AEM Series 2 Plug Play EMS 306040 User Manual

							  
   
ADVANCED ENGINE MANAGEMENT INC. 
2205 126
th Street Unit A    Hawthorne, CA. 90250 
Phone: (310) 484-2322 Fax: (310) 484-0152  Http://www.aempower.com 
Instruction Part Number: 10-6040, rev A (Oct 2009) 
  2009 Advanced Engine Management, Inc. 
 
 
Page 1 of 11 
   
Installation Instructions for: 
EMS P/N 30-6040 
1992-1995 Civic / Del Sol / Integra 
90-95 Accord / Prelude (2.1L Only) 
 
 
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. Misu se of this 
product can destroy your engine!    
If you are not well versed in engine dynamics and t he tuning of 
management systems or are not PC literate, please d o not 
attempt the installation. Refer the installation to  an AEM-trained 
tuning shop. A list of tuners can be found in the “ AEM EMS 
Tuning” subsection of the AEM Electronics Forums at  
http://www.aempower.com  or by calling 800-423-0046. 
  
NOTE: AEM holds no responsibility for any engine da mage that 
results from the misuse of this product!
 
    
This product is legal in California for racing vehi cles only and should 
never be used on public highways.   
						

							Page 2 of 11 
Thank you for purchasing an AEM Engine Management System.  
  
The AEM Engine Management System (EMS) is the resul t of extensive development on a 
wide variety of cars. Each system is engineered for  the particular application. The AEM 
EMS differs from all others in several ways. The EM S is a stand alone system, which 
completely replaces the factory ECU and features un ique Plug and Play Technology, 
which means that each system is configured especial ly for your make and model of car 
without any jumper harnesses. There is no need to m odify 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 suppl ied startup calibrations are configured to 
work with OEM sensors, providing a solid starting p oint 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 eliminat ion of add-on rev-limiters, boost 
controllers, nitrous controllers, fuel computers, e tc. It also includes a configurable onboard 
1MB data logger that can record any 16 EMS paramete rs at up to 250 samples per 
second. Every EMS comes with all functions installe d and activated; there is no need to 
purchase options or upgrades to unlock the full pot ential of your unit. 
 
The installation of the AEM EMS on the supported ve hicles 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\Honda-Ac ura\  
Multiple calibrations may be supplied for each EMS;  additional details of the test vehicle 
used to generate each calibration can be found in t he Calibration Notes section for that 
file.    
Please visit the AEM Performance Electronics Forum  at http://www.aempower.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 goo d starting point and can save 
considerable time and money, it will not replace th e need to tune the EMS for your specific 
application. AEM startup calibrations are not inten ded to be driven aggressively before 
tuning. We strongly recommend that every EMS be tun ed 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 p rocess; be warned that using your 
vehicle as a learning platform can damage your engi ne, your vehicle, and your EMS. 
  
						

							Page 3 of 11 
Read and understand these instructions BEFORE attempting to install this product. 
1)  Install AEMTuner software onto your PC   The latest version of the AEMTuner software can be  downloaded from the AEMTuner 
section of the AEM Performance Electronics forums.  Series 2 units are not supported 
by the older AEMPro tuning software.   
 
2)  Remove the Stock Engine Control Unit 
a) Access the stock Engine Control Unit (ECU). The loc ation of the ECU on the OBD1 
Hondas is behind the driver side kick panel. 
b) Carefully  disconnect  the  wiring  harness  from  the  EC U.    Avoid  excessive  stress  or 
pulling  on  the  wires,  as  this  may  damage  the  wiring   harness.  Some  factory  ECUs 
use  a  bolt  to  retain  the  factory  connectors,  and  it   must  be  removed  before  the 
harness  can  be  disconnected.  There  may  be  more  than   one  connector,  and  they 
must  all  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.  
c) Remove  the  fasteners  securing  the  ECU  to  the  car  bo dy,  and  set  them  aside.  Do 
not destroy or discard the factory ECU, as it can b e reinstalled easily for street use 
and troubleshooting.   
3)  Install the AEM Engine Management System. 
a) Plug  the  factory  wiring  harness  into  the  AEM  EMS  an d  position  it  so  the  wires  are 
not  pulled  tight  or  stressed  in  any  manner.  Secure  the  EMS  with  the  provided 
Velcro fasteners. 
b) Plug the comms cable into the EMS and into your PC.  
c) Turn the ignition on but do not attempt to start the engine.  
d) The USB drivers must be installed the first time yo u connect to a Series 2 EMS with 
an  onboard  USB  port.  When  the  Series  2  EMS  is  conne cted  to  the  PC’s  USB  port 
and  receiving  power  from  the  vehicle,  the  “Found  Ne w  Hardware”  window  will 
appear. Select  “Install from a list of specific lo cation (Advanced)” and browse to the 
following folder:   C:\Program Files\AEM\AEMTuner\USB Drivers (Series 2 )\ 
 
e) With the AEMTuner software open, select  ECU>>Upload Calibration to upload the 
startup calibration file (.cal) that most closely m atches the vehicle’s configuration to 
be tuned. Check the Notes section of the calibratio n 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\Honda-Ac ura\     
						

							Page 4 of 11 
f) 
Set the throttle range: Select Wizards>>Set Throttl
e 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 consi dered a sensor error and may 
cause some functions including idle feedback and ac celeration fuel to operate 
incorrectly.    
4)  Ready to begin tuning the vehicle. 
a) Before  starting  the  engine,  verify  that  the  fuel  pu mp  runs  for  a  couple  of  seconds 
when the key is turned on and there is sufficient p ressure 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 atmosp heric pressure correctly.  
 
b) Start the engine and make whatever adjustments may  be needed to sustain a safe 
and reasonably smooth idle. Verify the ignition tim ing: Select Wizards>>Ignition 
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 and compare the physical timing  numbers to the timing value you 
selected. Use the  Sync Adjustment Increase/Decrease  buttons to make the 
physical reading match the timing number you select ed. 
 
c) Note:  This  calibration  needs  to  be  properly  tuned  b efore  driving  the  vehicle.  It  is 
intended  for  racing  vehicles  and  may  not  operate  sm oothly  at  idle  or  part-throttle. 
NEVER TUNE THE VEHICLE WHILE DRIVING
 
 
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 la cking, 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,  m easure  ECU  pinout  voltages, 
replace  recently-added  or  untested  components  with  known-good  spares.  Check 
that all EMS sensor inputs measure realistic temper ature and/or pressure values.  
 
b) 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.  Thi s  indicates  that  the  EMS  has 
detected  the  expected  cam  and  crank  signals;    if  St at  Sync’d  does  not  turn  on, 
monitor  the  Crank  Tooth  Period  and  T2PER  channels  w hich  indicate  the  time 
between pulses on the Crank and T2 (Cam) signals. B oth of these channels should 
respond  when  the  engine  is  cranking,  if  either  sign al  is  not  being  detected  or 
measuring an incorrect number of pulses per engine  cycle the EMS will not fire the 
coils or injectors.   
c) If  the  Engine  Load  changes  when  the  throttle  is  pre ssed  this  usually  indicates  that 
there  is  a  problem  with  the  MAP  sensor  wiring  or  so ftware  calibration;  when  the 
EMS detects that the MAP Volts are above or below t he min/max limits it will run in 
a  failsafe  mode  using  the  TPS-to-Load  table  to  gene rate  an  artificial  Engine  Load 
signal using the Throttle input. This may allow the  engine to sputter or start but not 
continue running properly.   
						

							Page 5 of 11 
Application Notes for EMS P/N 30-6040   
 
Make:  Honda    Spare Injector Drivers:  Inj 5, Pin A8 
Model:  Integra/Civic/Prelude/Accord   Spare Injector Drivers:  Inj 6, Pin A6 
Years Covered:  1990-1995    Spare Injector Drivers:  I nj 7, Pin A16 
Engine Displacement:  1.5L - 2.2L    Spare Injector Drivers:  Inj 8, Pin A14 
Engine Configuration:  Inline 4    Spare Injector Driv ers:  Inj 9, Pin D4 
Firing Order:  1-3-4-2    Spare Injector Drivers:  Inj  10, Pin A11 
N/A, S/C or T/C:  N/A       
Load Sensor Type:  MAP       
Map Min:  0.32V @ -13.9 PSI    Spare Coil Drivers:  Coi l 2, Pin B6  
Map Max:  4.84V @ 10.94 PSI    Spare Coil Drivers:  Coi l 3, Pin B3  
# Coils:  1      Spare Coil Drivers:  Coil 4, Pin B4* 
EMS Ignition driver type:  5-0V, Rising Edge trigger        
      Boost Solenoid:  PW 2, Pin C10 
# Injectors:  4       
Factory Injectors:  190-240cc/min Saturated    EGT #1  Location:  Pin D5 
Factory Inj Resistors:  No    EGT #2 Location:  Pin D2 
Injection Mode:  Sequential    EGT #3 Location:  Pin D9  
Knock Sensors used:  1     EGT #4 Location:  Pin D10 
Lambda Sensors used:  1   (aftermarket wideband:      
  factory O2 not supported)    Spare 0-5V Channels:  MAF, Pin D8 
Idle Motor Type:  Duty-controlled solenoid     Spare 0-5V Channels:  ADCR11, Pin D12 
Main Relay Control:  No    Spare 0-5V Channels:  ADCR13 , Pin B7 
Crank Pickup Type:  Magnetic (2-wire)    Spare 0-5V Channels:  ADCR14, Pin C9 
Crank Teeth/Cycle:  24      
Cam Pickup Type:  Magnetic (2-wire)    Spare Low Side  Driver:  Low Side 1, Pin C6 
Cam Teeth/Cycle:  1    Spare Low Side Driver:  Low Side  2, Pin A10 
Transmissions Offered:  M/T, A/T    Spare Low Side Driver:  Low Side 8, Pin A18 
Trans Supported:  M/T Only    Spare Low Side Driver:  L ow Side 9, Pin C4 
Drive Options:  FWD       
Supplied Connectors:  Plug C with spare pins    Fuel Pump Relay control  Low Side 11, Pin A7 
      Check Engine Light:  Low Side 10, Pin A13 
Plug-N-Pin kit:  AEM part# 35-2611    Spare High Side  Driver:  High Side 2, Pin C11 
  (includes plugs A-D, pins)      
      Spare Switch Input:  Switch 1, Pin C7** 
      Spare Switch Input:  Switch 2, Pin C12** 
      Spare Switch Input:  Switch 5, Pin B8** 
      Spare Switch Input:  Switch 6, Pin C5** 
  
 WARNING:    * If converting a calibration that was original ly developed for a 30-1040 
(Series 1) EMS, please note that the 30-6040 uses C oil 4 rather than Coil 5 on pin B4. All 
settings used for Coil 5 on the 30-1040 calibration  will need to be adjusted for use with 
Coil 4 on the 30-6040. This will be especially impo rtant when used with coil-on-plug 
ignition conversions.   
**All switch input pins must connect to ground, the  switch should not provide 12V power to 
the  EMS  because  that  will  not  be  detected  as  on  or  off.  Connecting  12V  power  to  the 
switch input pins may damage your EMS and void your  warranty.  
 
The  function  of  the  following  pins  have  been  change d  from  the  original  30-1040  EMS, 
please see pinout chart for more info:     
A22, B4, C2, D4   
						

							Page 6 of 11 
 
Solution for distributed ignition ‘kick back’ when cranking: 
With  the  Series  1  EMS,  some  vehicles  would  experien ce  erratic  ignition  timing  at  low 
RPM.  The most  noticeable  symptom  would be  an  engine   that  ‘kicks  back’  when  cranking, 
and  in  some  cases  the  EMS  would  count  timing  errors   or  lose  ‘Stat  Sync’  at  low  engine 
speeds.   
These  problems  have  been  eliminated  by  adjusting  ca libration  settings  in  Series  2  Honda 
EMS startup calibrations, but could be re-introduce d by converting Series 1 calibrations or 
copying values from Series 1 calibrations. If users  wish to convert old Series 1 calibrations 
for  use  with  the  new  Series  2  EMS,  please  ensure  th at  the  following  options  and  tables 
match the Series 2 startup calibration:  
Crank H Sens Below,   Crank L Sens Above,   Cam(T2)  H Sens Below,  
Cam(T2) L Sens Above,   Coil Dwell Factor,   Dwell  Max, Dwell Min,  
Dwell vs RPM (table),   Dwell vs Batt Volts (table)  
    
Wiring accessories to the EMS: 
Please  follow  this  suggested  wiring  diagram  when  ad ding  accessories  such  as  UEGO 
gauges, Boost Control solenoids, or switches for us e with the EMS. Note that wire polarity 
is not important for the Boost Control Solenoid.   
   
						

							Page 7 of 11 
Connection Diagram for EMS P/N 30-6040 
Pin # OBD1 Honda / Acura AEM EMS 30-6040 I/O Availability 
A1 Injector 1  Injector 1  Output PnP for Injector 1 
A2 Injector 4  Injector 4  Output PnP for Injector 4 
A3 Injector 2  Injector 2  Output PnP for Injector 2 
A4 VTEC Solenoid Valve  High Side Driver 1  Output PnP for VTEC Solenoid 
A5  Injector 3  Injector 3  Output PnP for Injector 3 
A6 Primary 02 Heater Control  Injector 6  Output Avail, Injector Gnd, 1.5A max 
A7  Fuel Pump Relay  Low Side Driver 11  Output PnP for Fuel Pump Relay 
A8 Fuel Pump Relay (Accord/Prelude Only)  Injector 5  Ou tput Avail, Injector Gnd, 1.5A max 
A9 
Idle Air Control Valve  PW 1  Output PnP for Idle Air Control Valve 
A10 ---  Low Side Driver 2  Output Avail, Switched Gnd, 1.5A max 
A11 EGR Solenoid (Accord/Prelude Only)  Injector 10  Outp ut Avail, Injector Gnd, 1.5A max 
A12 Radiator Fan Control (Except Prelude)  Low Side Driver 12  Output PnP for Radiator Fan 
A13 Malfunction Indicator Light  Low Side Driver 10  Outp ut Avail, Switched Gnd, 1.5A max 
A14 ---  Injector 8  Output Avail, Injector Gnd, 1.5A max 
A15 A/C Clutch Relay  Low Side Driver 6  Output PnP for A/C Clutch Relay 
A16 Alternator Control (Except Accord/Prelude) Injector 7  Output Avail, Injector Gnd, 1.5A max 
A17 IAB Control Solenoid (Accord/Integra Only) Idle #2  Output Avail, Ground / +12V, 1.5A max 
A18 ---  Low Side Driver 8  Output Avail, Switched Gnd, 1.5A max 
A19 ---  Idle #4  Output Avail, Ground / +12V, 1.5A max 
A20 EVAP Purge Control Solenoid  Low Side Driver 4  Outpu t Avail, Switched Gnd, 1.5A max 
A21 Ignition Control Module  Coil 1  Output 
PnP for Ignition Control Module 
(12/0V Rising edge) 
A22 Ignition Control Module  CAN1L  --- Dedicated 
A23 Power Ground 1  Power Ground  Both Dedicated 
A24 Power Ground 2  Power Ground  Both Dedicated 
A25 Power Source 1  +12V Switched  Both Dedicated 
A26 Logic Ground 1  Power Ground  Both Dedicated 
       
						

							Page 8 of 11 
 
Pin # OBD1 Honda / Acura AEM EMS 30-6040 I/O Availability 
B1 
Power Source 2  +12V Switched  Both Dedicated 
B2  Logic Ground 2  Power Ground  Both Dedicated 
B3  ---  Coil 3  Output Avail, Rising Edge Trigger Coil Out 
B4 ---  Coil 4  Output Avail, Rising Edge Trigger Coil Out 
B5 A/C Switch Signal  Switch 3  Input PnP for A/C Switch Signal 
B6  ---  Coil 2  Output Avail, Rising Edge Trigger Coil Out 
B7 ---  ADCR13  Input Avail, 0-5 Volt Input, 100k pull up 
B8 Power Steering Pressure Switch  Switch 5  Output Avail, Switched Input 
B9  Starter Switch Signal  +12V When Cranking  Input Dedicated 
B10 Vehicle Speed Sensor  T3 (Vehicle Speed)  Input PnP for Vehicle Speed Sensor 
B11  CYP +  Cam Sensor  Input Dedicated, PnP 1 pulse per cycle 
B12  CYP -  Timing Ground  Output Dedicated 
B13 TDC +  T4 (Spare Speed)  Input Avail, Magnetic Speed Sensor 
B14  TDC -  Timing Ground  Output Dedicated 
B15 CKP +  Crank Sensor  Input Dedicated, PnP 24 pulses per cycle 
B16  CKP-  Timing Ground  Output Dedicated 
   
Pin # OBD1 Honda / Acura AEM EMS 30-6040 I/O Availability 
C1 ---  +12V Switched  Input Dedicated 
C2 ---  CAN1H  --- Dedicated 
C3 ---  Tach Output (LS7)  Output Avail, Switched Gnd, 1.5A max 
C4 ---  Low Side Driver 9  Output Avail, Switched Gnd, 1.5A max 
C5 ---  Switch 6  Input Avail, Switched Input 
C6 ---  Low Side Driver 1  Output Avail, Switched Gnd, 1.5A max 
C7 ---  Switch 1  Input Avail, Switched Input 
C8 ---  IDLE #3  Output Avail, Ground / +12V, 1.5A max 
C9 ---  ADCR14  Input Avail, 0-5 Volt Input, 100k pull up 
C10  ---  PW 2  Output Avail, Boost Control Solenoid 
C11 ---  High Side Driver 2  Output Avail, +12V, 1.5A max 
C12 ---  Switch 2  Input Avail, Switched Input   
						

							Page 9 of 11 
 
Pin # OBD1 Honda / Acura AEM EMS 30-6040 I/O Availability 
D1 
Voltage Back Up  Permanent +12V  Input Dedicated 
D2 Brake Switch (Except Prelude)  EGT 2  Input Avail, jumper set for 0-5V Input 
D3  Knock 1  Knock 1  Input Dedicated 
D4 Service Check Connector  Injector 9  Input Avail, Injector Gnd, 1.5A max 
D5  ---  EGT 1  Input Avail, jumper set for 0-5V Input 
D6 VTEC Pressure Switch  Switch 4  Input Avail, Switched Input 
D7  Data Link Connector  High Side Driver 1 Output Avail, same as pin A4 
D8  ---  MAF  Input Avail, 0-5 Volt Input, 100k pull up 
D9 Alternator FR Signal  EGT 3  Input Avail, jumper set for 0-5V Input 
D10 Electronic Load Detector  EGT 4  Input Avail, jumper set for 0-5V Input 
D11 Throttle Position Sensor  TPS  Input Dedicated 
D12 EGR Valve Lift Sensor (Accord/Prelude Only) ADCR11  Input Avail, 0-5 Volt Input, 100k pull up 
D13 Engine Coolant Sensor  Coolant  Input Dedicated, 2.2k pull up 
D14 Primary 02 Sensor  Lambda 1  Input Available, 0-5V Lambda 1 input  
D15 Inlet Air Temp Sensor  AIT  Input Dedicated, 2.2k pull up 
D16 Secondary 02 Sensor  Lambda 2  Input Available, 0-5V Lambda 2 input 
D17 Map Sensor  MAP  Input Dedicated 
D18 Shift Up Indicator Light (D15 only)  IDLE #1  Output Avail, Ground / +12V, 1.5A max 
D19 Sensor Voltage 1  +5V Sensor  Output Dedicated 
D20 Sensor Voltage 2  +5V Sensor  Output Dedicated 
D21 Sensor Ground 1  Sensor Ground  Output Dedicated, sensors only 
D22 Sensor Ground 2  Sensor Ground  Output Dedicated, sensors only 
   
						

							Page 10 of 11 
30-1040 (Series 1) vs 30-6040 (Series 2)  OBD1 Honda EMS pin differences: 
The EMS functions assigned to certain pins have bee n changed and no longer match the 
30-1040 EMS. Unless otherwise noted, the following  pins and functions will need to be 
manually reconfigured after using AEMTuner to conve rt a V1.19 (30-1100, Series 1 EMS) 
calibration for use with the 30-6100 Series 2 hardw are.  
 
 
Pin OBD1 Honda / Acura  30-1040 function 30-6040 function Notes 
A22  Ignition Control Module  ---  CAN1L   
B4  ---  Coil #5  Coil 4  Copy settings for Ign Phasing,  
knock feedback, cylinder ign trim 
C2  ---  ---  CAN1H   
D4  Service Check Connector  Knock #2  Injector 9  Knoc
k 2 not available