Series 2 EMS Instructions
Contents
1. 7 6 5 4 3 2 1 o 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 17116 15 14 1312 11110 9 8 191817161514 1312 1110 9 8 16151413121110 9 87 171615141312 1110 9 8 2726 25224 23 22 21 20 19 18 2726 2524 2322 21 20 27262524 23 222 21 20 119 11817 2524 23 22 21 20 11918 34 333 32 31 30 29 28 35134 33 32 31 30 2928 35 34 83 32 31 30 2928 31330 29 28 27 26 Connector A Connector B Connector C Connector D Page 19 of 21 AEM EMS EMS Ae 2004 STI 2 5L 2005 2006 STI 2 5L 30 6820 EMS pin description D1 GND control systems Dedicated also A34 B1 B4 B12 B31 C32 C33 D2 D7 D31 GND control systems Dedicated also A34 B1 B4 B12 B31 C32 C33 D1 D7 D31 in in E enso elector Tonle round ou Bea sensor Electronic Throttle Ground Out Dedicated Electronic Throttle control Motor Power Electronic Throttle Power in Dedicated ETC power D7 GND Injectors PowerGround in Dedicated also A34 B1 B4 812 831 C32 093 01 02 031_ Stanerswitch Main Relay circuit Switch 1 In Dedicated S i i Neutral Position switch Noted ooo D10 _ Power Steering oil pressure swith nouses S D11 Rear Defogger switch Switch 4 n Available switch should connect to GND when closed motusedbystoekecu o o o ooo Note o o Blower Fan switch Switch 5 on Available switch should connect to GND when closed Main Relay circuit Test Mode Connector Ignition Switch Switch1 Not Used D1 nt cme ERT S y2. This system is active on this EMS when used with the provided startup calibrations and can be adjusted through the use of the VVC 1 Target map Adjustments to the intake cam timing are made by changing the values in the VVC 1 Target map per Engine RPM and Engine Load The values in the VVC 1 Target map can vary from 0 degrees for zero intake cam advance to 50 degrees for full intake cam advance The channels VVC 1 Advance and VVC 1B Advance show the measured position of the camshafts WARNING Improper use of the Variable Valve Control VVC in the AEMTuner software can lead to engine damage Be very careful when building or tuning unknown engine combinations or using aftermarket pistons or valve train components OEM engines and valve trains are not designed or manufactured to allow valve to piston interference at certain cam angles AEM will not be responsible for engine damage resulting from improper use of the VVC function on engines with valve trains designed to allow mechanical interference Please note that some Subaru camshaft sensors will send false signals under some conditions often light load and low RPM This can be observed with an oscilloscope or high speed datalogger and occurs with the stock ECU as well These false signals will not cause engine misfires with the Series 2 EMS but will sometimes be reflected as quick jumps in the measured VVC 1 Advance channels Normal cam signal
3. Multiple calibrations may be supplied for each EMS additional details of the test vehicle used to generate each calibration can be found in the Calibration Notes section for that file Please visit the AEM Performance Electronics Forum at http Awww aemelectronics com and register We always post the most current strategy release PC Software and startup calibrations online On the forum you can find and share many helpful hints tips to make your EMS perform its best TUNING NOTES AND WARNING While the supplied startup calibration may be a good starting point and can save considerable time and money it will not replace the need to tune the EMS for your specific application AEM startup calibrations are not intended to be driven aggressively before tuning We strongly recommend that every EMS be tuned by someone who is already familiar with the AEM software and has successfully tuned vehicles using an AEM EMS Most people make mistakes as part of the learning process be warned that using your vehicle as a learning platform can damage your engine your vehicle and your EMS Page 2 of 21 Read and understand these instructions BEFORE attempting to install this product Subaru 2004 2005 2006 Model Year Differences Although there are very few differences between the 2004 and 2005 2006 models the ECUs are not interchangeable The 30 1820 EMS must be used in a 2004 vehicle and the 30 1821 EMS must be used in 2005 2006 vehicles Consult the
4. PERFORMANCE ELECTRONICS Installation Instructions for EMS P N 30 6820 2004 Subaru WRX STI USDM 2 5L turbo and EMS P N 30 6821 2005 2006 Subaru WRX STI USDM 2 5L turbo WARNING This installation is not for the tuning novice nor the PC illiterate Use this system with EXTREME caution The AEM EMS System allows for total flexibility in engine tuning Misuse of this product can destroy your engine If you are not well versed in m engine dynamics and the tuning of management systems or are not PC literate please do not attempt the installation Refer the installation to a AEM trained tuning shop or call 800 423 0046 for technical assistance You should also visit the AEM EMS Tech Forum at http www aempower com NOTE AEM holds no responsibility for any engine damage that results from the misuse of this product This product is legal in California for racing vehicles only and should never be used on public highways Vehicle fitment Series EMS Series II EMS 2004 Subaru WRX STI 30 1820 30 6820 2005 2006 Subaru WRX STI 30 1821 30 6821 2011 Advanced Engine Management Inc ADVANCED ENGINE MANAGEMENT INC 2205 126 Street Unit A Hawthorne CA 90250 Phone 310 484 2322 Fax 310 484 0152 http www aemelectronics com Instruction Part Number 10 6820 Page 1 of 21 Thank you for purchasing an AEM Engine Management System The AEM Engine Management System EMS is the result of extensive d
5. of Injectors 4 Inj 1 4 EGT 4 Location EGT 4 Factory Injectors 500 cc min saturated Spare 0 5V Input Channel ADCR 13 Factory Inj Resistors No Spare 0 5V Input Channel ADCR 11 Injection Mode Sequential Spare 0 5V Input Channel ADCR 14 Knock Sensors used 1 Knock 1 Spare Low Side Output Driver Low side 2 Lambda Sensors used 2 aftermarket wideband sensor required OEM O2 sensors not supported Spare Low Side Output Driver Low side 3 Spare Low Side Output Driver Low side 4 Spare Low Side Output Driver Low side 11 Idle Motor Type None Electronic Throttle Spare Low Side Output Driver Main Relay Control Yes Switch 1 in Coil7 output Spare Low Side Output Driver Crank Pickup Type Magnetic Spare Low Side Output Driver Crank Teeth Cycle 36 2 2 2 Spare Low Side Output Driver Cam Pickup Type Hall Effect Spare Low Side Output Driver Cam Teeth Cycle 3 Spare Low Side Output Driver Transmissions Offered Manual Spare Low Side Output Driver Trans Supported Manual Check Engine Light Low side 10 Drive Options AWD Spare High Side Driver High side 1 Supplied Connectors Spare High Side Driver AEM Extension patch harness 30 2988 Spare High Side Driver AEM Plug pin kit N A Spare High Side Driver Spa
6. use Before beginning this procedure please be familiar with the location and function of the CRUISE and SET COAST buttons on the Cruise Control Steering Column Stalk as depicted in Figure 2 Also be aware of the green CRUISE and SET indicator lights on the dashboard Figure 3 This procedure should be repeated any time any part of the ETC system has been serviced removed or replaced Note Do not attempt to start or run the engine during the calibration procedure The EMS will disable engine start running whilst in calibration mode CRUISE Figure 2 CRUISE and SET COAST buttons Figure 3 CRUISE and SET indicator lights 1 Initial Calibration Procedure a a gt eao 5 mS gt Turn the ignition key to the ON position The CRUISE and SET indicator lights will begin flashing in unison at a medium rate Press and hold the CRUISE button See Figure 4 for approximately three 3 seconds until the indicator lights stop flashing There will be a brief delay after which the CRUISE light will flash once Ensure the accelerator pedal is not being depressed and is in the full UP position The SET indicator light will flash rapidly for a few seconds as the EMS calibrates this position There will be a brief delay after which the CRUISE light will flash twice Depress and hold the accelerator pedal to the floor and ensure it is in the full Wide Open Throttle WOT position The SET indicator l
7. Cam signals Both of these channels should respond when the engine is cranking if either signal is not being detected or measuring an incorrect number of pulses per engine cycle the EMS will not fire the coils or injectors If the Engine Load changes when the throttle is pressed this usually indicates that there is a problem with the MAP sensor wiring or software calibration when the EMS detects that the MAP Volts are above or below the min max limits it will run in a failsafe mode using the TPS to Load table to generate an artificial Engine Load signal using the Throttle input This may allow the engine to sputter or start but not continue running properly Sufficient battery voltage during cranking starting Having enough battery voltage when you crank over your vehicle is critical to the operation of your vehicle and your AEM EMS For the EMS to function properly the battery voltage must remain at or above 8 Volts when the vehicle is first starting This is the time when your electrical system will be worked its hardest and be at its lowest voltage If you are connected to your Series 2 EMS with a USB communications cable and you experience disconnecting while the vehicle is cranking the reason may be a battery voltage of less than 8 volts If this is the case you can confirm this by connecting with a serial cable a serial adapter may be required if your computer is not equipped with a serial port and check in the AEMTuner software for a
8. Channel called Run Time Run Time is the amount of time in seconds that the EMS has been turned on for If you notice that this Channel goes to zero while the EMS is communicating with the computer and the vehicle is being cranked that means the EMS has had lower than 8 Volts at some point and has reset the system A thorough wiring check may reveal a large voltage drop causing this problem or it may simply be the need for a new or a larger battery Page 15 of 21 Application Notes for EMS P N 30 6820 30 6821 Subaru Impreza WRX STI USDM 2 5L Make Subaru Description Function Model Impreza WRX STI Spare Injector Driver max 1 5A Injector 5 C2 Years Covered 2004 30 6820 EMS 2005 2006 30 6821 EMS Injector 6 C1 Engine Displacement 2 5L Spare Injector Driver max 1 5A Spare Injector Driver max 1 5A Injector 7 A6 Engine Configuration Flat 4 Spare Injector Driver max 1 5A Injector 8 A7 Firing Order 1 3 2 4 Spare Coil Driver 0 5V falling edge Coil 5 N A S C or T C Turbocharged Spare Coil Driver 0 5V falling edge Coil 6 MAP Min 0 8V 14 7 PSIg Boost Solenoid PW 2 MAP Max 4 59V 23 8 PSIg EGT 1 Location EGT 1 Coils 4 with internal igniters EGT 2 Location EGT 2 Ignition driver type 0 5V Falling Edge trigger EGT 3 Location EGT 3
9. Ignition Power_ _In__ Dedicated also connects to A18 A19 B5 tt a Camshaft position sensor LH Vehicle Speed in PnP for Cam sensor LH Camshaft position sensor RH Cam n Crankshaft position sensor Signa Crank m Dedica Cd pe e O a GND ignition System Power Ground in Dedicated also A34 B1 B4 831 C32 033 01 02 07 031_ PS Coil 6 pot Ow Available Coil 5 output 0 5V falling edge trigger PnP for Coil 4 O 5V_ falling edge trigger PnP ror cna ov fang edge ier Tn ease acu poner er temai aaaiogmemoy LH PnP for Cam sensor RH eee A a a a T m To Out Low Side 9 Low Side 8 ow Fuel Pump control unit Signal 1 FPCU circuit Coil 8 Spare Vehicle Speed Speed Out Dedicated 0 5V signal to Fuel Pump Control Unit Vehicle Speed Fuel Pump control unit Spare Speed FPCU circuit sig 1 Coil 8 In PnP for wheel speed input shared with speedometer Dedicated Notes S u u u CANH Dedicated u Dedicated also A34 B1 B4 B12 C32 C33 D1 D2 D7 D31 u u u po CANL Crankshaft Position sensor Shield A C relay control Low Side 6 PnP for A C compressor clutch e 4 5 High Side 1 Available switched 12V output driver Electronic Throttle control motor relay ETC relay control Dedicated Wire View Of AEM EMS Crankshaft position sensor Signal Timing Ground Out Not Used Out Out Bs Bs Bo sex e y B21 B22
10. Please note that before AEM can issue an RMA for any electronic product it is first necessary for the installer or end user to contact the tech line at 1 800 423 0046 to discuss the problem Most issues can be resolved over the phone Under no circumstances should a system be returned or a RMA requested before the above process transpires AEM will not be responsible for electronic products that are installed incorrectly installed in anon approved application misused or tampered with Any AEM electronics product can be returned for repair if it is out of the warranty period There is a minimum charge of 75 00 for inspection and diagnosis of AEM electronic parts Parts used in the repair of AEM electronic components will be extra AEM will provide an estimate of repairs and receive written or electronic authorization before repairs are made to the product Page 21 of 21
11. by selecting Tools gt gt Configure Outputs Page 5 of 21 AEM Electronic Throttle Control System ETC The 30 6820 EMS incorporates an ETC system which controls the OEM electronic throttle body All components of this system unmodified and as delivered from the manufacturer are required for optimum and safe functionality of this system These components include but are not limited to wiring ETC relay accelerator pedal assembly and throttle body The EMS ETC control system incorporates multiple failsafe strategies such that in the event of a component failure the system will shut down the ETC system and if necessary the engine in a graceful manner It still remains the user s responsibility to ensure that all vehicle component and wiring systems are maintained to a level of workmanship consistent with industry standards Note As the EMS is intended for use on vehicles that are to be operated off road only the factory cruise control system will be non operational after installation of the EMS Installation Information The 30 6820 AEM EMS was designed to work with the vehicle its components and wiring as delivered from the manufacturer If any of the components or wiring have been changed or if the drive line from the original vehicle has been placed in another vehicle such in a custom race application then the user should take heed of the following notes A mechanical Wide Open Throttle WOT accelerator pedal travel stop
12. charged System Voltage e Ensure vehicle battery is in good condition and properly charged e Check all wiring for shorts or intermittent connections Motor Driver e Double check that throttle body TPS sensor is wired per OEM specifications e Check throttle body wiring for shorts or intermittent connections e Ensure EMS has not been installed in an area of extreme heat gt 120 C WDR e Contact AEM EMS Technical Support EEPROM e Perform ETC system calibration e Restore ETC system factory calibration e Contact AEM EMS Technical Support Page 11 of 21 Wiring accessories to the EMS Please follow this suggested wiring diagram when adding new accessories and retaining original accessories such as the multiplex coolant temperature gauge air conditioning switch reverse lockout UEGO gauges MAP sensors IAT sensors or switches for use with the EMS Note that wire polarity is not important for the Air Temperature sensor ii i S AEM UEGO P N 30 5130 AEM EMS P N NG J cela RRAN y Pink Switched 12V Power AS O2 Sensor 1 White 0 5V Analog signal Red 12V power 5A fuse A4 C31 or C35 Sensor Ground tapped n Brown Analog signal Black Battery or chassis ground C16 5V Sensor Power tapped _ Red 5V Sensor Power MAP Signal i Green MAP Signal MAP Sensor Ke Sensor Ground tapped Black Sensor Ground P N 30 2130 50 A4 C31 or C35 sis o C13 IAT S
13. pinout chart for further information Peak and Hold Injector Drivers Injectors 1 4 include Peak 4 amps and Hold 1 amp injector drivers These drivers may be used with peak and hold or saturated type injectors The vehicle s wiring harness may contain a resistor pack to prevent excessive current if low impedance injectors were used with the stock ECU With the 30 6820 installed users can elect to remove and bypass injector resistors for more precise control of low impedance injectors Please note that the injector response time will be different with and without injector resistors installed If a resistor pack has been removed and bypassed please use the correct battery offset wizard for your injectors Most battery offset wizards will specify lt P amp H DRIVER gt if they are intended for use without a resistor pack Fuel Pump Control As supplied from Subaru the OEM ECU interfaces with a fuel pump control unit FPCU to control the speed high or low of the fuel pump based on load The AEM EMS has the ability to replicate this functionality however it is configured in the Startup Calibration to run the fuel pump at high speed at all times The EMS Output COIL8 Pin B26 for 2004 models pin B27 for 2005 2006 models is used to send a 5V signal instructing the OEM fuel pump ECU to energize the fuel pump Configuring User PW Out to use LS12 and for example User PW Analog Into MAP Volts will allow the voltage sent to the fuel pump ECU
14. stock Engine Control Unit ECU The location of the ECU on the WRX is underneath the passenger side floorboard A 10mm socket is required to remove the kick panel that covers the stock ECU Carefully disconnect the wiring harness from the ECU Avoid excessive stress or pulling on the wires as this may damage the wiring harness All connectors must be removed without damage to work properly with the AEM ECU Do not cut any of the wires in the factory wiring harness to remove them Remove the fasteners securing the ECU to the car body and set them aside Do not destroy or discard the original ECU as it can be reinstalled easily for street use and troubleshooting Install the AEM Engine Management System Plug the factory wiring harness into the AEM EMS and position it so the wires are not pulled tight or stressed in any manner Secure the EMS with the provided Velcro fasteners Reconnect the negative battery terminal Plug the communications cable into the EMS and into your PC Turn the ignition on but do not attempt to start the engine At the time these instructions were written new EMS units do not require USB drivers to be installed on the PC The EMS will automatically be detected as a human interface device HID With the AEMTuner software open select ECU gt gt Upload Calibration to upload the startup calibration file cal that most closely matches the vehicle s configuration to be tuned Check the Notes section of the calibra
15. to be varied in relation to MAP Volts pressure Increasing the duty cycle of the LS12 output will decrease the speed of the fuel pump WARNING Reducing the voltage sent to the fuel pump can affect fuel pump output volume and or pressure If you wish to decrease pump speed at light loads or low RPM monitor fuel pressure and air fuel ratio very carefully to avoid engine damage WARNING Do not use pin B26 B27 to control a fuel pump relay directly it must be connected to the OEM fuel pump control unit only If an aftermarket fuel pump relay will be installed wire it to be controlled using a spare low side output for instance LS2 is available on pin A13 Be sure to configure the output to use the Fuel Pump function using Tools gt gt Configure Outputs Page 3 of 21 Variable Valve Control VVC The Variable Valve Control table in the EMS can be used to control the STI s AVCS system which is used to change the airflow characteristics of the engine by advancing the timing of the intake camshafts The AVCS outputs pin A28 A29 Injector 9 10 outputs on the EMS advance the phase angle of the intake camshafts this will have effects similar to moving an adjustable intake cam gear This is controlled by the VVC 1 RH camshaft and VVC 1B LH camshaft outputs VVC position is monitored using the T2 and T3 inputs for independent closed loop feedback The VVC settings can be adjusted in the VVC tab which may be hidden in the default AEM workspace
16. value you selected Use the Sync Adjustment Increase Decrease buttons to make the physical reading match the timing number you selected Crankshaft timing marks are not labeled for some vehicles Consult the factory service manual for more information Note This calibration needs to be properly tuned before driving the vehicle It is intended for racing vehicles and may not operate smoothly at idle or part throttle NEVER TUNE THE VEHICLE WHILE DRIVING Page 14 of 21 5 Troubleshooting an engine that will not start a Double check all the basics first Engines need air fuel compression and a correctly timed spark event If any of these are lacking we suggest checking simple things first Depending on the symptoms it may be best to inspect fuses sufficient battery voltage properly mated wiring connectors spark using a timing light or by removing the spark plug wiring continuity tests measure ECU pinout voltages replace recently added or untested components with known good spares Check that all EMS sensor inputs measure realistic temperature and or pressure values If the EMS is not firing the coils or injectors at all open the Start tab and look for the Stat Sync d channel to turn ON when cranking This indicates that the EMS has detected the expected cam and crank signals if Stat Sync d does not turn on monitor the Crank Tooth Period and T2PER channels which indicate the time between pulses on the Crank and T2
17. B24 B25 E B29 B30 B31 B32 B33 B34 B35 g 0O 7 6 5 4 3 2 1 T 65 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 17 16151141312 1110 9 8 1918171615141312 111019 8 16 15 14 4139211110 9 8 7 17 16 115 14 1312 11110 9 8 27 26 25 24 23 22 21 201918 27226 2524 23 22 21 20 27 2625 24 23 22 21 201918 17 2524 23 22 21 20 1918 3433 32 31330 2928 3534 33 32 31 30 2928 35 34 33 32 31 30 29 28 3130 29 28 27 226 Connector A Connector B Connector C Connector D Page 18 of 21 Fc a oe pe neces ou ae can ve use or aacttonarinjecore LSA men Pee mees ot ae an ve usea for action injector 5A m0 Per wainawien ainsi n ete ETC syemin E r a a Ceo emesmen swen in aratate suich shold comet GND wren dosed EA nantes fer setvcoastewien Serswicn in Deiat ETS st np exe Fue Temperate sensorar cata avaabie pmpersetirosvingt Pers Imate Air Temperature sersorsgna ar in Pn torir iake Temp sensor ATO ype temear c14 Engine Coolant Temperature sensor_ Coolant In PnP for Coolant Temp sensor RTD type thermistor Accelerator Pedal Position sensor Accelerator Pedal 5V C15 Power refer
18. Early cam signal edge Page 4 of 21 EMS DC Stepper Motor control Subaru Tumble Generator Valves There are two sets of Tumble Generator Valves TGV found on the intake manifold of the STI Each set of valves is driven by a DC stepper motor and has a 0 5V feedback signal to monitor valve position The Motor 1 and Motor 2 Target tables are used to set the position of the valves valve position can be controlled based on various parameters such as throttle position vehicle speed engine RPM or engine load The channels ADCR11 and ADCR14 display the current position of the valves When these parameters are near 0 Volts the valves are open and will allow maximum air flow When these parameters are near 5 Volts the valves are closed creating turbulence in the intake stream and restricting air flow The valves are always open in the AEM supplied startup calibrations WARNING the EMS can be configured to control the left and right bank independently The engine will run very poorly if one set of TGVs is fully open while the other set is fully closed so please be sure that the Motor 1 and Motor 2 Target tables are both the same Subaru MAF sensor Intake Air Temp sensor The MAF mass air flow sensor can be removed to help decrease intake air restriction as the base map uses the factory MAP sensor to determine engine load Please be aware that the IAT intake air temperature sensor is integrated into the factory MAF sensor If the
19. IN N A 9 N A Table 3 Failure Type Fault Code A calibration fault will be reported if the Accelerator Pedal Position APP or Throttle Position Sensor TPS sensors are found to be outside of the specification limits Table 4 details the electrical limits for these sensors Sensor Mechanical Position Voltage Limit VDC a wor iin in ie poorne ARE U Sve simi O a ono ea exam WOT T10 z 045 TPS2 Sub r WOT 46 T Table 4 Sensor Electrical Calibration Limits A fault code of 5 RP Relay may be caused by a fouled throttle bore a malfunctioning or missing ETC relay or if the throttle body has mechanically failed Page 10 of 21 Troubleshooting Operational Faults Should an operational fault be detected please read and follow the following suggestions for each system APP e Ensure the accelerator pedal position sensor is in good condition and plugged in e Double check that APP sensor is wired per OEM specifications e Check all wiring for shorts or intermittent connections TPSA TPSB e Ensure the throttle position sensor is in good condition and plugged in e Double check that throttle body TPS sensor is wired per OEM specifications e Check all wiring for shorts or intermittent connections Target e Ensure throttle body bore is clean and free from obstruction e Ensure vehicle battery is in good condition and properly
20. Ignition Switch Test Mode Connector In Dedicated soomonmannomanor TS S yy ett AC Switch Main Relay control Coil 7 In PnP for A C request switch 3 D17 1 D19 7 Main Relay circuit Coil 7 Main Relay control AC Switch Switch 6 Out Dedicated activates main relay with switched GND pT Notseg o po po nouses o SSM GST communication ine SSM GST communication line Available jumper set for 0 5V input Not Used ow Oon po Oo po nousa o po nousa o om oa O Available 0 5V O2 2 signal Rear Oxygen sensor Signal Lambdas n Oo e S E po pctv n ne jumper set for 0 SVinput O pe tse E D31 Rear Oxygen sensor Shield Power Grounna Out Dedicated also A34 B1 B4 B12 B31 C32 033 D1 D2 D7 D2 Wire View Of AEM EMS l l 7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 17 16151141312 1110 9 8 HS9ABATFNHENS5144312 1110 9 8 16 15 14 131211110 9 8 7 17 16 115 14 1312 11 110 9 8 27 26 25 24 23 22 21 201918 27 26 2524 23222 2120 27 26 25 24 23 22 21 20 19 1 8 17 2524 23 22 21 20 19 18 3433 32 31 30 29 28 3534 33 32 313302928 35 34 33 32 31 3029 28 3130 29 28 27 26 Connec
21. ence Out Dedicated reference power to accelerator pedal Electronic Throttle control Power C16 Supply 5V Sensor reference Out Dedicated sensor reference power Accelerator Pedal Position sensor Main Accelerator Pedal signal 1 in Dedicated main 0 5V signal from accelerator pedal few cameramen TET sips C18 Electronic Throttle control Main Dedicated main 0 5V signal from throttle motor Pero tse FuellevelSensor fT Noted c21 FuelTank Pressure Sensor signal Noted S we O 1 i 2 Manifold Absolute Pressure sensor 2 signal MAP PnP for Manifold Pressure sensor 3 Mass Air Flow sensor Signal 0O o m n Available 0 5V MAF input signal N o 0 Knock Sensor Signal Knock 1 Oon Dedicated software configurable knock filter circuit Tumble Generator Valve position sensor LH ADCR14 PnP for TGV 0 5V_ input Tumble Generator Valve position sensor RH ADCR11 Accelerator Pedal Position sensor Sub Accelerator Pedal signal 2 Oon Dedicated secondary 0 5V signal from accelerator pedal i a e koe m Dedicated software configurable knock filter circuit C2 C2 C2 C2 C2 PnP for TGV 0 5V input C2 5 6 7 8 peso tse S Wire View Of AEM EMS
22. ensor Air Temperature Sensor A4 C31 C35 Sensor Ground tapped P N 30 2010 c9 Switch 2 Input Switch connects to GND Ground 30 1820 Series 1 vs 30 6820 Series 2 EMS differences The EMS functions assigned to certain pins have been changed and no longer match the 30 1820 EMS Unless otherwise noted the following pins and functions will need to be manually reconfigured after using AEMTuner to convert a 30 1820 Series1 EMS calibration for use with the 30 6820 Series 2 hardware Pin Vehicle harness destination 30 1820 function 30 6820 function Notes A2 Front O2 sensor heater __ Injector 5 Injector Smovedtopinc2 A3 _ Front O2 sensor heater __ Injector 6 Injector 6 movedtopinC1 po Sensor Ground Additional spare output pT Additional spare output Bis Additional spare output Big 5 Additional spare output eC Bag ANE 8 a re HS Oo y O e ineotor O a S a a a S c24 ooo oe A o kKnock2 Additional spare input Page 12 of 21 1 Install AEMTuner software onto your PC 2 3 The latest version of the AEMTuner software can be downloaded from the AEMTuner section of the AEM Performance Electronics forums found at www aemelectronics com Series 2 units are not supported by the older AEMPro tuning software Remove the Stock Engine Control Unit a b Disconnect negative terminal from battery Access the
23. eter will drop to zero and the EMS will not fire fuel injectors or ignition coils If the engine is running it will coast to a stop If the engine is not running it will not start ETC Diagnostics The AEM EMS ETC system uses the CRUISE and SET indicator lights on the dashboard to display diagnostic information to the user The indicator lights flash in different ways for different purposes as described in the following sections CRUISE SET Figure 9 CRUISE and SET Indicator Lights as diagnostic outputs Boot Up When the ignition key is turned on and the EMS is powered up both of the CRUISE and SET indicator lights will flash briefly to signify the ETC system has booted up and that the indicator lights are functioning properly Fault Detected When the ETC system detects a fault the CRUISE and SET indicator lights will flash in an alternating fashion to alert the user a fault has been detected This will happen in one of two situations 1 Calibration Fault A failed calibration will be detected if one of the sensors is found to be out of the expected range during the calibration procedure The indicator lights will flash in an alternating pattern to alert the user of this fault for a period of approximately twenty 20 seconds After this time period the CRUISE light will remain off and the SET indicator light will flash a fault code Please reference Table 7 for a description of the fault codes The system will fla
24. evelopment on a wide variety of cars Each system is engineered for each particular application The AEM EMS differs from all others in several ways The EMS is a stand alone system which completely replaces the factory ECU and features unique Plug and Play Technology which means that each system is configured especially for your make and model of car without any jumper harnesses There is no need to modify your factory wiring harness and in most cases your car may be returned to stock in a matter of minutes For stock and slightly modified vehicles the supplied startup calibrations are configured to work with OEM sensors providing a solid starting point for beginner tuning For more heavily modified cars the EMS can be reconfigured to utilize aftermarket sensors and has many spare inputs and outputs allowing the elimination of add on rev limiters boost controllers nitrous controllers fuel computers etc It also includes a configurable onboard 1MB data logger that can record any 16 EMS parameters at up to 250 samples per second Every EMS comes with all functions installed and activated there is no need to purchase options or upgrades to unlock the full potential of your unit The installation of the AEM EMS on the supported vehicles uses the stock sensors and actuators After installing the AEMTuner software the startup calibration will be saved to the following folder on your PC C Program Files AEM AEMTuner Calibrations AEM Updates Subaru
25. factory MAF IAT sensor is removed you may wish to install an AEM IAT Sensor Kit P N 30 2010 which includes a sensor wire connector and aluminum weld in bung While the factory MAF sensor locates the IAT sensor upstream of the turbocharger inlet it may be preferable to install an IAT sensor downstream of the intercooler to accurately measure charge temperatures EMS Fuel Map Boost Fuel Trim Table The 30 6820 calibration maps provided utilize the Boost Fuel Trim Table to provide a 1 1 fuel compensation above and below atmospheric pressure To use this table the Boost Fuel Trim Table should be configured to provide twice as much fuel when the manifold pressure is twice as high and half the fuel when the manifold pressure is half as high this should help simplify the tuning process for different vacuum and boost levels Notice the values in the main Fuel Map do not change significantly above 100 kPa 0 psi boost the fuel correction is being made by the Boost Fuel Trim Table Note the Boost Fuel Trim Table must be adjusted if a different MAP sensor is installed or if the Load breakpoints are adjusted The Boost Fuel Trim value should be set to 90 at 10kPa O at 100 kPa 100 at 200 kPa 200 at 300 kPa etc Check Engine Light The Low Side 10 output LS10 activates the Check Engine Light on the gauge cluster It is configured to activate at low RPM in the AEM startup calibrations this can be reconfigured
26. fasa Engne Ground PowerGround in Dedicated also B1 84 B12 831 C32 C33 D1 D2 D7 D31 Wire View Of AEM EMS w ras Ea EE ras a pa ma ms me Cara On tow contol solenoid RH Signal 12V Switched tariion Power a19 LH azo aot Traz 12s aaa as ans ae ae g 7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 17 16151141312 1110 9 8 HS9NBA7NE15144312 1110 9 8 16 15 14 4131211110 9 8 7 17 16115 14 1312 11110 9 8 27 26 25 24 23 22 21 201918 2726 2524 2322 21 20 27262524 23 22 21 201918 17 2524 23 22 21 20 1918 3433 32 3180 29 28 35 34 33 32 31 30 2928 351334133133231 3029 28 3130 29 28 27 26 Connector A Connector B Connector C Connector D Page 17 of 21 re e S SS e B1 GND Power Supply Power Ground in Dedicated also AS4 84 812 831 C32 033 01 D2 07 031_ B2 _ Rear Oxygen Sensor heater signa Nouse Cd es e tse ek Ba GND Power Supply PowerGround in Dedicated also A34 B1 812 831 C32 C33 01 02 07 031_ Control Unit Power Supply 12V Switched Ignition Power_ _In__ Dedicated also connects to A18 A19 B86 Control Unit Power Supply 12V Switched
27. ight will flash rapidly for a few seconds as the EMS calibrates this position There will be a brief delay after which the CRUISE light will flash three times The SET indicator light will flash rapidly for several seconds as the EMS calibrates the ETC throttle body If the calibration procedure was successful and all the ETC sensors and actuators are found to be within tolerance then the CRUISE and SET indicator lights will flash in unison at a medium rate If the calibration procedure fails indicated by the CRUISE and SET indicator lights flashing in an alternating pattern please reference the sections entitled ETC Diagnostics and Calibration Troubleshooting elsewhere in this document Turn the ignition key to the OFF position The ETC system is now calibrated and ready for use Figure 4 Pressing the CRUISE button Page 7 of 21 2 EMS Calibration Connect to the EMS using AEMTuner Edit the Idle vs Target table such that all cells are set to zero 0 percent Edit A C Idle Load Comp and or Idle Extra lt 12 Volt Options to zero 0 percent Verify that the EMS parameter Idle Position parameter is zero 0 percent Select Wizards gt gt Set Throttle Range Wizard in the AEMTuner software and complete the procedure Restore the above Options to their original values to ensure proper idle control functionality oap Re calibrating the Electronic Throttle Control System ETC Calibration Once the ETC system calibration
28. ion Diagram for EMS P N 30 6820 TEP The Pug and Pay system comes with his configured for proper operation of his device is avalabl forreassignment ae A1 cutcnsswitch Swing n Available switch should connect to 12V when closed _ A2 Front Oxygen Sensor Heater Signal 2 Injectors Out Available can be used for additional injectors 1 58 max A3 Front Oxygen Sensor Heater Signal Injectore Out Available can be used for additional injectors 1 58 max _ Pe sensor Ground oa Dedicated sensors only connects to pin C31 pe y oom Tin Avale osv 02 sensor 1 connectstopinA26 Tumble Generator Valve RH close idles A10 Tumble Generator Valve LH close idles Att Tumble Generator Valve LH open Idle 7 Pressure control solenoid valve fuel tank Low Side 3 imei Dedicated also connects to A18 B5 B6 Not Used Oi Oil flow control solenoid Signal 12V Switched Ignition Power Not Used Available can be used for Switched Ground 1 5A max PnP for Tachometer Oooo eS Engine Speed Output to OEM aa tachometer Tacho out LS7 Front Oxygen sensor shies o Front Oxygen sensor signa t o2 n Available 0 5v O2 sensor 1 connects to pin AS a tse aso o d S i G o aa ooo S e G o E a32 wastegate Control solenoid vave pwa ow PnP tor Boost Control Solenoid a33 Front Oxygen sensor signare apcris ow Available 0 5V sensor
29. is installed in the floor and or carpet of the vehicle as delivered from the manufacturer If this stop is removed for any reason such as removing the carpet for use in a race vehicle the user must ensure that a stop of some sort is fabricated and installed This stop must be fabricated such that there is a minimum clearance of 0 250 inches between the accelerator pedal mounting bracket and the accelerator pedal actuating rod when the pedal is at WOT See Figure 1 Sb 0 25 Min Figure 1 Minimum Pedal to Bracket Clearance The CRUISE and SET COAST buttons and the CRUISE and SET dashboard indicator lights are an integral part of the ETC system calibration and diagnostic functions It is therefore not recommended that these buttons and lights be completely removed from the vehicle such as could be the case with a purpose built race vehicle If the OEM steering wheel and or gauge cluster have been removed please temporarily re install them to calibrate the ETC unit or add switches and lights to the vehicle as shown 12V power 12V power Cruise Set Coast Cruise Set switch Renn LED Y v LED 15k 15k C7 resistor resistor Cil AEM EMS A15 A16 Normally Open momentary switches LEDs should be rated for at least 10 mA current Electronic Throttle Control System Calibration Procedure The 30 6820 30 6821 EMS as delivered requires a specific calibration procedure to be performed prior to
30. of 21 EMS Idle Control Calibration The ETC idle control can be configured and calibrated via the AEMTuner software similarly to more traditional systems that use an idle air bypass valve There are a few calibration options that are set specifically to allow proper ETC idle control and must not be changed from the values set forth in the 30 1820 startup calibration The options listed below must remain set as depicted for predictable ETC idle control The other options that are not highlighted have been set up for stable idle control in the 30 6820 startup calibration but are however available for adjustment as the calibrator sees fit Idle On if TP Less 18 Idle Off if TP Over 13 Idle Invert ON Idle FB Dir Invert ON Idle PW Frequency 10000 0 uS ETC Fault Management The ETC system continuously monitors itself for proper operation If a fault is detected then the system will be placed in a failsafe mode and power to the electronic throttle body will be turned off This will allow the engine to start and idle at approximately 1500 2000 rpm as a limp home mode but the throttle body will not respond to accelerator pedal inputs The system will continue to monitor itself and assume that the throttle blade will be in its rest position while in this un powered failsafe mode If it is detected that this is not the case then the system will enter a second failsafe stage whereby the crank signal to the EMS is interrupted The tachom
31. procedure has been performed it should not need to be re calibrated unless one or more of the following is true e The APP sensor TPS or throttle body have been removed replaced or adjusted e The EMS has been removed and installed in a different vehicle e AEM Technical Support has requested it to be performed The following procedure describes the steps to re activate calibration mode on a system that has already been calibrated Activate Calibration Mode a Ensure the ignition key is in the OFF position b Press and HOLD both the CRUISE and SET COAST buttons Please note that the CRUISE button is activated by pressing the end of the Cruise Control Steering Column Stalk and the SET COAST button is activated by pulling the entire stalk downward as depicted in Figure 5 Both buttons must be depressed and held prior to moving on to the next step __CANCEL A RES ACC GSES lt Y SET COAST J Figure 5 Pressing the SET COAST and CRUISE buttons c Turn the ignition key to the ON position d Keep holding both the CRUISE and SET COAST buttons for approximately ten 10 seconds until the CRUISE and SET indicator lights Figure 3 begin flashing in unison at a medium rate e Release the CRUISE and SET COAST buttons f Calibration mode has now been activated Follow the steps in Electronic Throttle Control System Calibration Procedure Initial Calibration Procedure to complete the process Page 8
32. re High Side Driver Spare High Side Driver VVC Low Side Driver RH cam Injector 9 VVC Low Side Driver LH cam Injector 10 Spare Switch Input switch to GND Switch 2 c9 Spare Switch Input switch to 12V Switch 3 A1 Spare Switch Input switch to GND Switch 4 D11 Spare Switch Input switch to GND Switch 5 D13 ECU Pin Spare Switch Input switch to 12V Switch 6 D16 D17 Wire View of AEM EMS O o p ea LO i o 2 s als e 7 s e IE 3lafs 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 10 11 12 13 1415 16 17 118 19 20 21 8 9 10 11 12 13 14 15 16 8 9 101112113114115 7 8 910 1112 10 11 121314 15 16117118 19 20 21 22 23 24 25 26 27 28 29 30 31 17 18 19 20 21 22 23 24 16 17 18 19 20 21 22 13 14 151617 2223 24 25 26 27 28 29 30 31 Connector A Connector B Connector C Connector D Connector E WARNING Switch input pins Switch 2 Switch4 Switch5 must connect to ground the switch should not provide 12V power to the EMS because that will not be detected as on or off Switch input pins Switch 3 Switch6 must connect to 12V the switch should not provide GND to the EMS because that will not be detected as on or off Page 16 of 21 Connect
33. sh the code repeatedly until the ignition is turned off Page 9 of 21 Calibration Faults APP Minimum APP Maximum TPS Minimum TPS Maximum oy BR O P RP Relay Table 1 System Fault Code 2 Operational Fault When the system detects a fault during normal operation e g driving idling etc the indicator lights will repeatedly flash in an alternating pattern to alert the user of this fault until the ignition key is turned off Note that the ETC system will not be functional and the EMS may disable engine operation during this mode depending on the severity of the fault Once the ignition has been turned off and then on again the indicator lights will flash the fault code for the affected system The affected ETC system code will be first flashed on the CRUISE light after which the failure type will be flashed on the SET light These codes are listed in Table 2 and Table 3 The ETC system will remain un activated until the following boot up cycle i e key off then key on Operational Fault System 1 APP TPSA TPSB Target System Voltage Motor Driver WDR CO Ni O Or AJOIN EEPROM 9 N A Table 2 System Fault Code Troubleshooting Calibration Faults Operational Fault Failure Type 1 Out of Range Noise Disagreement General F2 N A N A CO Ni O Or AJ
34. tion for more info about the vehicle it was configured for These files can be found in the following folder C Program Files AEM AEMTuner Calibrations AEM Updates Subaru Set the throttle range Select Wizards gt gt Set Throttle Range and follow the on screen instructions When finished check that the Throttle channel never indicates less than 0 2 or greater than 99 8 this is considered a sensor error and may cause some functions including idle feedback and acceleration fuel to operate incorrectly Page 13 of 21 4 Ready to begin tuning the vehicle a Before starting the engine verify that the fuel pump runs for a couple of seconds when the key is turned on and there is sufficient pressure at the fuel rail If a MAP sensor is installed check that the Engine Load indicates something near atmospheric pressure approximately 101kPa or 0 PSI at sea level with the key on and engine off Press the throttle and verify that the Throttle channel responds but the Engine Load channel continues to measure atmospheric pressure correctly Start the engine and make whatever adjustments may be needed to sustain a safe and reasonably smooth idle Verify the ignition timing Select Wizards gt gt lgnition Timing Sync from the pull down menu Click the Lock Ignition Timing checkbox and set the timing to a safe and convenient value for instance 10 degrees BTDC Use a timing light to compare the physical timing numbers to the timing
35. tor A Connector B Connector C Connector D Page 20 of 21 AEM Electronics Warranty Advanced Engine Management Inc warrants to the consumer that all AEM Electronics products will be free from defects in material and workmanship for a period of twelve months from date of the original purchase Products that fail within this 12 month warranty period will be repaired or replaced when determined by AEM that the product failed due to defects in material or workmanship This warranty is limited to the repair or replacement of the AEM part In no event shall this warranty exceed the original purchase price of the AEM part nor shall AEM be responsible for special incidental or consequential damages or cost incurred due to the failure of this product Warranty claims to AEM must be transportation prepaid and accompanied with dated proof of purchase This warranty applies only to the original purchaser of product and is non transferable All implied warranties shall be limited in duration to the said 12 month warranty period Improper use or installation accident abuse unauthorized repairs or alterations voids this warranty AEM disclaims any liability for consequential damages due to breach of any written or implied warranty on all products manufactured by AEM Warranty returns will only be accepted by AEM when accompanied by a valid Return Merchandise Authorization RMA number Product must be received by AEM within 30 days of the date the RMA is issued
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