Engine Management System - Rasant Products · 1. Introduction Rasant Products would like to thank...
Transcript of Engine Management System - Rasant Products · 1. Introduction Rasant Products would like to thank...
Engine Management System
Installation Documentation
With Individual Throttle Bodies
Andrew Darud
Rev 2.0 – 02/06/2018
Overview:
1. Introduction .......................................................................................................................................... 3
2. Disclaimer .............................................................................................................................................. 3
3. Component List ..................................................................................................................................... 4
4. Required Tools and Supplies ................................................................................................................. 8
5. Installation ............................................................................................................................................ 9
Preparation ................................................................................................................................... 9
Harness Installation..................................................................................................................... 10
Ignition System Install ................................................................................................................. 15
Fuel System Install ...................................................................................................................... 16
6. Initial Power-up of the ECU ................................................................................................................. 19
Installation of AEM Infinity Tuner Software ............................................................................... 19
Setting ignition timing ................................................................................................................. 21
Final Steps ................................................................................................................................... 24
7. Tuning Basics ....................................................................................................................................... 27
Volumetric Efficiency – Fuel Delivery.......................................................................................... 27
Ignition Tuning ............................................................................................................................ 29
Infinity ECU Hot Keys: ................................................................................................................. 30
Creating a Log File in Infinity Tuner: ........................................................................................... 31
Viewing a Session (Log) File in Infinity Tuner: ............................................................................. 31
1. Introduction
Rasant Products would like to thank you for your order of our Engine Management Kit! We
are honored to be a part of your Porsche 911 build and would like to congratulate you as you
take steps towards modernizing and enhancing your 911.
Our goal at Rasant Products is to provide a quality product to fellow members of the
Porsche community as they seek to improve the performance, drivability, and enjoyment of
their vehicles. It is our sincerest hope that you find this customized kit exceeds your
expectations as you tune and drive your 911. We are fully committed to offering support both
during and after installation, so please feel free to reach out with any questions, comments, or
feedback you may have.
We look forward to working together as you get one step closer to perfecting your 911.
Best Regards,
Andrew Darud Rasant Products LLC
2. Disclaimer
Any Engine Management System used improperly can result in serious engine damage.
Rasant Products LLC is not liable for any personal or property damage while installing or using
our products. You continue at your own risk. We always recommend a qualified tuner to dial in
your new engine management system. Please follow all local regulations regarding vehicles that
have aftermarket parts installed.
3. Component List Item Quantity Description
AEM Infinity 8H
1 The heart of the kit, the Engine Control
Unit (ECU).
Distributor Adapter Kit for EFI
1 Rasant Products Cam/Crank Housing. This transmits both
Cam and Crank signals to your ECU.
Ignition Coils
6 Bosch coil-on-plug (COP) ignition coils
Spark Plugs
6 Bosch spark plugs with 5/8” hex (mandatory with the COP ignition)
Fuel Injectors
6 Bosch OEM Fuel Injectors
Engine Harness
1 Complete engine wire harness (terminals/connectors are populated)
Bussmann Fuse/Relay Center
1 Bussmann Fuse/Relay Center (complete with fuses/relays)
ECU/Fuse Center Bracket
1 ECU/Fuse Center Bracket (anodized aluminum bracket to mount the ECU and fuse/relay center)
MAP Sensor
1 GM 1 Bar Manifold Air Pressure sensor
IAT Sensor
1 GM Intake Air Temp sensor (fastening nut included as well)
Fuel Pressure Sensor
1 100 PSI Stainless Steel Fuel Pressure sensor
AEM Wideband O2 Sensor
1 Bosch LSU 4.2 Wideband O2 sensor
Wideband O2 Weld-in Bung
1 Weld-in O2 sensor bung (for your exhaust header)
Fuel Line and Hose End Kit
1 Fuel Line and Hose Kit (includes all the fuel line and hose ends needed to plumb between the fuel accumulator and the fuel pressure regulator)
Fuel Pressure Regulator
1 Adjustable Fuel Pressure Regulator
18-22 Ga Wire Butt Connectors
2 Wire butt connectors (for connecting ignition and tach signals)
14-16 Ga Wire Butt Connector
1 Wire butt connector (for connecting to factory fuel pump wires)
M3 Screw/Nut Set
4 M3 Fasteners (for the wire harness seal to vehicle body)
4. Required Tools and Supplies • 10mm open end wrench
• 13mm open end wrench
• 17mm open end wrench
• 5/16” open end wrench
• 11/16” open end wrench
• 3/4” open end wrench
• 7/8” open end wrench
• 3/8” Drive socket wrench
• 10mm socket
• 13mm socket
• 13/16” Spark plug socket
• 5/8” Spark plug socket
• 1/4” Drive socket wrench
• 7/32” Socket
• 5mm Allen key
• 3/16” Allen Key
• Phillips head screw driver
• Multi-Purpose Wiring Tool
(http://www.homedepot.com/p/Commercial-Electric-8-in-Multi-Purpose-Wiring-Tool-
06008/202039373)
• Ignition advance timing light
• Spark plug extension wire
• Zip ties
• Side cutters
• Silicone Lubricant
• Drill (optional, depending on vehicle configuration)
• 2 3/8” Hole Saw (optional, depending on vehicle configuration)
• Dremel (with cut off wheel attachment) for fuel lines
• Feeler gauge
5. Installation We recommend using the following procedure to install your Rasant Engine Management kit. Please
keep in mind that Porsche made several small variations to vehicle bodies and engines over the years.
Should you find something is not compatible with your vehicle, or you discover a more efficient process,
please let us know so we can modify your instructions accordingly.
Preparation
• Install your ITB’s according to the manufacturer’s instructions. Please use the fuel injectors
provided with the Rasant Kit in your ITB assembly and be sure to use a small amount of oil on
the O-rings to prevent damage during install.
• Install a weld-in bung and wideband O2 sensor (included with the Rasant Kit) into your exhaust
system, if one does not already exist. Your harness is wired to reach either the driver or
passenger side exhaust headers. Please be sure to install at an adequate angle, as having the
sensor too vertical can cause overheating issues. A horizontal install will allow condensation to
drip on the sensor.
• Remove the 12V battery ground strap from the battery.
• Jack up the rear of your vehicle with enough room to lay underneath the engine/transmission.
Always be sure to place the vehicle on jack stands with blocks at the front wheels while working
under your car.
Photo via wbo2.com
Wideband O2
sensor and
Bung Installed
Harness Installation
• Pull up the carpet on the vertical wall behind the passenger seat (where the rear passenger side
feet would be). On later year cars there is a factory hole in this location. For early year cars, you
must drill a hole for the harness to pass though. Use a 2 3/8” diameter hole saw to allow room
for the harness components to pass through. The provided seal will be used to cover this hole
and prevent rust. If you do need to cut a hole, it is always recommended to brush/spray some
paint on the newly exposed metal.
• Feed the wiring harness through this hole behind the passenger seat. It is helpful to have a
person on the other side to receive the wires being fed through. It works best to follow these
steps:
o Feed one bank of connectors through (cylinders 1-3)
o Feed the second bank of connectors through (cylinders 4-6)
o Feed the sensor connectors, ground and battery cable through
• Use a 1/8” drill to add holes for the harness seal fasteners. The harness seal is shown below:
• Secure the harness seal to the vehicle using the M3 fasteners supplied with the kit.
• Fasten the ECU Bracket to the factory luggage strap (where available) holes using supplied M6
bolts and washers. If the factory luggage strap is not installed on your vehicle, install fasteners
as necessary.
• The fuse/relay center (pictured below) is located on the ECU bracket and has two possible
configurations:
Single Plug Ignition
Twin Plug Ignition
Relays: 1: ECU Main Power 2: Fuel Pump 3: Ignition Coils 4: Fuel Injectors
Relays: 1: ECU Main Power 2: Fuel Pump 3: Upper Ignition Coils 4: Lower Ignition Coils (not shown) 5: Fuel Injectors
Fuses: 1: ECU Main Power (15A) 2: Fuel Pump (10A) 3: Ignition Coils (15A) 4: Fuel Injectors (20A) 5: ECU Full Time Power (10A)
Fuses: 1: ECU Main Power (15A) 2: Fuel Pump (10A) 3: Upper Ignition Coils (15A) 4: Lower Ignition Coils (15A) (not shown) 5: Fuel Injectors (20A) 6: ECU Full Time Power (10A)
• Begin passing the connectors through the hole in the passenger side of your engine
compartment. Again, having a helper on the other side to feed the wires through helps the
process. The photo below is looking in through your engine compartment. Feed the connectors
into the engine compartment in the same way you fed the harness through the location behind
passenger seat. Note: The battery cable, fuel pump wires, and O2 sensor wires should not go
into the engine compartment.
• Route the harness inside the engine compartment based on the diagrams below. Some items
that aren’t clearly visible in the photos include:
o The two ground terminals near the ignition coils. They need to be mounted on the M6
bolts which fasten the fan shroud to the engine.
o TEMP (ring terminal) should also be mounted to an M6 bolt on the fan shroud. The ring
terminal has an integrated thermistor which tells the ECU engine temp. Therefore, it’s
important that this ring terminal is on a fastener that heats up with the engine. We
suggest one of the fasteners that hold the fan shroud to the cam tower near either
cylinder 2 or 3.
o TACH (Tachometer signal, Grey wire) will tap into the factory harness on the driver’s
side with included butt splices. (Note: These have heat shrink tubing, so be sure to
shrink them down with a heat gun after installation.)
▪ It is a black wire with a purple stripe on the 1975 911, but varies between model
years. Please verify the correct wire for your vehicle.
o IGN ON (Ignition Key-On, Red wire) will tap into the factory harness on the driver’s side
by using the butt splices included in your kit. (Note: These have heat shrink tubing, so be
sure to shrink them down with a heat gun after installation.)
▪ It is a red wire on the 1975 911, but varies between model years. Please verify
the correct wire for your vehicle
A few notes for ITB installs:
o IAT to be mounted in the ITB air filter housing, or somewhere near the intake air stream
for common plenum setups.
Fuse/ Relay
Box
Starter
Fuel
Pump
02 Sensor ECU
GND
IGN 4
IGN 5
Cam/
Crank
CNT TEMP
FUEL 4
FUEL 5
FUEL 6
IAT
MAP
TPS Fuel
Pressure
FUEL 1
FUEL 2
FUEL 3
IGN 1
IGN 2
IGN 3
GND
IGN 6
GND
TACH (Grey)
IGN ON (Red)
• Finish installing the harness components under the car:
o Connect the fuel pump wires to the factory fuel pump connector pigtail with butt splices
included in your kit. (Note: These have heat shrink tubing, so be sure to shrink them
down with a heat gun or lighter after install)
o Wideband O2 Sensor
o Ground ring terminals should be mounted on M8 stud along with the transmission
ground strap (near the front of the transmission).
o Battery cable should be mounted to the positive terminal of the starter motor. Make
sure to double check that your battery is disconnected first.
• Go through all areas where the harness was installed and secure the harness with zip ties or p-
clamps as needed.
Ignition System Install
• Using a 13/16” deep well spark plug socket, remove the factory style spark plugs from your
engine.
• With a 5/8” deep well spark plug socket, install the supplied spark plugs into all six cylinders.
• Insert the ignition coils into the spark plug hole and install the connector. The connectors will
“click” when fully seated.
• Install the Rasant Products Cam/Crank Housing into the distributor hole in your engine and
secure the nut. There is no required orientation. A later step will provide an offset to the ECU.
o Note: The new distributor seal may be stubborn to install. Always use silicone lubricant
and verify that the distributor is fully seated before fastening the securing nut. Do not
use this nut to fully seat the distributor as serious damage can occur!
• Connect the wire harness connectors on the cam/crank adapter to your engine harness
Fuel System Install
• The fuel pressure sensor shall be installed in the front 1/8 NPT port of the fuel pressure
regulator.
• Considering there are several options for fuel rail, fuel filter, and fuel regulator mounting
locations, the kit is provided with unassembled fuel hose and hose ends.
• The kit includes the following fuel line components:
Component Quantity
-6AN PFTE Hose w/ black liner 6 ft
90 Degree -6AN Hose End 2
Straight -6AN Hose End 4
Metric Adapter to -6AN (to factory fuel filter) 1
-6AN Union 1
-6AN To Convex Flare (to factory return line) 1
90 Degree -6AN O-Ring to Male -6AN 1
Straight -6AN O-Ring to Male -6AN 1
-6AN O-Ring Plug 1
• For the majority of applications, the following hose/fitting layout is best:
• Install the appropriate fittings on the fuel pressure regulator as shown in the image below (note
the port in the front where the fuel pressure sensor shall be installed). Be sure to tighten all
fittings, including those already installed on the fuel pressure regulator. The set screw and nut
on top will be adjusted in a later step, but simply tighten at any position for now.
1
2
3
-6AN O-Ring Plug
From fuel rails: 90 Degree -6AN O-Ring to Male -6AN
To Fuel Tank: -6AN O-ring to -6AN
Union to Metric Convex
Note: These two sides are interchangeable to help accommodate your layout
-6AN O-ring to
-6AN Union to
Metric Convex
• Find a location to mount the fuel pressure regulator. It works best to place it towards the front
driver’s side of the engine component, as it provides easy access to the factory fuel return line.
• Make the appropriate measurements for the fuel lines according to your engine compartment
layout. I recommend using a Dremel tool with a cutoff wheel to cut the hose, be sure to cut
perpendicular to the hose length. The following document is a clear outline of how to properly
install the hose ends: http://documents.holley.com/199r11133.pdf
• Finally, install the fuel lines according to the diagram provided above.
6. Initial Power-up of the ECU Installation of AEM Infinity Tuner Software
• Prior to powering up your unit, download the AEM Infinity Tuner software from AEM:
http://aemelectronics.com/software-aemnet/infinity-engine-management-system-software
Note: AEM Data is an optional data viewing software. In my opinion, Infinity Tuner is all you
need for both collecting and viewing data.
• Proceed with installation using the general settings.
• Open the installed version of AEM Infinity.
o When prompted, navigate to your Infinity 8h folder and open the AllTabs_8h.itlyt layout
file (C:\Users\YourComputerName\Documents\AEM\Infinity
Tuner\Layouts\v96.1\Infinity-8h)
Click Download
• Remove the following relays from the Bussmann fuse center before powering up the unit:
• Re-connect your 12V battery ground cable.
• Key on the ignition. You should hear the relay “click” near the ECU.
• Connect your computer to the ECU Mini-USB port (cable is supplied in AEM Infinity box).
• When you are properly connected to the ECU the red “Not connected” message will change to
green.
• Verify that your engine configuration is accurately input to the ECU via the Wizards-> Setup
Wizard tab. Your configuration should match the image below, though differences may occur
depending on your engine displacement and VE tuning preference.
Remove these three relays: #2: Fuel Pump #3: Ignition Coils #4: Fuel Injectors
Setting ignition timing
An Engine Control Unit (ECU) needs to know the position of the camshaft and crankshaft in order to run
the engine properly. The Rasant Kit uses our exclusive cam/crank adapter which allows for an all-in-one
install without the need for adding separate cam/crank sensor locations. The cam/crank adapter can be
installed in any orientation and the timing offset can be easily input the ECU. The steps below outline
this process:
• Install the spark plug extension wire (not included) between the ignition coil for cylinder #1 and
the spark plug. Be sure the ignition coil is still connected to the main engine harness.
Alternatively, the higher end timing lights can pickup the spark energy from the wire harness
alone. This saves the trouble of using an extension wire as the timing light clamp goes directly
over our wiring harness.
• Place the timing light clamp around the spark plug extension wire. Your setup should look like
this:
• Provide 12V to the timing light. There are several options depending on your vehicle
configuration: factory 12V fuse locations, extension wires from the main battery, a spare 12V
battery, or a small 12V power supply.
• Install the ignition coil relay (#3) in the Bussmann fuse center. DO NOT INSTALL FUEL PUMP OR
INJECTOR RELAYS!
• Open the Setup Wizard in the Infinity Tuner software (Wizards-> Setup Wizard).
o Click the “Ignition Sync” button on the left window
o Select “Lock ignition timing at 10 degrees BTDC”
o Verify your screen matches the one shown below:
• Open the “Diagnostics” tab (“CamCrank” in later versions) in the Infinity Tuner Window
o Set “CamSyncAdjustment” to 0 (coarse timing adjustment -> 6 Degree increments)
o Set “TrigOffset” to 0 (fine timing adjustment -> 1 Degree increments)
• Set the timing light to 10 degrees BTDC. If your timing light reads 0 degrees or 5 degrees BTDC,
then change the value on the Wizard Ignition Sync page from 10 degrees to 0 degrees or 5
degrees (to match your timing light value). This is to ensure the timing light is reflecting accurate
ignition timing.
• Using a remote start switch (Actron makes a nice one: CP7853 Remote Starter Switch), or an
assistant to turn the key, crank the engine over while holding the timing light on the crankshaft
pulley.
o Note: Try to limit the amount of cranking time to less than 5 seconds per crank, with
time for the starter to cool down between cranking. This is to prevent damage to the
starter motor.
• Watch for the light to flash when the TDC notch (labeled Z1 on the flywheel pulley) is near the
notch on the fan housing. Since it can be difficult to identify the Z1 notch after the engine starts
spinning, it is wise to make a small spot with a paint marker on the Z1 notch before you begin
the process (if one does not already exist).
o Note: If the light is not flashing near the TDC notch on the flywheel pulley, adjust the
“CamSyncAdjustment” and crank the engine again. Repeat this process until the notches
are nearing alignment. You should not need to increase this beyond a value of 60.
• With the “CamSyncAdjustment” value fixed, start adding to “TrigOffset” (in 1-5 degree
increments, depending on how close the timing is). If the timing appears to be getting further
from the TDC notch, then try adding one more to the “CamSyncAdjustment” and continue with
adjusting “TrigOffset” until the Z1 notch aligns with the fan housing notch. If “TrigOffset”
reaches higher than 6 degrees, “CamSyncAdjustment” should be incremented again.
• When the Z1 notch is aligned with the fan housing notch, then the ignition timing has been set
appropriately.
• Go back to the wizard and uncheck “Lock Ignition Timing at…”. Now the ignition timing should
follow the ignition table. The ignition table will be discussed in greater detail in section 7.2.
Note: Once the install is complete and the engine is fully warmed, go back and verify the ignition timing
with a timing light and spark plug extension. This time you can make small adjustments to the
“TrigOffset” with the engine running. Again, use the “Lock Ignition Timing” function in the ECU and
match that value with your timing light. Adjust “TrigOffset” until the timing marks align.
Final Steps
• Verify that the harness is connected to each component and properly secured throughout the
vehicle.
• Install all remaining relays into the fuse center.
• Key the vehicle on, listen for the fuel pump to prime, and look in the engine compartment to
check for fuel leaks.
• Adjust the fuel pump priming time to 30000 ms (milliseconds) in the Infinity Wizard. This will
allow you more time to adjust the fuel pressure regulator.
• Adjust the fuel pressure regulator to ~39.2 PSI by following the manufacturer’s instructions that
are provided with the regulator. The pressure is monitored via the Infinity Tuner Software on
the Injector Tab. The variable is called FuelPressure:
• Once the fuel pressure is properly set, adjust the fuel pump priming time back to the default
(2000 ms)
• Now you’re ready to start your engine! If you’re new to tuning, or not experienced with the
AEM unit, I recommend reading on to the Tuning Basics section prior to starting.
7. Tuning Basics Volumetric Efficiency – Fuel Delivery
The Volumetric Efficiency (VE) measurement is the comparison of actual air flow through the engine
compared to the theoretical maximum air flow. Modifying things like cam profiles, cylinder port shapes,
intake system, and exhaust system cause a change in the VE.
The engine controller uses VE to understand how much fuel it needs to add. If the ECU knows the
displacement of the engine and how efficiently air is moving through, it can easily calculate the amount
of fuel needed.
VE is updated by changes in one table in the controller. RPM is on the x-axis and either MAP or TPS
(depending on your tuning preference) on the y-axis. This is called the VE Table:
The best way to understand if you need to update the VE Table is to monitor the “NewVE” variable
(shown below) in the Infinity Tuner software. This variable indicates what VE value should be in the
table. If the initial VE value is significantly off, it may take a few iterations of updating values in the VE
table based on the NewVE variable.
The VE will be the first value you update while the car is idling. An easy way to update VE is to use the
logging feature in the top menu bar (Logging -> Start PC Logging). When using PC logging, the Plot
Window (shown above) will update. Clicking on the “pointer” will allow you to move to different points
in the plot window. As you move to different points in the plot window, you will notice that the other
windows on the screen also update. This is the best way to compare VE and NewVE when updating the
VE table.
Plot Window
Pointer
Ignition Tuning
Ignition tuning and VE are the other most important variables that require tuning. It is a bit more
involved for the tuner and has the most potential to damage the engine. For this reason I recommend
tuning ignition only if you are experienced with engine management systems. There are many shops out
there that will support a few dyno runs and basic tuning for a reasonable fee.
For those who are willing to accept the risk with their engine, I will provide my personal advice and
tuning method. Typically ignition tuning is done by ear or some knock-sensing device (knock ears, knock
sensor, ridged wire connected to the engine to feel vibration, etc.). While there is somewhat of a
controversial debate about the best way to tune ignition timing, I personally tune by ear. In order to dial
in the peak RPM points I also recommend using a dyno, since tuning at high RPMs on the street is not
ideal.
When tuning by ear you are listening for a “pinging” sound. This can range from a very subtle tinging to
loud banging, as though there are rocks flying through your engine. If you reach this point, you have too
much ignition advance. Updating the ignition timing table is straightforward and follows the same
structure as the VE table. The table below is found on the IgnMap tab and is used to update ignition
advance:
Infinity ECU Hot Keys:
Z + 10 : By highlighting a section of a table, entering z+10, and pressing enter, all selected numbers will
increase by 10. This can increase by any amount, I just use 10 in this example:
Z - 10 : By highlighting a section of a table, entering z-10, and pressing enter, all selected numbers will
decrease by 10. This can decrease by any amount, I just use 10 in this example:
h : Use “h” for the horizontal blending of cells. This is a great tool for updating ignition and VE
tables. You may know the value for two different cells, but not the ones in between. When
updating tables, a smooth transition between cells is important. After highlighting desired cells
with acceptable known values, press “h” to create a smooth transition between them. Example:
v : Use “v” for the vertical blending of cells. This is the same as above, but works for updating cells
vertically. Example:
Z+10
Z-10
h
v
Creating a Log File in Infinity Tuner:
• With the ECU connected and powered on, select Logging -> Start PC logging on the top menu
bar.
• When you are finished collecting data, select Logging -> Stop and save PC log on the top menu
bar. From here you have two options:
o Click “yes” to save the log file to your computer and enter in a file name when
prompted. This will allow you to go back and review the data anytime.
o Click “no” to simply view the log file, but not save it. This can be very helpful when
tuning as you don’t have to save each file, but it allows you to view and calibrate with
the recorded data.
Viewing a Session (Log) File in Infinity Tuner:
• With your layout file open, go to File -> Open Saved Session
o Locate your Session File (.itssn)
• When viewing the session file, you can use the mouse pointer on any Plot screen to scroll
through the data. You’ll notice that all tables will update as you scroll across a plot.
o See example below. The purple line on the plot screen is the point I selected, all text
grids and tables are updated to reflect the data at that point in time.