 Can t open security script support del sec The security file dcl sec is not on the program support path or there has been a file open error E1006 support dcl sec is not a Security Script The data contained in the security file dcl sec is not internally consistent E1007 Can t allocate input buffer for support
163. lue of the current or highlighted indicator A 2D variable name is of the form GRP SUB NAME x where x is the independent variable Edit2 RTLink The RTLink option transmits the value of the indicator to the ECM as it is being changed either by keypad or indicator For the RTLink option to function the calibration must support RealTime updates and the Data Link must be enabled On 2D variables which support Track RTLink will toggle between the calculator display and the independent variable when the SpaceBar is pressed This is intended to give the user an indication of which indicator values are currently being used as Real Time updates data display and a mouse can t presently co exist without degrading system response times Edit2 Track The Track option automatically highlights an indicator based on the current value of the independent variable KalMaker tracks the state of this variable and if an indicator is highlighted it means that the value corresponding to that indicator is being accessed The Track option is available only on certain 2D variables The calibration must support RealTime updates and the Data Link must be enabled When Track is enabled the value of the independent or tracked variable is displayed instead of the calculator and the mouse cursor is hidden to improve performance Pressing the SpaceBar exits Track and enables the mouse cursor The RTLink option must also be selected for changes to occ
164. ly enabled If you use a calibration set up for a knock sensor in a vehicle which doesn t have one then you must disable both ESC and M43 logic If no knock filter is installed and the 82 Vol 1 Vehicle Speed Sensor system expects one it will get a continuous knock signal and pull out full retard even if M43 is masked Note If the system is used on non GMH engine a knock filter from a engine of similar cylinder bore diameter should be used There are many US systems for which Memcals can be obtained Vehicle Speed Sensor It is important to run a VSS but not essential There are several reasons why you should run a VSS The main function of this sensor is to control all Transient Fuel and Transient Steps Transient functions are those that occur between stages for example decelerating Controlling transient stages by delivering extra or less Fuel Spark and Idle Control Steps gives a high degree of drivability and Idle Control Without this sensor many engines stall when slowing to a stop The VSS also controls the Lockup Converter speeds Hint Aftermarket Speed Sensors are available that screw into the Transmission where the speedometer cable usually goes The speedometer cable piggy backs onto the VSS unit allowing the use of cable driven speedos Vol 1 83 Vehicle Speed Sensor 84 Vol 1 Wiring Information 85 Chapter 6 Wiring Information KALMAKER CEE EEE EEN Garner tor Den Th
165. mage Pinging If the engine pings when MAT is high adjust SPK BAS MATCRN MAT Correction Engine Won t Start Excessive Fast Idle when Warm You may want decrease the time that the engine fast idles at startup once warm This requires an adjustment of the Warmup and Cranking variables The accuracy of Warm up and Cranking variables are dependant on final bpw being correct If output fuel is correct at operating temps then usually the warm up and cranking will be 202 Vol 1 Chapter 15 Troubleshooting Common Engine Problems very close At normal operating temperature above 80 deg C there should be no fuel or spark or idle steps being added as the engine should be in closed loop To check this go to Engine All in the List View screen and check CLP AFR and CLT AFR Also there should be no TRA STEPS WARNING Do not adjust any of these parameters until you have tuned the engine at normal operating temperature and you are satisfied that your VE fuel maps are correct and spark maps are correct Usually these do not need touching but to decrease the time that the engine fast idles at startup once warm adjust IAC WUP RUNDLY clt Determining what this setting should be is a matter of trial and error Factory settings vary for example BAYA only has 4 second fast idle but AWZB has 12 seconds fast idle at normal operating temperature Vol 1 Chapter 15 Troubleshooting 203 Common Engine Problems 2
166. may have to hold throttle slightly open just to keep it running Setting idle speed for lumpy cams Lets assume you ve put a reasonable size cam in like a Crane 284 into a 5 0L Holden A happy idle speed with this cam is about 800 rpm and it will pull approx 60kpa MAP 1 Scroll down to 215 IAC DES RPMDR in the Cal Variables 2 Adjust to 800 rpm Note Don t adjust the throttle position stop screw on the throttle body at this stage This is not the way to adjust idle speed Note If you cant seem to get any response from Idle Speed or any other idle control you may have to reset the idle mode To do this hold engine speed above 2000 rpm for a few seconds and then return to idle If this doesn t work disconnect the ECM or the ECM fuse Vol 1 Chapter 12 Getting Idle Right 149 Set Idle Speed Scroll to No 47 SPK BAS IACADV to adjust the idle advance spark Increasing Idle Advance Spark will help the engine to run more smoothly with a bigger cam Increase Idle Advance Spark the same amount at the different load points for example increase to 28 degrees at 20 30 40 50 60 amp 70 kpa Adjust 80 amp 85 kpa to ramp smoothly down to 10 degrees at 90 kpa that is e 80kpa 22 degree e 85kpa 16 degrees e 90kpa 10 degrees The result is that if manifold pressure vacuum is fluc tuating between say 40 to 70 kpa the timing will stay the same Note When the engine is started it is
167. may prefer to use a database to record calibration information This could then provide links to workshop management programs and the like Vol 1 Chapter 3 Kalmaker Editor Menu Commands 41 Menu Functions When selected information relevant to the calibration such as file size name etc are displayed as well as the several test fields of calibration information The program opens the kal inf file in the binary load directory and searches for the file name If one is found the calibration information is read and displayed otherwise the fields are blank If a calibration has no entry in the information file the description will be initially blank If a calibration has no entry the description must be filled in and saved The fields do not wrap that is they are set up as separate lines of text 8 lines of 64 characters length Help The Help function is normally selected from the Buffer Edit Option The Buffer Help option is intended for situations where the user wishes to navigate quickly through the variable list When a calibration file has been loaded and the Buffer Help option is selected a list of calibration variable names is displayed A help screen is displayed for each variable name selected Dump The Dump utility enables the user to save calibration information to a text file The Dump utility writes out each variable name its value and units This dump is useful for comparing several calibrations at once or com
168. me to hundreds of lines if the calibrations are totally dissimilar The difference format is as follows e fa variable name is common to both calibrations and the variables differ the results are written out The variable name is written leftmost Buffer1 variables are written to the second column and Buffer2 variables to the third Units are written rightmost e Ifa variable name is unique to one calibration then the variable name is written leftmost The variable value is written to either the second or the third column depending upon which buffer it is unique to Units are written rightmost Unique variable names are separated by a line of hashes e Ifthe calibrations are the same no output apart from headers will be written There are two difference options e Diff to Screen The file is differenced to a temporary file and viewed The temporary file is deleted when the file viewing task is exited Note that locating the temporary file on a ram disk will soeed the dump e Diff to File The user is prompted for a filename The difference is written to the file and the task exits The file is a standard text file and may be viewed or edited with a text editor or imported into a word processor Xlate The Translate option enables the user to translate the data of the calibration in Buffer1 to Buffer2 Translation is pointless if the calibrations share the same program but can be useful if the calibrations have different p
169. mps it can be seen that for a change from standard tyres to 17 inch tyres on AMBX VAR KPH PPK decreased from 1250 to 1200 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker 61 Vehicle Modifications and Kalmaker You can scale according to this example Alternatively you can calculate the pulses per km knowing the tyre diameter final drive ratio and VSS to mainshaft ratio Hint It may sound a trivial adjustment to make but in some circumstances where the ECM is adapted to a hybrid vehicle this is important Failure to do this in one particular conversion saw the vehicle cut out at 40km h actual road speed due to the fact that the VSS constant was so far out of adjustment the ECM thought that 40km h road speed was really 255km h the high speed fuel cut off point Different Final Drive As in the above example VAR KPH PPK should be scaled so the right number of pulses per kilometer are input to the ECM Note The speedometer must be re calibrated separately as there is no connection between the speedo reading and the ECM roadspeed variable Engine has been bored or stroked but nothing else has changed The camshaft intake exhaust system and injectors remain the same If the engine has been stroked volumetric efficiency will change slightly and spark sensitivity will change because piston speed and acceleration have changed If the compression ratio has increased sufficiently detonation may occur Also
170. n light code 12 indicates the system is operational A code 12 consists of one flash followed by a short pause then two flashes in quick succession This code will be flashed three times If there are other trouble codes present they will flash in a similar manner See Table 32 on page 207 If no other trouble codes are stored Code 12 will continue to flash until the ground is removed from the Diagnostic terminal Trouble codes can only be obtained with the engine stopped Grounding the Diagnostic terminal with the engine running puts the ECM into the Field Service Mode In the Field Service Mode the Check Engine Service Engine Soon light will show whether the system is in open or closed loop In open loop the 206 Vol 1 Chapter 16 Trouble Codes Trouble Code Listing Check Engine Service Engine Soon light flashes 2 5 times per second in closed loop it flashes once per second To remove any stored trouble codes and extinguish the Check Engine Service Engine Soon light remove Battery power from the ECM for a period of 30 seconds When power is restored the light will go out and any trouble codes will have been removed from the ECM s memory Note ALWAYS BE SURE that the ignition key is turned off whenever you remove any fuse or disconnect the battery Trouble Code Listing The following is a list of trouble codes that can be set by the ECM to indicate problems with either the sensor or the wiring of specific circuits
171. n real time Important Note that the user can track a variable change it and have nothing happen This can occur when there are two or more tables for a particular function For example there may be a low temperature VARLO map rpm table and a high temperature VARHI map rpm table If the user tracks and changes VARLO map rpm when the coolant is hot and VARHI map rpm is actually being used then the low temperature table will change in real time As the system is using VARHI map rpm however nothing will happen to the engine operation No changes will be noticed until coolant temperature falls to the level at which VARLO map rpm is chosen Note that tracking occurs on only one of the two independent variables The user must select one of the independent variables For example if the variable VAR map rpm has rom breakpoints at 400 800 up to 6400 rpm and map breakpoints at 20 30 up to 100 map then the user must select the rom range in which map is tracked Once the rpm range has been selected engine rom must fall within this range plus or minus margin for the indicator to be highlighted Vol 1 Chapter 3 Kalmaker Editor Menu Commands 35 Menu Functions Edit3 Margin The Margin option configures the tracking margin For tracking to work assume we have a 3D variable VAR map rpm with map indicators at breakpoints of 20 40 60 80 and 100 map The map variable transmitted by the ECM used to track VAR map is tested to se
172. naming convention is Zero Dimension GRP SUB NAME 104 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups The empty square brackets mean a single byte or word variable the bits of which mean something different to magnitude One Dimension GRP SUB NAME A single byte or word variable the bits of which are its magnitude Two Dimension GRP SUB NAME var A 2D variable whose independent variable is var In this case NAME is a function of var eg IACADV map degrees means a two dimensional variable IACADV whose values are in degrees The variable is looked up depending on the value of map Three Dimension GRP SUB NAME vrx vry A 3D variable whose independent variables are vrx vry In this case NAME is a function of vrx and vry eg RUNADV map rpm degrees means a three dimensional variable RUNADV whose values are in degrees The variable is looked up depending on the value of map and rpm Variable Groups Calibration Variables are divided into six main groups e GEN General variables 6 14 e VAR Internal variables 15 40 e FUL Fuel variables 85 184 e SPK Spark variables 41 84 e IAC Idle variables 185 234 e DGN Diagnostic variables e OUT 235 259 e DTC 260 263 e ETC 264 315 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 105 Variable Groups General Variables The General GEN groups describe the effect of the available engine options There ar
173. nd write paths for KalMaker You should generally leave them at their default settings unless you have installed any components in different directories See Installing the Software on the PC on page 14 If this is the case use this command to set all paths in order for KalMaker to know where to read information from and write information to Choosing this command displays the Environment screen The fields contain the directory paths that KalMaker searches when finding files Edit the fields if necessary by typing in the path s using keyboard keys Use the TAB key or the mouse to move between fields If the first Vol 1 Chapter 3 Kalmaker Editor Menu Commands 19 Menu Functions key pressed in a field is not a RIGHT ARROW the field is cleared Table 2 Exit Key Functions Environment ExitKey Function Cancel Any changes made are lost OK Any changes made take effect immediately for the duration of the current session but are not saved to disk Save Any changes made take effect immediately and are saved to the config file kal2 cfg An example environment is listed below Table 3 Example Environment Field Path Description SUPPORT c kal KalMaker is installed here TEMP d drive d should be a ram disk SCRIPT c kal scr c kal scr contains scripts HELP c kal scr c kal scr contains help files CAL d c kal bin read calibrations from these paths INPUT d c cap c cap contains data captu
174. ndependent banks of cylinders each with their own block learns and integrators Grouped injection is used on 1992 93 Tuned Port and VR V6 Holden Commodores Alternating Double Fire double channel This mode is similar to banked mode except that each group of cylinders injects fuel each crank revolution as used on some high output four cylinder applications Sequential multi channel Sequential injection requires a separate channel for each injector Injection is similar to hardware single fire except that each injector is fired in sequence Sequential injection has the following advantages over double fire e Fuel can be timed to inlet valve opening allowing better low rpm emissions especially with large camshafts It is also beneficial for severe cam timing where fuel must be injected at certain valve openings to avoid standoff e On some applications injection timing can be individually delayed to cater for cylinder to cylinder variations due to manifold discrepancies e On some applications injection periods can be individually calculated to cater for airflow skew eg with high helix blowers Sequential injection has the following disadvantage e In order to be effective fuel must be injected while the inlet valve is open This reduces the time available for injection so that the injector must be made larger than the double fire Vol 1 Chapter 5 Injection Modes and Injectors 75 Base Pulse Constant equ
175. nder Integrator and Block Learn If the system is running closed loop any errors in the VE table are filled in by the Closed Loop Correction Integrator and the Block Learn Table The closed loop correction corrects for short term errors the block learn table corrects for longer term errors Stoichiometric means 14 7 to 1 air fuel ratio which is the air fuel ratio at which fuel burns most efficiently The DELCO Engine Management System is set to read 14 7 Air Fuel or A F Ratio when in closed loop at No 100 FUL RUN STOICAF For the system to enter Closed Loop the A F value obtained from the FUL OUT RUNAFR table must be equal to FUL RUN STOICAF so if both these values are 14 7 then the system will run in closed loop If the VE is not correct at any given point in Closed Loop the oxygen sensor will pick this up as either a rich or lean condition and try to correct it Generally the system is set to run in Closed Loop 14 7 from part throttle to approx 3 4 throttle At idle the A F Ratio is a bit richer approximately 14 to 1 From 3 4 to full throttle the calibration can be set to run the A F Ratio as rich as 12 5 to 1 When the system goes into Open Loop it stops trying to Vol 1 Chapter 14 The Volumetric Efficiency Table 173 Mapping VE retune itself to 14 7 Instead it relies on the air fuel ratio in the VE map for fuel requirements Providing the VE s are correct at the associated load points it will be
176. ng a calibration to a modified engine there may be a chip already available The factory and some chip modifiers have produced chips for modified engines Armed with KalMaker if you can obtain a Memcal and read it you can compare it with an original and analyse the changes that have been made KalMaker will also allow you to compare and contrast the products from different chip modifiers This is an interesting exercise e Asin computer programming the best way to learn is by looking at what other people have done By looking at a number of factory and after market calibrations you can get a feel for what variables need changing and when they need to be changed Note Only factory calibrations can be completely relied upon to be right e In many situations only a few bytes need to be changed to adapt a calibration to a particular engine The factory calibration software is extremely well organised and thought out and in this respect and all respects for that matter it completely outclasses after market controllers e Many variables need not be changed at all Some variables need extensive instrumentation to be changed with any sort of confidence As noted above by comparing several calibrations you will get an idea of those variables which need to be changed Vol 1 Chapter 9 Pre Calibration Checks 127 Pre Calibration Checks e Don t change a lot of variables at once Many variables are interrelated and extensive cha
177. ng your eye on Idle Spark which is usually around 20 to 28 degrees Idle Speed Decide what idle speed you think your engine will idle at This can be changed later 1 Set your Desired Idle Speed in 216 IAC DES RPM 2 Switch to Gauge View and check IAC steps If you have zero steps then you most likely have the throttle stop too far in the throttle blades are open too far Back off the thgrottle stop and try again If you have lots of steps showing it means that the IAC is open too far trying to compensate for the throt tle being too closed Screw the stop in and try for min imum steps in neutral 3 From here fine tune Stop the engine start again and see what happens Transient Steps Its now time to check whats happening to Transient Steps 1 Switch to List gt View gt Engine All Down at the bottom left column you will see IACTRA This has to be Zero steps before Closed Loop Idle can be achieved 156 Vol 1 Chapter 12 Getting Idle Right Idle Problems on Non GM Engines and Throttle Bodies If you can t reach zero the most likely reason is that your engine vacuum is higher lower in kpa than what is stored in the variable 234 IAC TRA BYM MAP rpm for the load point 2 Try decreasing the kpa around the idle speed load points You dont often get this problem with performance cams using standard Holden calibrations in fact you often need to increase these to get the 227 IAC TRA BYPD
178. nges are inviting trouble Pick one area at a time and proceed carefully It is best to alter one variable name at a time and test the result This method is also best for obtaining a feel for what works and what doesn t Random playing around will result in a mess e When you want to change a three dimensional variable most commonly spark advance the best approach is to obtain plots or dumps from several similar calibrations This will give you a reasonable idea of the magnitude and sensitivity of any changes you wish to make The best method to view these variables is multiple plots of the variable on a single page e The software will interpolate between adjacent sites when tuning in other words the current site is affected by the adjacent site s settings As such always make sure that if a large change at one particular site is made the surrounding sites are set to a similar value in order to minimise the influence of the adjacent sites on the current site e With turbo supercharged engines it is especially important to be aware of the relationship between increased boost pressure air intake temperatures air fuel ratios and ignition timing As a rule more boost effectively increases the intake charge density i e forces more oxygen into the engine for a given time period and increases proportionally to boost pressure It follows that given the engine now consumes more oxygen it needs more fuel to keep the A F ratios
179. ngine light should flash a code 12 and others if they have been set If the check engine light flashes this confirms that the ECM is operating properly and that the link problem is elsewhere Vol 1 Chapter 15 Troubleshooting 199 KalMaker Link Trouble Shooting If the ECM is not running check the following e Is the Development Board or Memcal installed correctly e Is the SRAM installed correctly Notch to notch right hand end of device to right hand end of socket e Are the correct Backup resistors installed Notch to the top of the board Check the coding on the resistor packs and ensure that they match the number of cylinders Lack of resistors will also stop ECM from running at all e Is the Security Device installed correctly with the notch to the left of the board Is the Write line installed correctly A missing or incorrectly installed write line will corrupt the SRAM immediately after the ignition is turned on In this case you will have to return the SRAM for programming at extra cost as this is not covered under warranty Contact the supplier immediately TATE EU EEE T cela Kc Je SG OS 7 m i e __ i Centre st mr m oa rn a aw FIGURE 24 Security Device Orientation e Is the program installed on SRAM incorrectly The SRAM is a 32K or 128K device The program must be loaded high end of program must match end of SRAM If a 128K SRAM is used for a PCM it is configured as 2x6
180. ngs See Stalling Stumbling Deceleration on page 150 Vol 1 Chapter 12 Getting Idle Right 157 Idle Problems on Non GM Engines and Throttle Bodies Note Ifyour engine stalls even after adjusting the Idle SAG settings watch your BPW and Spark Advance to see what they do when you are about to stall An increasing BPW may mean that the sudden increase in fuel is drowning the spark An engine that idles at 800rpm at 50kpa will need slightly less fuel at 600rpm at 60pka and then again at 400 at 70kpa Cold Start Idle Once you have your engine idling at normal operating temperature you can then look at your cold start problems It is a good idea to capture these settingsby datalogging as the engine won t stay cold for long Describe data logging Usually you only need to change your 103 FUL AFR IACAFR clt atthe corresponding Coolant ranges However AFR Timeout delay and decay which increases AFR on startup may be too excessive for your engine causing cold start problems like dead spots and backfiring If you start the engine with no throttle and it runs rough until you give it a blip the AFR Timeout Delay and Decay may be at fault If this is the case compare the AFR Ratio the Commanded Fuel gauge in the Gauge View screen with the IAC AFR in the variable 103 FUL AFR IACAFR clt f IAC AFR is say 13 1 at that temperature but your AFR Ratio gauge says 9 1 it might slowly increase to 13 1 you have too
181. ning and processing the calibration script file required for the loaded calibration binary E1219 Can t open output file file A file open or DOS critical error occurred while attempting to open the indicated output file for writing E1220 Can t write output file file An error occurred while writing to the indicated file E1300 Can t find file A DOS critical error has occurred while creating a list of ram script files for reading Usually caused by searching for a directory or drive which is not ready or doesn t exist E1301 No files found that match path No files have been found which match the ram filelist wildcard E1302 Out of memory allocating file list An error occurred while allocating memory for the ram file list E1303 Link Identification Failure If the calibration script loaded indicates the calibration can support serial communications and a link address has been selected in the configuration then program sends a request to the ECM or PCM for a unique program identification number This error occurs if no response is received The most likely causes are a defective link cable or plugged into the wrong parallel port or the ECM or PCM program in backup This error can also occur if an early ECM is used E1304 Incompatible Calibrations If the calibration script loaded indicates the calibration can support serial communications and a link address has been selected in the configuration then prog
182. nstallation a text file KAL3 TFG is created which contains the setup information obtained during the install procedure This information consists of directory names for binaries and scripts etc The install program then loads KCFG EXE which reads the text file KAL3 TFG and produces the binary file KAL3 CFG e KAL3 CFG is used by KalMaker to load input and output files If the configuration file is not written by the install procedure you can create it as follows Ch assuming KalMaker was installed on drive C cd KAL3 default Kalmaker directory KALCFG KAL3 TFG KAL3 CFG creates binary config file KAL3 CFG from KAL3 TFG You should then be able to run KalMaker as documented Once KalMaker is installed the setup can be changed via the Setup menu however KCFG can produce the same results Vol 1 Chapter 2 KalMaker Installation 15 Configuring Laptop Screen Resolution Configuring Laptop Screen Resolution Later laptops with larger screen resolutions of 1076 x 800 will usually only run Kalmaker in a small window You can change this when opening Kalmaker by typing GVE 35 at the KAL3 prompt If your laptop generates an error message like Initial Grafix error type in the same code as above using different numbers for example GVE 33 If this works you will need to change the config file so that Kalmaker starts with this setting every time Proceed as follows 1 Atthe KAL3 prompt type edit and then press enter
183. nt sensor indicated a temperature below 30C for 3 seconds when MAT gt 13 or engine running over 1 minute Probably inefective thermostat operation A defective coolant temperature sensor or an open in the CTS circuit can also be a problem If a Code 21 or 23 is set along with Code 15 TPS circuit should also be checked for an open condition Vol 1 Chapter 16 Trouble Codes 207 Trouble Code Listing Table 32 Trouble codes listed numerically Continued 21 22 23 24 25 31 32 33 34 35 41 42 43 44 Throttle pos sensor above 2 5 volts for 2 seconds when engine speed below 1600 rpm indicates a problem with the TPS sensor or an open in TPS circuit Check for a sticking or misadjusted TPS Throttle pos sensor below 2 volt for 2 seconds while engine running indicates a defective or maladjusted TPS sensor a short to ground or open in TPS Signal or TPS 5v reference Check TC 21 for correct operation MAT sensor shows lt 30 degrees C for 3 seconds after engine running 1 minute or coolant gt 30C Probably an open MAT Signal circuit defective MAT sensor or an open in TPS CTS MAT Ground wire No speed sensor pulses when engine between 2000 4000 rpm throttle closed high vacuum not in neutral and all for 5 seconds indicates a defect in the VSS or an open or short to ground in VSS Signal circuit Should only indicate when the vehicle is in motion Disregard if vehicle is stationary If ECM
184. odule as used in the 4 cylinder Holden Camira JE and the Chev V8 TPI and TBI distributors These ignition Vol 1 Chapter 7 Distributor Interface 99 Ignition Module Operation modules can be connected to any magnetic reluctor type distributor through pins P and N for example Ford Chrysler Nissan MSD Mallory etc Used in conjunction with the matching GM coil the ignition module connects to the Delco ECM via the standard 4 wire ignition interface This includes all the Australian Delcos and many USA models including the 86 to 89 Chev TPI 1227165 and the 90 TPI 1227730 I e Baier Briae haran nm elt d j Ae 4 d i e i I a Dig Keess bss FIGURE 17 Schematic of GM Ignition Module The pinouts vary between Delco computer models but provided you match the 4 wire interface EST Reference Bypass and Ref Low in accordance with the factory wiring diagram for the computer model you are using it will work fine The 4 wire interface for the 808 Delco ECM for example is as follows EST D4 Ref BR lt Byp D5 100 Vol 1 Chapter 7 Distributor Interface Ignition Module Operation e Ref Low B3 Similarly if using a Hall Effect disributor from any brand of 4 6 or V8 use a V8 Holden EFI ignition module Connect the 3 wires from the Hall Effect pickup inside the distributor to the matching Hall Effect ignition module Connect the ignition module to the ECM in acc
185. on buffer and AutoLoad is enabled then the changes are automatically sent to the ECM This is the same as pressing the Edit Load button after an Edit Save If AutoLoad is in effect it ensures that whatever is saved to the global buffer is also sent to the ECM If AutoLoad is not in effect an Edit Load must be made explicitly to save data to the ECM Table 4 Exit Key Functions Parallel Port ExitKey Function Cancel Exit any changes made are lost OK Exit any changes made take effect immediately for the duration of the current session but are not saved to disk If a parallel port has been selected a check for a link cable on that port is made Any changes made take effect on exit and are saved to the config file kal2 cfg If a parallel port has been selected a check for a link cable on that port is made Enables the configuration of the parallel port It should usually be set at default auto load Save Clock Factor The clock factor function should only be altered when experiencing compatibility problems with certain non standard laptop PC s Usually this function should not be altered The serial link software reprograms the PC 8254 Timer Chip as a baud rate clock This assumes that the 8254 frequency is the AT standard 1193180 hertz The clock factor has been included in order to accommodate the non standard clock rates present on Dell and certain other laptops or PC s The ECM communicates at 8
186. on the same EPROM See Kalmaker Switch Variables on page 125 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker 71 Kalmaker Switch 72 Vol 1 Chapter 4 Vehicle Modifications and Kalmaker Injection Modes and Injectors 73 Chapter 5 Injection Modes and Injectors KALMAKER CEE EEE EEN Garner tor Den There are a number of ways to inject fuel based on the number of independent channels available to the ECM number and type of injectors and the engine configuration Each mode has advantages and disadvantages depending upon its application The following general rule applies to them all the longer it takes to inject fuel the better control you have over it It follows that if an injection mode allows a longer injection time it also offers better control It also follows that injectors should be sized according to the injection mode The fuel injection hardware operates independently of software The software calculates a pulse width or widths and sends it to the injection hardware which then drives the injectors Synchronous and Asynchronous Injection Synchronous injection means that the injection pulses are timed to the ignition reference pulses in some fashion That is they can be some multiple of reference pulses or they can be delayed from the start of the reference pulse Synchronous injection is normally used except in the following circumstances e When output pulse width becomes too small to be r
187. operation and maintenance of the Delco computer that has been modified using Kalmaker Street Pro 3 software and hardware In so doing this User Guide also contains a number of Electronic Fuel Injection topics with the express purpose of describing the possibilities that exist for enthusiasts to enjoy inexpensive high performance fuel injection modifications using factory GM components regardless of engine make In addition an explanation of the operation of the KalMaker program is discussed to serve as a walk through for the first time user When reading this manual pay particular attention to important points that are stressed by the notation of Hint Note bold and italics When using this manual it is assumed that the reader has read and understood the Holden VN VP FACTORY ENGINE MANUAL If you do not already have a copy handy stop at this point and obtain one It is also assumed that the ECM is correctly wired and a suitable distributor interface has been acquired See Distributor Interface on page 97 All wiring diagrams and information are contained in the Factory Manuals IMPORTANT Throughout this manual there are several troubleshooting guides and tips to problem solving Please DO NOT call for technical assistance until you have exhausted all suggested solutions All products are tested before dispatch and as such a fee of 50 plus 50 an hour thereafter will be charged for repair on any returns Vol
188. ordance with the factory connections of the model computer you are using If using a 808 or 165 it will still be the same 4 wires as above If using a GM 4 6 or V8 DFI coilpak system with either Magnetic or Hall Effect Crank Trigger the same principle applies These are the 3 types of ignition interface that GM use with these model computers Unfortunately engines that use optical or sequential ignition systems often will not interface with the Delco easily for example the Lexus V8 Many older points type distributor engines can use an electronic distributor from a newer engine or an aftermarket items such as MSD or ProComp which are are easily adapted to the GM ignition module Newer engines can either have a Hall Effect trigger added to the crank such as Lexus and then use existing distributors or add DFI Coilpaks which require quite a basic easy to fabricate crank trigger The magnetic reluctor pickup type coilpaks are the type GM use on the following vehicles e 4cyl Chev S10 Cavalier Lotus Lada Niva TBI etc e 6 cyl Chev V6 e 8cyl Corvette ZR 1 LT 5 engine only The Buick Commodore V6 use a twin Hall Effect 3 x 18 type pickup and is a very nice system but it is more difficult to fabricate the trigger to suit other applications Locking the Distributor Phasing the Distributor Static Timing Vol 1 Chapter 7 Distributor Interface 101 Ignition Module Operation 102 Vol 1 Chapter 7 Distri
189. ossary Chapter17 Glossary KALMAKER Pe Garner tor Dern 223 Table 35 Glossary Term Description ACC Air Conditioning Clutch AE Acceleration Enrichment ASCII When used to describe a file a text file or one where bytes are interpreted as ASCII characters American Standard Code for Information Interchange Bytes 00 1F are control characters bytes 20 7F are printable characters and bytes 80 FF are graphics characters BARO Barometric Pressure BINARY When used to describe a file a file where no interpretation occurs Byte values are 00 to FF hex or 0 255 decimal BIT Bits can have a value of 0 or 1 BLM Block Learn Multiplier BOOST Map Baro Positive Manifold Pressure BUFFER A generic term used for an area of memory Also used as a term for an interface when ever data comes into a device faster than it leaves such as a printer BYTE Basic unit of data One byte is 8 bits and can have a value from 00 all bits zero to FF all bits 1 hex A word is two bytes a double word is 4 bytes or calibrator Vol 1 Chapter 17 Glossary 223 Glossary Table 35 Glossary CALIBRATION The replaceable part of an automotive controller which calibrates it for a particular drive train It may consist of machine instructions constant data or both A MEMCAL can be also referred to as the calibration
190. ound 2000 rpm and 40 kPa MAF Thit STFT indicated a RICH situation FIGURE 22 Gauges Screen Engine Running Rich To do this 1 Select the VE map from the list of variables See FUL OUT VE on page 168 The VE Map table is displayed 164 Vol 1 Chapter 13 Calibrating Mapping Fuel 2 Click to select 2000rpm with the 40 kpa bar FIGURE 23 Fuel Map This is the point that is running rich 3 Lower the bar height to lean it out 4 Switch back to the Gauges screen and check the STFT If it is close to 100 the 2000 rpm load point is set correctly 5 Adjust every bar an equivalent amount at every rev range frame that is every 400 rpm 6 Repeat for every load point to achieve a good fuel map If you go to the 3D of the fuel map you can see the shape of the 2000rpm line is the same as this bar graph The buttons at the bottom of screen provide shortcuts to map all these load points without having to go back to the guage screen after each adjustment There can be quite significant gains to be had on even stock engine setups and as you modify the engine the more the engine fuel and spark requirements will move from the original maps Vol 1 Chapter 13 Calibrating 165 Mapping Ignition Mapping Ignition Ignition adjustments SPK BAS RUNADVA should be approached with the same degree of caution as adjusting the fuel tables NEVER start with a lot of ignition advance it is best to s
191. out If the VE is correct the STFT will all be at 100 plus or minus 2 or 3 10 Save Once you have the VE data correct you will notice how crisp and responsive the engine is across the whole rpm range not to mention the improved fuel economy Tuning Open Loop VE Tables Manually Not everyone has access to an A F Meter let alone a dyno If this is the case make sure your open loop VEs usually at 85kPa and above are set at or slightly richer than the previous closed loop MAP load point 80Kpa after the closed loop VEs have been determined The following procedure MUST be undertaken with caution as engine damage will result if your AF ratios are too lean at WOT You can manually map the open loop region that is 85 90 95 and 100kPa by temporarily changing the A F table FUL OUT RUNAFR to 14 7 This region will now function as if it were in Closed Loop so you can use the Gauges Screen and the STFT to establish satisfactory open loop VEs for WOT Be attentive to detonation pinging as your actual VE s could already be lean Tuning A F ratios for Economy Street Pro 3 can switch on Lean Cruise Mode See Lean Cruise Mode on page 162 This mode was only used by GM EFI tuning experts with enough knowledge to make it work without damaging their engine Lean Cruise Mode works by switching to another table to run from approx 15 1 to 17 1 A F ratio It only does this after a set short time of cruising within
192. output file file A file open or DOS critical error occurred while attempting to open the indicated output file for writing E1322 Can t write output file file An error occurred while writing to the indicated file E1323 Ram Script not Loaded An attempt was made to select the default data list before a ram script was loaded A ram script is loaded automatically if applicable when a calibration script is loaded E1324 Multiple Data Lists unavailable Only one data list is available in the loaded ram script so there is no need to select a default data list E1325 Using Default Data List The default data list the first data list if not specifically selected is being used as no other selection has been made Vol 1 187 KalMaker Application Errors E1326 Serial Link not Initialised An attempt was made to play a data list before a ram script was loaded and initialised This normally happens automatically whenever a data capture file is loaded E1327 Ram Script not Loaded An attempt was made to play a data list before a ram script was loaded and initialised This normally happens automatically whenever a data capture file is loaded E1328 Data List Buffer Empty An attempt was made to play a data list with no capture data in it E1329 Can t find Ram Script file for file When a data capture file is loaded the script paths are searched for the appropriate ram script The error is displayed if the req
193. ow the current column or the current variable This is intended for use when the user has made several changes wants some values returned to their previous state but doesn t want to loose the changes already made Edit Save The Save option writes the Local or Display Buffer to the Global Buffer If the changes made to the Local Buffer are not saved they are lost when the user exits the current variable Once a variable has been saved the Undo variable is updated This means the variable cannot be returned to the value it had upon entry only to the value it had on its most recent Save If the AutoLoad option has been set see Setup Parallel Port then changes are automatically transmitted to the ECM whenever changes are Saved to the Global Buffer If the variable is a 3D variable for example all values in that variable are transmitted to the ECM 30 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions Important The Edit Save option does NOT write to disk This function is performed by the Buffer Write option The user is always prompted for a filename whenever a calibration file is to be written to disk Edit Next The Next option selects the next variable to be Edited and exits the current variable If changes have been made to the Local Buffer the user is prompted to Save the changes before exiting the current Edit screen Edit0 The Ed screen has a unique format The changes made to EditO variables
194. paring two calibrations that are too different to be differenced Because of the large number of calibration variables these files can become quite large The dump format is as follows e The variable name is written leftmost e The variable value is written in the middle column e The variable units are written rightmost e 2D and 3D tables are written in row major order with unit headers There are two dump options e Dump to Screen The file is dumped to a temporary file and viewed The temporary file is deleted when the file viewing task is exited Note that locating the temporary file on a ram disk will speed the dump e Dump to File The user is prompted for a filename The dump is written to the file and the task exits The file is a 42 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions standard text file and may be viewed or edited with a text editor or imported into a word processor Diff The Difference utility compares the contents of Buffer with Buffer2 and writes the difference as text The Difference operation can compare calibrations which use the same program and thus have the same number and name of variables The Difference operation can also compare calibrations that are not the same In this case one calibration may have variables that the other does not In this case the output is written separately The size of the difference output can vary from a few lines if the files are the sa
195. proceed as follows 1 Select Buffer 1 2 Select Write The Calibration Save Size box is displayed 3 Set the box for the appropriate size calibration VN VP Holden are saved on 16k eproms VR VS manual trans are saved on 32k and all VR VS auto matics are saved on 64k Hint Basically it doesn t matter which size you save to If you have an Eprom burner and you have 64k eproms in stock save it to 64k 4 Click OK The Path List is displayed again Hint This is where you opened the cal from 5 Double click on the folder you want to save it in for example MyCals The Enter File Specification box is displayed at C KAL3 MyCals by default Hint The name of the original calibration you are working on is displayed at the bottom of the screen 6 Give your calibration a meaningful name for example C KAL MyCals MyV8 bin Note Use the BIN extension for your calibrations to ensure that they a compatible with most Eprom Burner software 134 Vol 1 Chapter 10 Opening Loading and Saving a Calibration Writing a Calibration Hint Factory cals are stored in a folder called BIN This isn t a bin or trash bin It means they are binaries 7 Press Enter Writing a Calibration You can use a standard Delco ECM and modify its MEMCAL with your own EPROM instead of running a Real Time ECM permanently In this manner your real time ECM can be used to tune more than one engine Note Ifyou wish to undertake this method
196. r Control IAC Variable List IAC TRA BYMFAC bypass decel map step factor IAC TRA BYMSTP bypass decel map max steps IAC TRA BYMMAPIrp bypass decel map threshold m IAC TRA BYTDTA bypass decel tps delta IAC TRA BYTSTP rpm bypass decel tps transient steps IAC TRA MACSTP bypass decel tps acc steps A5 B1 DB FB IAC TRA BYPDEC bypass decel decay steps IAC TRA DEFDEC default decay steps IAC SAG RDB1 sag stage1 rpm deadband IAC SAG RPM2 sag stage2 absolute rpm threshold IAC SAG STEP1 sag stage1 steps IAC SAG STEP2 sag stage2 steps IAC DES ACCDEL iac control desired rpm acc delta IAC DES CLTDEL clt iac control desired rpm cht delta IAC DES CLTDDM iac control clt delta multiplier drv IAC DES RPMDR bat iac control desired rpm drv IAC DES RPMPNIbat iac control desired rpm pkn IAC DES RPMMT bat iac control desired rom man IAC CTL TPS min tps for idle control IAC CTL DTADLY iac control delay closed tps transition IAC CTL PDXDLY iac control delay pkn drv transition IAC CTL ACXDLY iac control delay acc off on transition IAC CTL RDBL iac control large deadband IAC CTL RDBSD iac control small deadband drv IAC CTL RDBSP iac control small deadband pkn Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 119 Variable Groups Engine Trouble Codes The Engine
197. ram sends a request to the ECM or PCM for a unique program identification number This error occurs if the unique number returned by the ECM or PCM differs from that contained in the calibration script Vol 1 185 KalMaker Application Errors E1305 Link Update disabled This error occurs if there has been any error in link identification or incompatibility between received program information and calibration script information E1306 Can t open Ram Script for file An error occurred while opening the ram script required by the calibration file file for reading E1307 Can t open Ram Script file An error occurred while opening the ram script file for reading This error occurs if a ram script is loaded manually E1308 Can t allocate memory for file The ram script is read into allocated memory where various operations are performed on it Caused by a memory allocation error E1309 file is not a Ram Script The ram script file does not have the required header string E1310 file is corrupted The ram script file header information is inconsistent E1311 Can t load Ram Script file for file A general error has occurred while opening and processing the ram script file required for the loaded calibration binary E1312 Can t allocate Data List Buffer xxxx bytes An error occurred while allocating memory for the data list buffer This is required for the data received from the ECM or PCM E
198. ration Settings Getting Idle Right 145 Chapter12 Getting Idle Right KALMAKER Pee ee ee m Garner tor Dern It is important to understand how the idle system works before modifying it There are two main idle modes e transient e closed loop The system cannot be in both simultaneously Note Closed loop idle has nothing to do with closed loop fuel Transient or open loop idle is based on the position of the IAC stepper motor In transient idle steps are added to accommodate loads or transitions for example going from P N into DR AC on off fan on off then the steps are decayed out In closed loop idle the desired idle is located in a band known as a Deadband Idle speed is increased or decreased when it falls outside this deadband in order to maintain a desired idle rpm Set Idle Speed Idle speed is most affected by fuel mixture If it is rich it will idle fast If it is lean it will idle slow if at all Because Kalmaker has a Closed Throttle Fuel map 123 FUL OUT VET you can quickly set idle mixture Whenever the throttle is closed fuel is apportioned via the 123 FUL OUT VECT map and ignores the MAP sensor which can be unstable at idle for modified or non GM engines Vol 1 Chapter 12 Getting Idle Right 145 Set Idle Speed The instant the throttle opens fuel is apportioned via the main VE map This really helps idle and also stops kangaroo hops at very low speeds You can end up with
199. re consistently as you can then use similar calibrations in different size engines Note Once you change the BPC you have to recalibrate the whole VE table When using unknown injectors you should first change the Cylinder Size to suit the engine then adjust njector Rate so that you have approx 80 to 90 VE at full throttle This is a bit hard with a new engine but if you have this right you wont have to remap whole VE table if you have to change the Injector Rate later Table 34 List Of Fuel Injectors on page 211 is a partial list of fuel injectors and flow rates so that you can calculate the BPW of an injector that may appear in this table Injector Flow Rate The following table lists the maximum horsepower obtainable from injectors based on the injector flow rate operating on a 100 duty cycle The horsepower figures assume a Base Specific Fuel Consumption BSFC of 0 55 lbs of fuel per hour at maximum HP this is an average figure Table 19 Injector Flow Rates Horsepower 100 Duty Cycle Injector Size Lb Hr cc Min 4Cyl 6Cyl 8Cyl 20 210 145 218 291 22 231 160 240 320 24 252 175 262 349 Vol 1 Chapter 5 Injection Modes and Injectors Base Pulse Constant Table 19 Injector Flow Rates 70 734 As an example we ll choose a 24lb hr injector and configure the injector size in seconds gram so we can populate the FUL OUT INJRAT and FUL OUT CYLSIZ variables 189 204 218 233 247 262
200. re files OUTPUT d c kal bin write calibrations to these paths c kal mybin Parallel Port The Parallel Port option enables e the Data Link port to be selected or disabled e the AutoLoad option to be enabled or disabled When the port option is selected a check button form is displayed The link data port may be selected from one of the three displayed addresses which are the three parallel port addresses supported by a standard PC If the port is selected to be not present all data link dependent functions are disabled and no link checking is performed Calibrations can still be loaded edited and saved but no communication with the ECM can occur If a parallel port address is selected and retained a check is made for the presence of a link cable If one is not found a cable not found message is displayed This message is for information only and has no other effect The link cable check is made by a BIOS table search Some network drivers alter this table and may cause a spurious cable not found message 20 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions If the software is installed on a Laptop with bi directional parallel port functionality EPP or ECP the BIOS setup should be for a standard unidirectional or AT Parallel Port The AutoLoad option works as follows If the user selects Buffer Edit edits a calibration variable and subsequently saves the local display buffer to the global calibrati
201. rent variable from the Local Buffer to the Clip Buffer If a variable of the same name already exists in the Clip Buffer it is overwritten Edit Clip Delete Clip item The Clip Delete command removes the selected variable from the Clip Buffer Edit Clip Copy Clip item The Clip Copy command copies the selected variable from the Clip Buffer to the Local Buffer If a 3D variable is being copied from Clip the user is prompted to copy by row or column Edit Clip Read Clip file The Clip Read option reads the contents of a previously saved Clip file into the Clip Buffer The variables already in the Clip Buffer are overwritten and the user is prompted to continue Edit Clip Write Clip file The Clip Write option writes the contents of the Clip Buffer to a file The Buffer contents are unaltered There are no filename limitations Edit Clip cOpy all Clip The Clip CopyAll option copies the Clip Buffer to the Global Buffer If a variable in the buffer is incompatible with that in the Global Buffer a message is displayed If the AutoLoad option has been set the Clip variables are transmitted to the ECM This enables the effect of a group of changes on engine operation to be gauged Edit Clip Undo all Clip As part of the CopyAll option the Global Buffer variables to be overwritten are copied to a Clip Undo Buffer If the user requires the Clip CopyAll to be undone the UndoAll option restores the previous values If the AutoLoad option h
202. rive the more the better e Standard Parallel printer Port or Serial Port preferred e VGA mono colour graphics capability Note It is assumed throughout this manual that a mouse is connected to the PC Should you not have a mouse we strongly recommend obtaining one and an appropriate mouse driver If not please refer to the Working Without a Mouse on page 58 12 Vol 1 Chapter 1 Introduction KalMaker Installation 13 Chapter 2 KalMaker Installation KALMAKER Poe ee ee Garner tor Dern Installing Kalmaker on a PC or laptop is a straight forward procedure The two floppy discs that were supplied with the kit are all that is required See Kit Contents on page 10 Ensure that the pre requisites described in PC or Lap Top Specifications on page 11 and Copy Protection on page 10 have been fulfilled Pre installation Issues and Checks There are some pre installation issues that will affect operation of the Kalmaker system that you must address before installing the software e Configuration Some effort should be made to configure KalMaker in a consistent fashion The program has the potential to generate large numbers of files over time especially if several calibration scripts are used These files can cause problems if not managed properly Volume 2 Chapter 3 Kalmaker Environment on page 8 describes some configuration issues and also describes the file naming and directory folder conventions used in KalM
203. rograms and they are similar Vol 1 Chapter 3 Kalmaker Editor Menu Commands 43 Menu Functions If for example the user has a proven calibration C1 which uses program P1 and there has been a minor program change from P1 to P2 then the easiest way to use the proven data of C1 in the program P2 is to translate from P1 to P2 In this case the data variables are read from C1 and written to their corresponding locations in C2 C2 may have extra variables as a result of the program changes and these are untouched as there are no corresponding variables in C1 to overwrite them The user is prompted for the base name which is used to make two file names for the two output files The first file written is the translated binary output It consists of the data of calibration C1 written over the calibration data of calibration C2 It uses program P2 The second file is a text report file and indicates the completeness of the translation e If there are no variables unique to either calibration then the translation is complete and reversible e If the destination calibration has variables the source doesn t then the translation uses the value of the destination calibration and this is noted in the translation report e Any variables the source calibration has which the destination doesn t are discarded This means that the translation is not reversible ie if the output of the translation T1 is translated back to calibration C
204. rrection SPK BAS ALTCRN vac bap spark altitude correction SPK BAS EGRADV vac rpm egr spark correction 62 SPK PND PNDRPM pkn drv spark enable rpm 63 SPK PND PNDADV pkn drv spark SPK DFC DFCADV min dfco spark 5D A5 B1 DB 59 SPK DFC SPKDEL dfco spark decay delta FB 58 SPK DFC SPKMIN min dfco spark FB 60 SPK DGN DGNADV diagnostic advance 61 SPK DGN DGNRPM diagnostic rpm threshold 70 SPK OUT MAXDSPK max change in spark calculation 69 SPK OUT DELREF refperiod delta for accel spark 68 SPK OUT ACCFAC accel spark factor 110 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups Table 24 Spark SPK Variable List SPK OUT MAXADV max output spark 5D A5 B1 DB 66 SPK OUT MAXSPK max output spark FB 67 SPK OUT MINSPK min output spark FB 64 SPK OUT REFANG reference angle 65 SPK OUT TIMLAG distributor lag constant 72 SPK ESC TIME knock retard time 71 SPK ESC LOCLT knock retard ch threshold 73 SPK ESC LORPM knock retard lo rpm enable 74 SPK ESC HIRPM knock retard hi rpm enable 75 SPK ESC MAXRTD max knock retard 77 SPK ESC ATKRAT rpm knock retard attack factor 78 SPK ESC RCVRAT rpm knock retard recovery factor SPK DSR RPMQ rpm filter coefficient FB SPK DSR QDX gdx rpm queue index FB SPK DSR DTPS spkrtd delta tps threshold FB SPK DSR TPS if tps gt this skip spkrtd FB SPK DSR CLT if clt lt this skip spkrtd FB SPK DSR KPH if kph l
205. running at the preset levels For more details on setting VEs manually See Tuning Open Loop VE Tables Manually on page 178 Mapping VE The main fuel tables FUL RUN VEA map rpm FUL RUN VEB map rpm really need to be adjusted while the vehicle is on a dyno being driven When undertaking this adjustment is strongly advised that extreme care is used to make sure that the engine DOES NOT RUN LEAN under high loads The only accurate way of doing this is to monitor the Air Fuel A F ratios with a wide range A F meter attached to the vehicle The adjustments you make to A F ratios will depend on the desired result for example maximum power or best economy and the engine loads Table 31 Air Fuel Ratio Set Table 31 Air Fuel Ratio Set Suggesied Air Fuel Ratio Desired Result Application Load 12 11 Reduced Knocking exhaust gas high temperatures 13 12 Maximum Power high 14 7 1 Best Emissions and closed loop light 15 0 Best Economy light IMPORTANT It is essential that turbo supercharged engine A F ratios are carefully monitored when calibrating An engine under high boost and or load that is running lean will be very likely to knock and can result in almost INSTANT ENGINE FAILURE With turbo supercharged engines the rule of thumb is to run them a little on the rich side for safety s sake When calibrating in general the suggested approach is to ALWAYS start with the mixtures b
206. s When prompted to do so save the changes From the mani menu click Buffer1 Write You will be prompted for a calibration size Select either 16 32 or 64K See Table 29 on page 135 Click OK In the input dialogue box click on the CAKAL OUT lt your folder gt Type the filename Give it a meaningful name and an extension of bin Note bin is the default extension recognised by most 10 11 12 13 14 EPROM burners Your calibration will then be saved to the c KAL OUT lt your folder gt Exit KalMaker Connect the device programmer to the PC Run the software that was included with the device programmer and operate according to the manufacturer s instructions Read the calibration from the path c KAL3 OUT lt your folder gt and burn this calibration into an EPROM with Plug the EPROM into the modified Memcal which includes the PAL Plug the MEMCAL into the stock DELCO computer and test 136 Vol 1 Chapter 10 Opening Loading and Saving a Calibration Pre Calibration Settings 137 Chapter 11 Pre Calibration Settings KALMAKER CEE EEE EEN Garner tor Dern Once you have loaded your base calibration See Opening Loading and Saving a Calibration on page 131 some settings may need to be established before you can continue tuning your engine This is especially important for non GM engines The first step after loading a calibration is to link the PC to the ECM Linking to the ECM
207. t this skip spkrtd FB SPK DSR RPMH if rom gt this skip spkrtd FB SPK DSR RPML if rom lt this skip spkrtd FB SPK DSR LTPS low tps mode logic threshold FB SPK DSR LGRPM idle drive spark rom threshold FB SPK DSR PTNRMAX tipin max pos drmspark FB SPK DSR PTPRMAX tipin max neg drmspark FB SPK DSR PTIM drmspk enable time pos dtps FB Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 111 Variable Groups Table 24 Spark SPK Variable List SPK DSR PDRMUL gdx tipin gain FB SPK DSR NTPRMAX tipout max pos drmspk FB SPK DSR NTNRMAX tipout max neg drmspk FB SPK DSR NTIM drmspk enable time neg dtps FB SPK DSR NDRMUL gdx tipout gain FB SPK DSR LGRMUL idle drive gain FB SPK DSR LGPRMAX idle drive tip in max drmspk FB SPK DSR LGPRMAX idle drive tip in max drmspk FB SPK DSR SPKMIN dsr spkrtd enable threshold FB SPK DSR BMPKPH bumpspk logic low kph threshold FB SPK DSR BMPGXT bumpspk gear change ignore time FB SPK DSR BMPDRN time bump spark is active FB SPK DSR BMPDCY bumpspk hold time before decay FB SPK DSR BMPMAX max bumpspk FB SPK DSR BMPOFS bumpspk bias FB SPK DSR BMPSPkK tps rpm tipin bump spark FB SPK DSR BMPDELI tps tipin bump decay FB SPK TQM TPS tqmspk tps threshold DB FB
208. t Pro 3 Variables Variable Groups Table 25 Fuel FUL Variable List 127 FUL OUT BATFACI bat fuel pump battery correction 125 FUL OUT INJOFSI bat injector voltage offset 126 FUL OUT INJOFS bpw non linear injector bias 128 FUL OUT INJDLY tps rpm injector delay 113 FUL OUT NPWH narrow pulsewidth lo threshold 114 FUL OUT NPWL narrow pulsewidth hi threshold 116 FUL OUT APWL min async pulsewidth 115 FUL OUT APWH max async pulsewidth 117 FUL OUT APWN max async ae pulsewidth 160 FUL BLM LOCLT blm update enable lo clt 161 FUL BLM HICLT blm update enable hi clt 162 FUL BLM INTTH blm update int error 164 FUL BLM UPDDLY blm update delay 163 FUL BLM UPDDLYCT blm update delay closed tps 167 FUL BLM RPMINC blm rpm breakpoint hysteresis 168 FUL BLM MAPINC blm map breakpoint hysteresis 165 FUL BLM MAXCEL blm cell upper bound 166 FUL BLM MINCEL blm cell lower bound 153 FUL CLP LOCLT closed loop mode enable ch 156 FUL CLP O2RLTH 02 rich lean threshold 157 FUL CLP O2ERDB 02 error deadband FUL CLP ERRMUL rpm o2 error multiplier 5D A5 B1 158 FUL CLP ERRMUL map rp 02 error multiplier DB FB m 155 FUL CLP INTHI integrator upper bound 154 FUL CLP INTLO integrator lower bound 159 FUL CLP PROP bpw propstep 5D A5 B1 FUL CLP PROP err propstep DB FB Vol 1 Chapter 8 KalMaker Street Pro 3 Variables 115 Variable Groups Table 25
209. t integrator value The ve update option disables block learn update and correction 10 GEN OPT EOPTBI bpw trim This option enables variation of the output fuel pulse by a calibrated resistance between two ECM terminals It is used on VL Group A applications to give individual adjustment to fuel 106 Vol 1 Chapter 8 KalMaker Street Pro 3 Variables Variable Groups Table 22 General GEN Variable List 10 GEN OPT EOPTB 8 These two flags indicate to the software how cylinder many cylinders the engine has If neither are 10 GEN OPT EOPTB 6 set calibration is for a 4 cylinder Note that cylinder the software cylinder setting must match the backup fuel calibration otherwise the engine will not run correctly 10 GEN OPT EOPTB ae de The accel enrichment delta map term and decay decel enleanment delta map and delta tps terms are decayed This decay can occur each fuel calculation at fixed time intervals if this option is not set or can occur each refpulse time interval depends on engine rpm if this option is set 10 GEN OPT EOPTB ae cht This option modifies the tae coolant multiplier mult by multiplying it with the timout airfuel ratio 10 GEN OPT EOPTBItbilpfi Enables either multi point or single point injection TBI300 or TBI770 Note that this software cannot drive the TBI220 twin throttle body injectors used on GMC Truck applications TBI applications are not
210. t mouse button press moves to the left a right mouse press moves to the right While the Translate operation is enabled any of the Axis buttons may be pressed Vol 1 Chapter 3 Kalmaker Editor Menu Commands 39 Menu Functions Edit3 3D Rotate This option acts similarly to Translate except that the mesh is rotated around either of the three Axes A left mouse press rotates the object anti clockwise a right mouse press rotates it clockwise Edit3 3D Scale This option also acts similarly to Translate except that the mesh is scaled along either of the three Axes This is useful if the writing on one of the axes is hard to see Edit3 3D Config This option opens a panel of slider bars These sliders correspond to the four operation options The position of the sliders corresponds to the amount the object is scaled rotated or translated or ortho d As some machines are slower than others this speeds up the object moving operations As the speed increases the precision with which the object is moved decreases Configurations are saved along with the transform matrices to the transform file For changes to be saved to file they have to be saved twice once at the Config Save option and once at the 3DView Save button Edit3 3D Save This option copies the current transformation matrix to the transform file It overwrites the existing default transform matrix It also saves the ortho translate rotate and scale deltas Edit3 3D
211. tain value for example at highway cruising speeds When Lean Cruise Mode is commanded spark advance increases as well and occasionally returns to closed loop mode to double check itself If the engine is run too lean spark plugs valves and pistons can be damaged However when done correctly up to 10 in mileage gains are possible above the already excellent mileage from closed loop mode 162 Vol 1 Chapter 13 Calibrating Mapping Fuel In summary the Delco computer controls fuel to maintain a 14 7 A F ratio at all times under normal conditions During other than normal conditions open loop mode is used so that A F ratios other than 14 7 can be commanded Remember when an engine is running fuel is determined from one of two sets of variables e Engine at Idle throttle Closed Refer to IAC maps which will control all things related to the IAC stepper motor e Throttle open Refer to FUL maps Mapping Fuel The proper procedure to map VE is to run the engine on an engine dyno at each speed and load point and let Kalmaker do the mapping automatically with VE Update See How To Use VE Update on page 175 You can also tune the VE table FUL OUT VE manually to quickly arrive at a set of values that are close to the mark Setting up the VE Table Manually The amount of fuel injected can be altered by either the VE table See FUL OUT VE on page 168 or the AF table See FUL AFR RUNAFR on page 167 The main cal
212. tart conservatively The approach should be to gradually advance the timing until the engine makes maximum torque at a given load and then retard the timing 1 3 degrees as a margin of safety ALWAYS BE AWARE OF ENGINE KNOCK This phenomenon will kill your engine Spark Calculation The output spark is calculated as the sum of the main spark and a number of separate advances and correction factors Spark retard is then subtracted from the total sum The main spark advance can have a significant effect upon system performance and together with the VE table should be the focus of most of the calibration effort output spark main spark hirpm spark t clt correction clt offset altitude compensation esc retard It is important to obtain a measure of the spark sensitivity how the system reacts to spark advance over normal operating conditions This will vary from engine to engine An engine will accept spark advance up to a certain limit after which power decreases The rate at which power decreases is an indication of how sensitive the engine is to spark As mentioned previously ALWAYS BE AWARE OF TOO MUCH SPARK ADVANCE IT WILL KILL YOUR ENGINE Most Used Variables Listed are the 25 most used variables starting at top of list Hint Press the Help Button when in each Variable for further information Table 30 Most Used Variables Var Variable Purpose Vol 1 Chapter 13 Calibra
213. te VE UPDATE will only function when in Closed Loop Fuel mode that is at 14 7 to 1 AFR When you ve finished you can use the Clip Copy function and copy the AF table from the base calibration from Buffer 2 See Edit Clip on page 28 Comparing and Storing VE Update Calculations The VE UPDATE feature only updates the Static Ram in the ECM not the VE Map in the laptop This is done later Hint This is quite handy as you don t need to have the laptop plugged in You can drive around for a week or two auto updating Vol 1 Chapter 14 The Volumetric Efficiency Table 175 Setting Closed Loop VE Table Manually Caution If you disconnect power from the Real Time ECM you will lose all your VE update data You can save the changes into your laptop from the ECM so that you can see how much the Fuel Map has changed 1 Save the current calibration Refer to this procedure that is Buffer 1 Write Program Size etc etc Open the same calibration in Buffer 2 Refer to this procedure This will allow you to compare the two fuel maps the one before VE Update and the one after Select Buffer 1 Link All gt gt PC All Data will now be transferred to the laptop When this step has completed select Buffer 1 Diff To Screen This will illustrate the differences between the new data from the ECM and the current calibration in Buffer 2 Get a screen dump to illustrate this Save this new info to the same calibr
214. terminal B 10 is connected to the ganged common ground circuit A 12 D 1 D 3 D 6 and D 10 See SYSTEM GROUND on page 91 Code 24 will not set even though there is a nonfunctional or defective VSS circuit conversely if terminal B 10 is NOT connected to ground and there is no functional VSS system the ECM will set a Code 24 when the vehicle is driven MAT sensor showed above 145 degrees C for 2 seconds after engine ran for over 1 minute Indicates a defective MAT sensor or a short to ground in circuit MAT Signal circuit The voltage from the MAT to the ECM should be about 4 Volts DC Unknown Error Code Unknown Error Code MAP sensor voltage too high gt 4 00 v Possible vacuum leak to sensor or faulty sensor MAP sensor voltage too low lt 0 25 v with ignition on or engine running gt 1200 rpm and throttle open gt 20 Closed throttle idle speed is more than 75 rpm above or below correct value for more than 45 seconds No Crankshaft reference pulses Ignition voltage lt 11 volts etc Open or short on EST or BYPASS line to ignition module Indicates a faulty ignition module or an open or short to ground in Bypass circuit or a short in EST Control circuit Check connections between Ignition module and EST and the by pass terminals B4 and D5 Ignition Module may be faulty Engine Knock Sensor circuit open or shorted Also indicates a faulty knock sensor or a problem in the related wiring circuits There should be over 6 Vol
215. the minimum spark for best torque is dependent on air fuel ratio among other things This means that changes to the air fuel table may mean corresponding changes to the spark table and vice versa Closed Loop and Open Loop Closed Loop is a mode of operation in which the ECM uses feedback from the O2 sensor to make corrections to the air fuel ratio Another name for this mode is Short Term Fuel Trim Note The engine being calibrated should be set up for closed loop if only for development Closed loop operation does not mean less power it supports the calibration by making fuel adjustments on the fly When the engine is running closed loop any deviations from stoichiometric are compensated for by Closed Loop Correction Terms While this sounds ideal there is one drawback to closed loop the air fuel ratio must be stoichiometric 14 7 1 otherwise the o2 sensor will not switch Note Closed loop cannot compensate completely for inaccurate VE It takes time for the Engine Management System to react to a lean or rich spot and by this time the engine could be operating somewhere else Vol 1 Chapter 13 Calibrating 161 Closed Loop and Open Loop Inspection of the run air fuel table FUL AFR RUNAFR map rpm will reveal many non stoich air fuel ratios in the table The reason for this is that in many cases stoich air fuel is not the ideal ratio Part throttle cruising can take ratios up to 15 1 for economy See Lean Cruis
216. the type of wiring system that exists in the vehicle into which you are installing the ECM you will have to either tap into the appropriate wire in the ignition switch harness or make the necessary connection Vol 1 Chapter 6 Wiring Information 89 Terminal Listings at the main fuse block For our rewiring purposes this fuse will be referred to as the ECM fuse A 7 Circuit 422 Automatic Trans TCC CONTROL Connected to the TH 700 R4 automatic transmission TCC Solenoid Terminal D This circuit allows the ECM to control the TCC function by providing a ground through this terminal This requires the inclusion of a functional VSS system See Vehicle Speed Sensor on page 67 If you ARE using the ECM to activate the TCC function a wire should be connected from this terminal to the ALDL connector Terminal F This connection allows you to activate the TCC function by supplying an external ground to this ALDL terminal to verify TCC operation A 9 Circuit 451 DIAGNOSTIC TERMINAL Connected to Terminal B of the ALDL connector This circuit is referred to as the Diagnostic Test circuit See ALDL Modes on page 205 Terminal A of the ALDL connector should be connected to the ganged common ground circuit of ECM Terminals A 12 D 3 D 6 and D 10 which is in turn connected to a secure engine ground Grounding Terminal B of the ALDL by jumpering it to Terminal A with the ignition key turned to the ON position engine NOT running c
217. ther e PC or laptop e KalMaker program e Link cable e ECM e Kalmaker not set to correct Port in Setup Enviroment e Parallel port or Serial port PC or Laptop You should have a good working knowledge of the connections and capabilities of your PC or Laptop and be familiar with the BIOS settings Check the following e Check that the Dongle is plugged into parallel printer port e Check that the link cable is connected to dongle SP2 or Serial port SP3 Hint SP2 only If the machine has two parallel ports link cable can be connected to either Note The dongle should not have a printer or other device such as a ZIP drive connected to it while KalMaker is running e Does the computer have 8 Mb memory If not use another machine or upgrade the memory e Turn OFF EPP or ECP capability to the parallel port e Disable power management KalMaker Program Check the following e KalMaker has been configured for a correct standard parallel port LPT1 is usually assigned to port 0378 clock factor is 146 Some non standard machines may require a factor 1 3 units either side of this number 198 Vol 1 Chapter 15 Troubleshooting KalMaker Link Trouble Shooting e Communications can be checked without loading a program by selecting List Load and List View from the pull down menu to load a RAM script and view a Data List The same mechanism is used for viewing a data list and real time editing
218. ting Most Used Variables Table 30 Most Used Variables continued GEN OPT EOPTCA VE INT UPDATE LEAN CRUISE VECT ENABLE DISABLE BLM Displayed here are 8 buttons press the individual button to enable Select this to Automatically Tune Fuel See The Volumetric Efficiency Table on page 171 Select to Enable See variables 106 to 110 See Lean Cruise Mode on page 162 Closed throttle fuel map used mainly with bigger cams See FUL OUT VECT on page 167 Turns off Block Learn Update while tuning 37 VAR KPH PPK Speed Sensor Constant Tyre size diff ratio effect TCC Transient Fuel and IAC 47 SPK BAS IACADV effects idle quality use more advance for bigger cams 48 SPK BAS RUNADVA This is the Main Spark Advance map See Mapping Ignition on page 166 50 SPK BAS CLT CRN controls Main Advance when engine coolant too hot or cold 51 SPK BAS MAT CRN controls Main Advance when air temp excessively hot 64 SPK OUT REFANG Change reference angle to suit different distributors 71 SPK ESC LOCLT temperature setting allows knock sensor to activate or not 76 SPK ESC IGNCTS knock sensor can ignore engine noise like roller rockers etc 103 FUL AFR IACAFR commanded air fuel ratio in closed loop idle Adjust to suit temp 106 FUL AFR RUNAFR commanded air fuel ratio Only top end may need changing to suit say 12 5 to 1
219. ting in the Ballpark 152 Running rich at idle when cold 153 Problems with Large Injectors 153 A Note on Cam Choice 153 Idle Problems on Non GM Engines and Throttle Bodies 154 Trouble Codes and Default Maps 155 ERT 155 Idle Speed 156 Transient Steps 156 Idle Proportional Spark 157 Idle Sag Settings 157 Cold StartIdle 158 Cranking Base Pulse Width 158 Add More Fuel at Start 158 Add IAC Steps on Warmup 159 Calibrating 161 Closed Loop and Open Loop 161 Power Enrichment Mode 162 Lean Cruise Mode 162 Mapping Fuel 163 Setting up the VE Table Manually 163 Fuel Calculation 163 Mapping Ignition 166 Spark Calculation 166 Most Used Variables 166 Diagnostics 168 The Volumetric Efficiency Table 171 Integrator and Block Learn 171 Integrator 171 Block Learn 172 Integrator and Block Learn In Action 172 The VE Map 7 7 7 7 7 7 7 173
220. tion on ignition switch etc The wire from this terminal Vol 1 Chapter 6 Wiring Information 93 Terminal Listings can be ganged with the similarly coloured wire from ECM Terminal B 1 Also connected to this same 12V source should be fuel pump relay terminal 30 and one side of the oil pressure activated fuel pump back up switch if fitted D 1 Circuit 450 SYSTEM GROUND Connected to the ganged common ground wire circuit along with ECM Terminals A 12 D 3 D 6 and D 10 refer SYSTEM GROUND on page 91 which are in turn connected to a secure engine ground D 2 Circuit 452 TPS CTS Ground Connected to Terminal A of the 3 pin TPS connector This circuit is the common 5V return line for the TPS and CTS D 3 Circuit 450 SYSTEM GROUND Connected to the ganged common ground wire circuit together with ECM terminals A 12 D 1 D 6 and D 10 refer SYSTEM GROUND on page 91 which are in turn connected to a secure engine ground D 4 Circuit 423 EST CONTROL Connected to one of the four wires that run as a group to the 4 pin ignition module plug This circuit allows the ECM to trigger the ignition module This is also the circuit the ECM uses to actually control timing by advancing or retarding the spark relative to the reference signal it gets from circuit 430 Pin B5 which is the mapped timing data stored in the MEM CAL D 5 Circuit 424 BYPASS Connected to one of the four wires that run as a group to the 4
221. to Link CalRx above but in this case the ECM or PCM transfers the ram or internal memory to KalMaker This memory is then used to enable certain variables such as block learn cells to be viewed The ECM ram is transferred automatically after a Link CalRx The Link RamRx option exists separately to allow the ram variables to be transferred independently of calibration variables The ram variables are continuously changing in the ECM or PCM so the transferred ram variables in KalMaker are a static snapshot Consequently the ram variables which are viewed are slow changing long term trims Link CalTx The Link CalTx option enables calibration data to be transmitted from KalMaker to the ECM The ECM reads the transmitted data variables via the serial link and stores them in response to a KalMaker request Note that in order for the transfer to occur a calibration must be loaded into Buffer1 The calibration must use the same program as that in the ECM The ECM program information is sent before any data is transmitted KalMaker proceeds with the transfer if the data is consistent with the program data contained in the calibration script An indicator bar displays the progress of the transfer The mouse cursor is hidden during the transfer in order to improve performance The Link CalTx data transfer is available only with RealTime programs The data transfer can occur while the engine is running and is seamless to program operation
222. tor as well as the two independent variables Edit3 RTLink The RTLink option transmits the value of the indicator to the ECM as it is being changed either by keypad or indicator For the RTLink option to function the calibration must support RealTime updates and the Data Link must be enabled On 3D variables which support Track RTLink will toggle between the calculator display and the independent variables when the SpaceBar is pressed This is intended to give the 34 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions user an indication of which indicator values are currently being used as Real Time updates data display and a mouse can t presently co exist without degrading system response times Edit3 tracK The Track option automatically highlights an indicator based on the current value of the independent variable KalMaker tracks the state of this variable and if an indicator is highlighted it means that the value corresponding to that indicator is being accessed The Track option is available only on certain 3D variables The calibration must support RealTime updates and the Data Link must be enabled When Track is enabled the value of the independent or tracked variables are displayed instead of the calculator and the mouse cursor is hidden to improve performance Pressing the SpaceBar exits Track and enables the mouse cursor The RTLink option must also be selected for changes to occur i
223. tor must also be fitted in accordance with engine demand and application Most multi point systems work on a fuel pressure of 43 45 psi The fuel pressure regulator is located in the fuel line after the fuel has passed through the rails allowing excess fuel pressure to return to the fuel tank Once fuel leaves the pump a high pressure line between 9 5mm 3 8 inch and 12 7mm 1 2 inch in diameter is required to feed fuel to the fuel rails A 9 5mm 3 8 inch diameter line will feed up to 500 hp while a 1 2 inch line is required if you will make more than 370Kw 500 hp The return line is under approximately 5 6 psi of pressure requiring a minimum line size of 9 5mm 3 8 inch to accommodate the system Use steel tubing and the fewest number of 90 degree fittings possible for the high pressure circuit Adjusting the TPS Throttle Position Sensor For non GM or modified GM Throttle Bodies setting the correct TPS voltage can be done after engine start up in accordance with the instructions at TPS Voltage on page 140 The following procedure may resolve any problems before you start 1 Connect a Digital Volt Meter between the Dark Blue wire in TPS 3 wire harness and Black wire in TPS 3 wire harness 2 Loosen TPS mounting screws Vol 1 Chapter 4 Vehicle Modifications and Kalmaker Fuel Pump and Fuel Pressure 3 With ignition ON manually adjust TPS to obtain a reading of 0 54 volts 0 08 volts 0 46 volts to
224. ts at ECM A B connecor terminal 7 unless system is detecting detonation O2 sensor showed lt 0 250 volt for over 20 seconds while operating closed loop Indicates a defective oxygen sensor unit O2 signal circuit shorted to ground or the existence of some other condition ie low fuel pressure fuel contamination etc which would cause a lean mixture condition ECM Terminals D6 See D 6 on page 94 and D7 See D 7 on page 95 should be checked and then inspect hoses and intake manifold gaskets 208 Vol 1 Chapter 16 Trouble Codes Trouble Code Listing Table 32 Trouble codes listed numerically Continued 45 51 52 53 54 55 O2 sensor showed gt 0 550 volt for over 50 seconds while in closed loop with engine running over 1 minute and throttle open more than 2 indicates a defective oxygen sensor unit or some other condition ie high fuel pressure leaking injector fouled spark plug etc which would cause a rich mixture condition Also check the charcoal canister for fuel if fitted PROM Error Check insertion of MEMCAL in socket and bent pins Check that CALPAK is in place fully inserted and no bent pins System voltage at ECM terminal B2 in excess of 17 1V for more than 2 seconds A faulty charging system may be the cause Fuel Pump Circuit Low Voltage Indicates a defective fuel pump relay low voltage below 2V on FP Signal circuit or the loss of voltage for more than 1 5 seconds to the fuel p
225. uffer Edit View option displays the default data list from within the Edit screen The data list is not selected from within Vol 1 Chapter 3 Kalmaker Editor Menu Commands 49 Menu Functions Buffer Edit because the data list is viewed frequently and a default select option here would be a hindrance The default data list is saved together with tracking information to a track file by selecting Edit Margin Save The track file has the same file name as its associated ram script but a different extension The track file is automatically loaded with a ram script if it exists List View The View option enables the user to select one of the available data lists for display to the screen as text The actual information contained in the data list is calibration specific and is covered in the relevant Engine or Transmission Reference Once the View option has been selected the mouse cursor is hidden to improve performance Pressing the SpaceBar or Escape key exits the display and enables the mouse cursor The View option discards the data once it has been displayed List Capture The Capture facility is similar in all respects to the View option above the only difference being in the destination of the displayed data Data displayed to the screen using List Capture is written to a Capture buffer which is allocated when KalMaker starts up The user can specify the size of this buffer it can capture several hours of data if there is
226. uired script cannot be found E1330 Track structure allocation error The information used for variable tracking as well as the default data list is stored in a track file in the script directory and is loaded automatically with the script file This error is displayed if an error occurs while allocating the memory required for the track information E1331 Track file read error An error occurred while reading the default data list from the track file E1332 Track file read error An error occurred while reading the tracking information from the track file E1333 CheckSum Link Failure Before transmitting the calibration data to the ECM or PCM the program checks that the program in the ECM or PCM is the same as that loaded in the current buffer This error is displayed if a request is made for this information but no data or invalid data is received E1400 Can t find file A DOS critical error has occurred while creating a list of gauge script files for reading Usually caused by searching for a directory or drive which is not ready or doesn t exist E1401 No files found that match path No files have been found which match the gauge filelist wildcard 188 Vol 1 KalMaker Application Errors E1402 Out of memory allocating file list An error occurred while allocating memory for the gauge file list E1403 Can t open Gauge Script for file An error occurred while opening the gauge script required by th
227. ump while the engine is running If the Fuel pump relay circuit and connections are good check the oil pressure switch if fitted ECU A to D error Check ECU grounds or excessive input voltage In addition to the above indicated individual possible problem areas all trouble codes except TC51and TC53 could also have a defective ECM listed as one of the possible reasons for the trouble code being displayed Table 33 Trouble codes by fault type Problem Code s NO problem 12 Oxygen Sensor 13 44 45 Coolant Sensor 14 15 TPS Throttle 21 22 MAT Temperature 23 25 MAP Pressure 33 34 Speed Sensor 24 Crankshaft Sensor 41 Spark timing 42 Knock Sensor 43 Memcal problem 51 52 Alternator overvoltage 53 Control unit input 55 Vol 1 Chapter 16 Trouble Codes 209 Trouble Code Listing 210 Vol 1 Chapter 16 Trouble Codes Table 34 List Of Fuel Injectors Ibs Test Test per Press k Press P Sty ManufacturerPart hour Pa SI Ohms Colour le Mfg Number 10 3 36 3 Bosch 280150207 12 8 36 3 Bosch 280150210 12 9 43 5 MP Bosch 280150716 13 300 Bosch 0 280 150 208 13 1 300 Bosch 0 280 150 716 14 39 2 MP Bosch 280150208 14 33 14 5 Gray MP Bosch 280150727 ND DDK 14 2 25 Dark MP Bosch Blue 14 2 35 Dark MP ND Blue 14 30 16 2 Gray MP ND 14 11t0 18 Gray MP Bosch 14 1 43 5 Bosch 280150211 14 1 43 5 MP Bosch 280150220
228. ur in real time Important Note that the user can track a variable change it and have nothing happen This can occur when there are two or more tables for a particular function For example there may be a low temperature VARLO map table and a high temperature VARHI map table If the user tracks and changes VARLO map when the coolant is hot and VARHI map is actually being used then the low temperature table will change in real time As the system is using VARHI map however nothing will happen to the 32 Vol 1 Chapter 3 Kalmaker Editor Menu Commands Menu Functions engine operation No changes will be noticed until coolant temperature falls to the level at which VARLO map is chosen Edit2 Margin The Margin option configures the tracking margin For tracking to work assume we have a 2D variable VAR map with indicators at breakpoints of 20 40 60 80 and 100 map The map variable transmitted by the ECM used to track VAR map is tested to see if it falls within a breakpoint plus or minus the margin The margin is the percentage difference between one breakpoint and the next It is not always constant as sometimes breakpoints are unevenly spaced Table 8 10 percent Margin Low BreakPoint High 20 20 22 38 40 42 58 60 62 78 80 82 98 100 100 Table 9 25 percent Margin Low BreakPoint High 25 20 20 35 40 45 55 60 65 75 80 85
229. uration file E1105 No printer port at xxx No printer port was found in the BIOS table at the selected address E1106 Link cable not detected on Iptx xxx A link cable was not detected on the selected parallel port A link cable can pass this test an still be defective however E1200 Can t find file A DOS critical error has occurred while creating a list of files for reading Usually caused by searching for a directory or drive which is not ready or doesn t exist E1201 No files found that match path No files have been found which match the filelist wildcard E1202 Out of memory allocating file list An error occurred while allocating memory for the file list E1203 Can t open binary file An error occurred while opening the indicated file for reading E1204 file is not a calibration binary A binary calibration must be either 16K 16384 bytes 32K 32768 bytes or 64K 65536 bytes The size of the file indicated is none of these Vol 1 183 KalMaker Application Errors E1205 Can t find script file for file The calibration script required for the loaded calibration cannot be found along the script search paths E1206 Script file invalid for file The calibration script required for the loaded calibration is not contained in the security file E1207 Script file inconsistent for file The calibration script information does not match that contained in the security script
230. urn to a value of 100 When the engine is started the STFT is at 100 until the O2 sensor starts working the CTS reports normal engine temperature and the time delay constraints have been met in other words Open Loop Once the ECM goes into closed loop the STFT begins to adjust the fuel delivery to maintain a 14 7 A F ratio Block Learn Block Learn Long Term Fuel Trim is used to automatically adjust the VE table The VE table is a table of values of RPM vs MAP The values are plotted for each Load Point or every 400rpm See FUL AFR RUNAFR map rpm on page 114 At every Load Point there are a range of RPM vs MAP values gathered together in a Block referred to as a Block Learn Cell Each Block Learn Cell has its own Block Learn value called BLM in the Delco The BLM value ina given Block Learn Cell affects all the values in the cell Over time the BLM will settle at a value that gives a 14 7 A F ratio with no closed loop correction The BLM can be up to 32 different numbers depending on the ECM model Note If you disconnect the battery the BLM adjustments revert back to 128 or neutral Integrator and Block Learn In Action In closed loop the Integrator increases or decreases as the ECM gets feedack from the O2 sensor The BLM value follows but there is a delay As the BLM rises for example the AFR drops gets richer in response to the changing VE table The Integrator will then stop rising and begin to fall Once the
231. y notice when using KalMaker that a variable can be set to a certain value and saved When the variable is edited again its displayed value differs from its previous value The reason for this difference is in the way KalMaker translates calibration values and the way the values are stored in the calibration Calibration values are usually one or two bytes in length A byte can only have 256 integer values and a word 65536 integer values which aren t convenient units to work with Automotive calibrations don t use floating point numbers because operations with them are far too slow for Real Time operation KalMaker converts the computer units into real world floating point units such as kiloPascals or degrees Celsius which are easier to work with As part of this conversion the resolution of the units is increased to make them convenient to use When these floating point values are saved they are converted back to integer units This conversion truncates or rounds the floating point units The precision loss caused by truncation is always less than one part in 256 for byte variables or one part in 65536 for word variables Vol 1 Chapter 15 Troubleshooting 197 KalMaker Link Trouble Shooting KalMaker Link Trouble Shooting IMPORTANT DO NOT call for technical support until you have read the following AND performed ALL the recommended procedures KalMaker does not link E1305 Link Update disabled Problem is ei

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