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INSTRUCTION MANUAL

PLUG AND PLAY EMS KIT

LOTUS ELISE/EXIGE/2-ELEVEN

2004+ with 2ZZ-GE ENGINE

DOCUMENT 19-0046

Radium Engineering LLC

Summary of Contents for EMS

Page 2: ...Contents 1 Introduction 2 Warnings and Cautions 3 Before Getting Started 4 2004 2005 EMS Mounting 5 2006 EMS Mounting 6 Installation of Accessories 7 Before Initial Start Up 8 Engine Tuning 9 Tables and Pinouts ...

Page 3: ...e evaluated by a professional tuner familiar with AEM software and tuning 2 WARNINGS AND CAUTIONS Use this system with EXTREME caution The EMS System allows for total flexibility in engine tuning however misuse of this product can lead to major engine vehicle damage If you are not well versed in engine dynamics and the tuning of management systems or are not PC literate please do not attempt insta...

Page 4: ... speaker panel is necessary The following components are included in the basic Radium Lotus EMS kit JUMPER BOX All Lotus EMS kits use a Radium jumper box shown on right The jumper box consists of a conformal coated printed circuit board and a billet aluminum enclosure The factory Lotus ECU connectors plug into this unit making the kit plug and play The included main harness plugs into the other si...

Page 5: ...d links the jumper box to all other components in the system including the Radium EMS This harness is custom engineered for the Lotus application by Radium Engineering and makes installation plug and play Radium Main Harness 2004 2005 Lotus Radium Main Harness 2006 up Lotus ...

Page 6: ...ts fully unlocked state ready to be inserted into the header After insertion rotate the latch and it will draw the connector into the header Once fully engaged the latch will lock in place To release push the small release button with your thumb shown and rotate the latch back to the unlocked position The 2004 05 connectors use slide locks to engage the connectors with the headers The picture show...

Page 7: ...nplug both the connectors going into the ECU This is done by pulling the connector slide lock mechanism as shown 4 Situate the Radium main wiring harness in the engine bay and plug the connectors that match the factory connectors from previous step into the factory ECU Make sure the slide locks are in the unlocked position as the connector is inserted into the ECU header Once inserted and seated s...

Page 8: ...his for both connectors 5 Use a 10mm socket to remove the LH side nut holding the ECU to its mounting bracket leave the washer in place Using a 13mm socket remove the other mounting nut on the bottom RH side of the ECU Leave ECU in place and do not remove from firewall In the EMS kit locate the two hex standoffs Thread these onto the aforementioned studs They have different thread pitches to corre...

Page 9: ...m main harness locate the two ECU connectors similar to what is shown in the picture Plug these into the top two headers of the Radium jumper box The plugs are keyed to work in the correct headers and are color coded black and brown Be careful not to use the incorrect header socket Once the plug is inserted rotate the latch which will fully seat the connector and lock it in place ...

Page 10: ...ivets holding the air box bracket to the bulkhead wall Four rivets are located on the vertical face shown and two are located on the top face hidden by the carpet Insert the included M5 button head Allen screws into the holes as place holders until the EMS bracket is installed inside at a later step ...

Page 11: ...k the immobilizer control unit from the bulkhead wall as shown Using the included hook and loop tape Velcro relocate the immobilizer to another spot out of the way of the EMS bracket and wiring 12 Unsnap the grommet from the hole Using a razorblade make a slit in the factory wiring harness bulkhead wall grommet from the engine bay side ...

Page 12: ...me trimming may be necessary to make room for the added wires 14 Secure the EMS and relays to the included mounting bracket and hardware Plug in the EMS and relays using the connectors from the main harness Note the relays are all the same Route the USB cable and the green connector towards the front of the cabin near the center console If the optional traction control switch and or pwr select swi...

Page 13: ... the earlier step Screw the four button head Allen screws from step 10 into the four rivet nuts in the bracket and tighten The EMS system is now installed If you purchased the Auxiliary harness continue reading for additional instructions on how to hook up this harness and the related accessories ...

Page 14: ...y negative cable 2 Remove the speaker panel behind the seats on the interior of the car 3 Remove the air intake filter box 5 Remove the four nuts holding the ECU to the bulkhead wall and remove the ECU from the vehicle 4 Locate the factory ECU on the bulkhead wall in the engine bay near the intake manifold Release the latches on the two ECU connectors and unplug them from the ECU ...

Page 15: ... the jumper box to the bulkhead wall 6 Locate the ECU connectors removed in step 4 and plug them into the Radium ECU jumper box Fully lock the latches in the connectors Place the ECU jumper box onto the mounting studs on the bulkhead wall ...

Page 16: ...acket included in the Radium EMS kit mount the Radium EMS using the 3 long included screws Use 4 of the included M5 screws to mount the factory ECU as shown above Note the orientation of each component Mount the relay to the rivet nut circled using one of the included M5 screws relay not shown The other spare rivet nut can be used for the aux relay if the optional aux harness was purchased ...

Page 17: ...ine up the four holes around the RA logo with the four drilled out rivet holes from step 9 Insert the included M5 screws from the engine bay side and tighten down 11 Unsnap the grommet from the hole Using a razorblade make a slit in the factory wiring harness bulkhead wall grommet from the engine bay side ...

Page 18: ...2005 style ECU connectors Feed this end through the bulkhead wall pass through first Start with the largest connector 13 From the engine bay side gently tug and ease the harness through the hole Next work the second smaller 2005 style ECU connector through the hole ...

Page 19: ...ead for the 12 pin auxiliary harness is fully in the engine bay 15 Make sure the two 2005 style connectors are in the unlock position and plug them into the top side of the jumper box Make sure connectors are fully engaged and slide locks are closed ...

Page 20: ...k ECU Make sure the latches fully close and lock the connectors in place Plug the remaining connector into the relay mounted to the bracket not shown The EMS system is now installed If you purchased the auxiliary harness continue reading for additional instructions on how to hook up this harness and the related accessories ...

Page 21: ...t These are the EMS wires for the wideband oxygen sensor input Pin 4 is the signal Analog and pin 11 is sensor ground Analog Note Many aftermarket wideband kits will not require the Analog Check the wideband manufacturer for more details If this is the case leave this wire disconnected If an AEM wideband O2 sensor gauge controller was purchased install it according to their instructions The newest...

Page 22: ...ed for proper operation The optional auxiliary harness contains a labeled connector to attach a GM Intake Air Temp IAT sensor This sensor is available from Radium Engineering as part of the Speed Density Conversion kit This sensor can be installed in the intake manifold via a drilled and tapped 3 8NPT hole or in the intercooler piping after the charge cooler If installing on a naturally aspirated ...

Page 23: ...s do NOT require the Radium auxiliary harness These are simple to install and do not require cutting or splicing For 2004 2005 EMS kits the switches green connector will secure to the mating green connector that is part of the Radium main harness For 2006 EMS kits the switches green connector will secure to the mating green connector that is found in the factory wiring loom located underneath the ...

Page 24: ...and IAT signals will be altered and not accurate If this EMS kit was installed in an Exige S 2 Eleven or any Lotus that uses both a factory TMAP sensor and the mass air flow sensor one or the other MUST be unplugged Otherwise the engine load signal to the EMS will be altered On the Exige S the TMAP sensor is mounted on the intercooler as shown and the mass air flow sensor is mounted on the air int...

Page 25: ...ntrol Power 12V switched power to the 2 pin turbo boost solenoid connector Note The turbo boost solenoid does not require polarity 2 Boost Control Output PWM ground to the 2 pin turbo boost solenoid connector Note The turbo boost solenoid does not require polarity 3 Not used 4 O2 Sensor Signal Short flying lead that can be pulled from sleeving Commonly used as an aftermarket O2 sensor input Note T...

Page 26: ...n Slow Relay 3 16 Cam Sensor Signal 68 Fuel Pump Relay 17 69 Hot Soak Starter Internal Connection Relay 18 IAT Sensor Ground 70 Trinary Switch AC Fan Request 19 Knock Sensor Cable Screen 71 20 TPS Signal 72 21 Oil Pressure Switch VVTL 73 Diagnostic Connector L Line 22 Ignition Coil Feedback 74 23 75 Vapor Pressure Signal except 2004 Elise Exige 24 Oil Pressure Switch 76 Fuel Tank Sender Signal 25 ...

Page 27: ...S2 4 4 Crank Sensor Ground F 1 ABS Unit Right Rear F 1 Knock Sensor Cable Screen 2 Clutch Switch Air Bag Harness Canada Only 2 3 3 Ignition Coil Feedback 4 Pre Post O2 Sensor Ground 4 VSV Purge Valve Ground G 1 G 1 Ignition Coil 1 2 Start Relay 2 Ignition Coil 4 3 Ignition ACC 3 Ignition Coil 3 4 Diagnostic Connector K Line 4 Ignition Coil 2 H 1 Throttle Pedal S1 Ground H 1 Coolant Temp Sensor Gro...

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