SERVICE MANUAL - E85 tuning.hu
Contents
1. programmable E85 conversion kit SERVICE MANUAL recommended by the Hungarian Bioethanol Association 2 F as e 6 1 9 D 2 a A5 256 eret Nihin EIXE EE ai ARS N TNI j NPT Ss 3 po a LS v c P Q pill ti co UU a gt e so uf SOrCTIETIETIC TETT a i Co Tm h iy i3 i a Ws vA Hi Sg beware i gt amp T TR su awT r rE www bioetun com BIE T LIN 1 THEORETICAL DIAGRAM BioETUN E85 mode switch E85 CONVERSION KIT communication wire engine management system NTC temperature sensor eater pe map ae tl Original engine temperature sensor MINIMUM TOOL REQUIREMENTS FOR INSTALLATION digital multimeter for ohm and voltage measurements LED break detector for injector control soldering iron insulation tape shrink tube pliers crimp tool for the injector connections tools for opening the car s dashboard engine housing PC compatible computer Windows XP operating system serial port if no serial port is available usb rs232 converter INSTALLATION PROCEDURE Step 1 The measurements Measuring injector resistance The BioETUN 1 4 electronic system is used for the conver sion of central or single cylinder injection automobiles to use E85 fuel The resistance of the injectors must be meas ured in all cases using a simple multimeter For central in jection engin2. difficult will require a specialized tool and removal can potentially damage the connector or the prongs The new gaskets may require using slightly more force to click the components together When properly connected there should be a clearly audible click A common issue especially for Nippon Denso connectors involves the opening of the female connectors being slightly wider than the prong of the respective male connector Make sure to check for this as it can lead to faulty contacts If necessary a tiny screwdriver can be used to modify the tightness of the female connector Always use a furry fabric cable tie to affix the cables together The connected connectors can be tied to the original cables or the combiner with cable ties If installing them inside the engine housing ensure that nothing is pressing on the connections and none of the contact are vibrating When preparing the injector connectors you will need jumper cables for every cylinder which will be used to transmit the power needed for operating the injectors These jumper cables should be roughly 150 200 mms in length and should have a male connector on one end and a female on the other Ensure accurate prong distribution The jumper cables should be connected as shown on the following diagram Jumper cable 12V Male connector Female connector towards an engine controller onto injector CONNECTING A SUZUKI SWIFT TBI Control for a Swift Throttl
3. 2V or the black ground wires of the BioETUN electronics system The switch should be connected as shown on the following diagram ignition 12V to switch CONNECTING THE HEAT SENSOR The NTC heat sensor included with the package Is used to monitor the system s temperature Using the basic configuration the cable set is meant for this sensor The orange cable should be connected to one of the wires while the ground should be connected to the other The wire colors are irrelevant you can solder to any of the prongs proper grounding is however very important The heat sensor should ideally be affixed to the heating tube with cable ties It is important to ensure that the sensor not be cooled by air movement during driving To this end wrapping it in a thermally resistant and insulating material may be worthwhile Connecting to the factory standard thermostat is also possible To do this connect to the shorter white orange cable instead of the orange one Almost all cars have two or more heat sensors some types integrate the two into a single thermostat Make sure that you connect to the 5V factory sensor Voltage should be above 4V cold and around OV hot The appropriate sensor should be set in the BioETUN TUNER program with the cold start parameters optimized for the type of sensor in question CONNECTING THE COMMUNICATIONS PORT BioETUN devices should almost always be optimized for the car in question After install
4. ation the BioETUN TUNER program can be used to monitor precise operation The newest version of the BioETUN TUNER program can be downloaded from www bioetun com by clicking on the Download menu The DSUB9 es 9 pin connector included in the package can be used to connect to the electronic system Be careful when attaching the connector most communications malfunctions are caused by not connecting all of the prongs correctly The prong numbers are visible on the connector this should be of great help when attaching the connector The correct attachment of connector can be seen on the following diagram ICRIMPING THE INJECTOR CONNECTORS 2 white yellow 3 white brown 5 black white or white blue soldered side view BIOET LIN 4 A crimp tool will be necessary for properly attaching the injector connectors included in the package Ensure that the rubber gaskets are attached securely to the connecting pins Always crimp them together with the connectors If the gaskets are misaligned on the wires or are insufficiently attached they will fail to operate adequately and water or vapor can enter the injector connectors This can eventually lead to oxidation A common issue is not squeezing the crimp tool hard enough allowing the cable to slip off the prong Carefully push the prongs and the prepared connectors together making sure they click into place Double check correct prong distribution because removing them later on will be
5. e Body Injection central injection can be achieved by connecting the first two channels black green black blue or green blue in parallel The components should be connected as shown on the following diagram E85 mode switch communication connector temperature sensor based on original wiring red Ignition 15 12V BioETUN black green black blue O green i igi Swift Swift original yellow black O X 0 injector valve x engine management cut system Injector control from a frontal view the yellow black cable for the grey connector on the left side of the central injector The other yellow cable is the power for the injector Warning do not attempt to use this as the power source for the BioETUN system ground from the firewall next to the ignition coil power ignition switch 12 V from the ignition coil NTC heat sensor positioning cable tied to the water pipe behind the engine protected against cooling After cutting the yellow black cable the single color green and blue cables twisted together towards the injector The black green and black blue cables twisted together should be wired towards the cable set that is the factory standard engine control MADE IN HUNGARY Connection diagram For a 4 injector vehicle Communications connector souy black 5 white yellow or white O 2 hite b d whit Configuration switch ore ee included in package BIE MN a ere black white or white b
6. er the Downloads menu username e85 password tuning While the device is dust and moisture resistant we suggest installing it inside the cabin for in stance under the dashboard Should this not be practicable it should be installed inside the engine compartment protected from water and fixed in place with cable combiners The device is heat resistant up to 85 degrees Celsius but must not be installed near sources of radiating heat such as the turbo or exhaust knee Optionally the BioETUN 1 4 electronics warning light can also be installed The warning light may be a LED or an incandescent bulb of no more than 5 A amperage The warning light s operation is detailed in the program description Switching the purple wire of the mode switcher to ground the programmed E85 mode will activate The switch will light up when switched on so we suggest connecting an ignition switched 12V next to the switch The device has a default program meaning that the car should start with the installed electronics system without need for any further programming CONNECTING THE SWITCH The switch included in the package Is capable of signaling E85 mode When active it lights up green To connect it you will need ignition switched 12V ground and the connecting wire for the BioETUN 1 4 electronics system purple wire It is a good idea to ensure adequate power supply before installation possibly via connecting a separate cable off the red 1
7. es the system can only be used for controlling injectors above 3 ohms while for central injection engines only injectors above 10 ohms can accom modate the system Details for the conversion of the first generation Suzuki Swift central injection model are described in a separate document available at e85tuning hu under the Downloads menu Determining the injector control signal Two cables are attached to the injector through the con nectors Generally one of them will be 12V while the oth er is the negative control signal BioETUN 1 4 processes and forwards the negative signal making it important to determine which is the control cable before conversion A LED break detector for example is an appropriate tool for this Warning A detector with an incandescent light bulb should not be used because the factory electronics can in terpret the incandescent bulb as a short circuit leading to the possibility of a malfunction Measuring thermostat voltage The BioETUN 1 4 electronic system can operate with the included NTC heat sensor in which case further measure ments are unnecessary However connecting to the car s factory standard 5V heat sensor is also possible For the first option the orange cable should be used while for the second the white orange cable the electronics should be programmed accordingly via the BioETUN Tuner software If you wish to perform temperature measurements con nected to the factory
8. lue purple O programmable F85 conversion Mode display light LED NTC heat sensorr kit brown pA included in package IN ignition switch 15 AD1 orange red 12V ON o I sls Sls slal 2 8 I efg Fou Ere ol i aad ale z 63s a O oO s O ki HU S 2 2 Fa Factory engine thermostat To optional NOTE Only one of the two can be selected _ ge d factory i engine control 12V 12V 12V 12V wire connection e al Ly gt Ly Hla i Injector i Injector E Injector tov bbi inform ci www bioetun hu
9. standard thermostat then you will need to find the thermostat wire where 0 5V voltage is pre sent between cold and hot operation If there are several thermostats or one combined thermostat you will need to find the 5V system in all cases Step 2 Connecting the electronic system wiring The BioETUN 1 4 system is capable of independently controlling a maximum of 1 4 cylinders The de vice is agnostic to the exact sequence in which the cylinders are connected but it performs measure ments on Channel 1 black green green wire hence that channel needs to be connected in all cases The wires connecting to the factory standard electronics are always dual colored for example black yellow while the wires connecting to the injectors are single colored for example yellow The connectors included with the electronic system are composed of plastic housing rubber gas kets and connecting pins It is best to use a crimp tool to attach the pins to the cables then connect them according to the control pin schematics Do not forget the rubber gaskets as they serve to guarantee long term oxidation free operation for the connectors Power supply for the electronic system Is via 12V ignition switch only Thorough grounding and an appropriate continuous power supply is a must even when jump starting We suggest that you download the service documents before attempting to connect the electronic system they are available at e85tuning hu und
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