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G4 Wiring and Installation Manual

2

© 2009 Link

Table of Contents

0

Part I Introduction

4

................................................................................................................................... 4

1

Support Options

Part II Choosing a Configuration

5

................................................................................................................................... 5

1

Injector Outputs

................................................................................................................................... 6

2

Ignition Outputs

................................................................................................................................... 6

3

AuxiliaryOutputs

................................................................................................................................... 7

4

Analog/Temperature Inputs

................................................................................................................................... 7

5

Digital Inputs

................................................................................................................................... 8

6

Trigger Inputs

................................................................................................................................... 8

7

Summary

................................................................................................................................... 10

8

Installer IO Table

Part III Component Installation Locations

12

................................................................................................................................... 12

1

ECU Location

................................................................................................................................... 12

2

Ignition Component Placement

................................................................................................................................... 13

3

MAP Sensor Location

Part IV Storm Header Pinout

13

Part V Xtreme Header Pinout

14

Part VI Power and Ground Wiring

15

................................................................................................................................... 15

1

Power Supplies

................................................................................................................................... 16

2

+14V In

................................................................................................................................... 16

3

+14V Aux9/10

................................................................................................................................... 17

4

Power Ground

................................................................................................................................... 17

5

Sensor Ground

................................................................................................................................... 17

6

+5V Out

................................................................................................................................... 17

7

+8V Out

................................................................................................................................... 18

8

ECU Hold Power Wiring

Part VII Input Signal Wiring

19

................................................................................................................................... 19

1

Trigger Inputs

.......................................................................................................................................................... 20

Reluctor/Magnetic Sensors 

.......................................................................................................................................................... 21

Hall/Optical/Proximity Sensors 

................................................................................................................................... 22

2

MAP Sensor

................................................................................................................................... 24

3

TPS Wiring

................................................................................................................................... 25

4

Engine Coolant Temperature Sensor

................................................................................................................................... 25

5

Intake Air Temperature Sensor

................................................................................................................................... 26

6

Narrow Band Oxygen Sensor

................................................................................................................................... 27

7

Wide Band Oxygen Sensor

Summary of Contents for G4 Storm

Page 1: ...Link G4 Storm Link G4 Xtreme Copyright 2009 Link ElectroSystems Ltd Wiring Installation Manual...

Page 2: ...12 2 Ignition Component Placement 13 3 MAP Sensor Location Part IV Storm Header Pinout 13 Part V Xtreme Header Pinout 14 Part VI Power and Ground Wiring 15 15 1 Power Supplies 16 2 14V In 16 3 14V Aux...

Page 3: ...wer Supply 40 Switching Through a Relay 41 Switching an LED 41 4 Idle Speed Control 42 Two Terminal ISC Solenoid 43 Three Terminal ISC Solenoid 43 Four Terminal ISC Stepper Motor 44 Six Terminal ISC S...

Page 4: ...fter market engine management systems in the world can provide While every effort has been made to keep G4 ECU s as user friendly as possible it should be recognised that added features bring added co...

Page 5: ...ge Inputs 3 4 Internal MAP 11 Temperature Inputs 2 4 Knock Sensor Inputs 0 2 Regulated Outputs 8V 5V 8V 5V Trigger Inputs 2 2 Storm shares one header pin for DI4 and An Volt 2 2 1 Injector Outputs The...

Page 6: ...th Modulated PWM above 300Hz Note that PWM frequencies above 300 Hz may be required to drive a tachometer for a V8 above 4500 RPM An electronic throttle motor must only be wired to Aux 9 and Aux 10 Sp...

Page 7: ...re from 0 5V transducer Temperature channels are designed to be used only with PTC or NTC thermistor sensors Almost all factory temperature sensors fit this category Do not wire the output of a 0 5V t...

Page 8: ...ses Trigger 1 will need to be used In many cases Trigger 2 must also be used Engines with Variable Valve Timing may also require Digital Inputs be wired to cam shaft position sensors Refer to the Trig...

Page 9: ...ction 3 Injector 3 Cylinder 3 Injection 4 Injector 4 Cylinder 4 Injection 5 Injector 5 Cylinder 5 Injection 6 Injector 6 Cylinder 6 Injection 7 Fuel Pump Speed Control 1 Injection 8 Fuel Pump Speed Co...

Page 10: ...ity Optical or Hall Trigger 2 Analogue Temp Input 1 NTC Thermistor sensors Only Analogue Temp Input 2 Analogue Temp Input 3 Analogue Temp Input 4 Analogue Volt 1 0 5V Input from sensor or external con...

Page 11: ...tput 2 Auxiliary Output 3 Auxiliary Output 4 Auxiliary Output 5 PWM less than 300 Hz or general switching functions ISC Stepper Auxiliary Output 6 Auxiliary Output 7 Auxiliary Output 8 Auxiliary Outpu...

Page 12: ...r tuning cable 3 If water immersion or spray is likely particularly for marine applications additional protection may be necessary A sealed plastic container may be employed here 4 Allow sufficient sp...

Page 13: ...should be installed in a location near the engine but away from excessive heat vibration and moisture It is not recommended to mount the MAP sensor directly on the engine Refer to Input Wiring sectio...

Page 14: ...G4 Wiring and Installation Manual 14 2009 Link 5 Xtreme Header Pinout Viewed looking into ECU header or wire side of loom connector...

Page 15: ...The switch labelled ignition switch is usually the key The wire that is used to turn on the main relay should be energised when the key is in the ON position Do not use a source that provides power w...

Page 16: ...e 14V In wire must remain above 7 Volts at all times This is especially important while the starter motor is being cranked A significant drop in voltage will result in the ECU undergoing a reset that...

Page 17: ...that require a ground e g throttle position sensor water temperature sensor etc Failure to do this may result in unstable sensor readings causing erratic ECU operation Do NOT be tempted to ground sen...

Page 18: ...red through the relays now and run as normal 4 When the ignition switch is turned off the ECU senses this through its Digital Input 5 The ECU resets the stepper motor to its default position then shut...

Page 19: ...required information Trigger 1 is used to determine crankshaft position Trigger 2 is used to determine the engines position in the firing order cam position Often called the sync signal Digital Inputs...

Page 20: ...tely different 7 1 1 Reluctor Magnetic Sensors Reluctor Magnetic sensors have a toothed trigger wheel that passes across the face of the sensor The movement of the teeth past the sensor generates a vo...

Page 21: ...lses These sensors require a power supply and typically have three wires The 8V Supply offers a regulated 8V for optical or hall sensors These wires are not used for reluctor sensors Note many hall se...

Page 22: ...P sensor an external MAP sensor can be wired to an Analogue Volt input To use the internal MAP sensor connect the MAP pressure hose to the barbed fitting on the ECU s end plate Xtreme ECU s require th...

Page 23: ...ires the connection of three wires 1 Signal The MAP signal must be wired to an Analogue Volt input Configure this input as MAP sensor and select the appropriate calibration in PCLink Tuning Software 2...

Page 24: ...ttle to move through its full range of motion The TPS should be adjusted so that it is not reaching the end of its movement at either closed throttle or full throttle An ideal output voltage range is...

Page 25: ...air entering the engine The air temperature sensor must be set up to most accurately measure the temperature of the air entering the engines combustion chambers On a naturally aspirated engine this no...

Page 26: ...antly improve the probe performance at idle and during warm up phases of operation This is because the probe temperature must exceed 300 C before accurate readings are possible An Auxiliary Output can...

Page 27: ...tuning purposes A wideband sensor can be used to run Closed Loop Lambda CLL for improved economy and emission A wideband sensor is a necessity if Quick Tune refer to the PCLink Tuning Software online...

Page 28: ...variable valve timing Switches and Controllers The diagrams below show the two methods of wiring Digital Inputs to a switch When wiring other devices such as controllers it will be necessary to determ...

Page 29: ...uts is recommended for VVT wiring Note that in practice any Digital Input Auxiliary Output combination can be used Cam Shaft Digital Input Auxiliary Output Inlet or Inlet LH DI 1 Aux 1 Inlet RH DI 2 A...

Page 30: ...ing high impedance injectors When driving low impedance injectors directly it is essential that before running the engine the correct Injection Mode Peak and Hold and Peak and Hold Currents are config...

Page 31: ...ector drives This means that for most engines sequential injection can be used Depending on the number of Injection Drives the following Injection Modes may available Single Point Group Sequential Mul...

Page 32: ...quirements that would normally require extremely large injectors Very large injectors make tuning difficult at low loads idle and low power operation With staged injection one smaller set of injectors...

Page 33: ...p Staged Injection Set the Injection Mode to Sequential Staged when using this configuration 8 2 Ignition Drives Note For information on wiring Ignition Outputs as additional Auxiliary Outputs refer t...

Page 34: ...onventional igniters begin to charge the coil when their input is high Spark occurs when the input goes low This is known as a Rising Dwell Edge Some factory igniters eg some Ford and Honda MSD igniti...

Page 35: ...her sensitive devices especially the ECU Do not run non ignition related wiring close to igniters coils or HT leads wherever possible Maintain maximum distance from radio transmitters and coaxial cabl...

Page 36: ...der is fired conventionally on the compression stroke while the other cylinder has its piston in the same position but on the exhaust stroke One crankshaft rotation later these two cylinders are two w...

Page 37: ...ch ignition drive is matched to the correct cylinder the firing sequence will need to be determined Note this option is only possible when the engine has an even number of cylinders When using a waste...

Page 38: ...ition Therefore a second sensor mounted on the camshaft or driven at camshaft speed is required to send a sync pulse If an engine does not have an appropriate sensor then either one will need to be fa...

Page 39: ...should be used DO NOT connect 12V directly to any auxiliary output The following list shows only some of the devices that can be controlled by Auxiliary Outputs Idle Speed control ISC Solenoids and St...

Page 40: ...a solenoid If Auxiliary Outputs 5 to 8 are already used then it will be necessary to wire a relay to control the solenoids power supply Aux 5 to 8 high side drivers can supply up to 0 5 Amps this mean...

Page 41: ...l ISC is required to provide an acceptable idle speed when the engine is cold or when loads AC etc are applied Without idle speed control an engine will idle too slowly when cold Often the cold idle s...

Page 42: ...gine is cold 8 4 1 Two Terminal ISC Solenoid A two terminal ISC solenoid may be wired to Auxiliary Channels 1 to 8 Injection channels can not be used for ISC control Ignition Channels 1 to 8 can also...

Page 43: ...ct the terminal to Auxiliary Output 1 and note that this output should be configured as ISC Solenoid Slave Three terminal ISC Solenoid Wiring 8 4 3 Four Terminal ISC Stepper Motor An ISC Stepper Motor...

Page 44: ...stepper motor after key off This avoids extended cranking periods caused by resetting the stepper at key on The diagram below shows a schematic of a six terminal stepper motor These are similar to a f...

Page 45: ...l signal 8 6 Variable Valve Timing VVT Solenoids Continuously Variable Valve timing CVVT VVT VVTi AVCS Cam Position solenoids can only be connected to Auxiliary Outputs 1 to 4 It is recommended to eas...

Page 46: ...VVT solenoids These solenoids must be rewired to be ground switching 8 7 Electronic Throttle Control At the time of writing this manual G4 Xtreme ECUs are equipped with tested Electronic Throttle Cont...

Page 47: ...s directly to a Xtreme ECU make sure Injector Driver Mode is set to Peak and Hold and the correct peak and hold currents have been set Spare Injection drives can be used as additional auxiliary output...

Page 48: ...lve so no oil enters the engine Likewise setting Stepper Calibration to Fully Open should cause the motor to completely open the valve Once finished tested set Stepper Calibration to Off If the motor...

Page 49: ...CU to your laptop the USB drivers must be installed Failure to install the drivers on your laptop first may result in windows assigning incorrect drivers These drivers will not work with the G4 ECU an...

Page 50: ...en prompted if you wan to install drivers select Continue Anyway 3 Start PCLink Tuning Software by double clicking on the PCLink Tuning Software icon on the windows desktop 4 Switch the key to the ON...

Page 51: ...the set up procedure 3 Check all oil and water levels are correct Connecting to PCLink Tuning Software Use the following procedure to establish a connection between your Link ECU and PCLink Tuning So...

Page 52: ...ection is to be used and an air temperature sensor is fitted select the required IAT Mode e g 2D Table or 3D Table Note that the default 2D Table is recommended for the majority of applications b Turn...

Page 53: ...to OFF for now 4 Click on Ignition Advanced then Individual Cyl Ign Trim a Set Individual Ign Mode to OFF for now 5 Click on Dual Ign Table a Set Dual Table Mode to OFF for now 6 Click on 4D Ign Table...

Page 54: ...anual will greatly simplify set up of Auxiliary Outputs Note that one auxiliary channel should always be wired and configured for the fuel pump relay drive 1 Click on Auxiliary Outputs then select the...

Page 55: ...uts tab of the runtime values lower area of PCLink Tuning Software screen 2 Configure each additional Digital Input channel Ensure unused channels have their Function set to OFF 3 Perform a Store to p...

Page 56: ...he An Temp channel wired to the engine coolant temperature ECT sensor a Set the channels function to ECT b Select Temp Sensor Type If a custom type sensor is to be used then the resistance vs temperat...

Page 57: ...ntrol a Set Launch Control Mode to OFF 3 Click on Flat Shifting a Set Flat Shifting Mode to OFF 4 Click on Boost Control only visible if an Auxiliary Output is configured for a Boost Control Solenoid...

Page 58: ...ress F1 Note that trigger calibration must be performed again once the engine is running Due to the acceleration and deceleration of the crankshaft at low speeds an inaccurate measurement of engine ti...

Page 59: ...k on the Fuel heading then Fuel Set up a Locate the Master setting This will need to be adjusted during or just after start up 6 Crank the engine until it starts Some throttle may be required for firs...

Page 60: ...closing time however the overall result is that less fuel will flow for a given pulse width than would be expected with an ideal injector To compensate for this the injector pulse widths are increase...

Page 61: ...air fuel ratios change while the battery voltage drops the dead time table can be trimmed to maintain the same stable air fuel ratio Injector Dead Time can be viewed as a row graph A smooth curve need...

Page 62: ...29 G Getting Help 4 H Hall Sensor Wiring 20 High Impedance Injectors 30 High Side Driver Wiring 40 I IAT Wiring 25 Idle Speed Control Wiring 41 Igniter Requirements 33 Ignition Component Placement 12...

Page 63: ...minal Stepper Wiring 44 Storm Pinout 13 14 Support Options 4 Switching an LED 41 Switching Through a Relay 40 T Tachometer Wiring 45 Temperature Inputs Wiring 7 Three Terminal ISC Solenoid Wiring 43 T...

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