Home
>
AEM
>
Infinity Plug & Play Harnesses
>
AEM Volkswagen 20022005 MKIV GolfJetta 18T 303903 User Manual
AEM Volkswagen 20022005 MKIV GolfJetta 18T 303903 User Manual
Have a look at the manual AEM Volkswagen 20022005 MKIV GolfJetta 18T 303903 User Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 223 AEM manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
30-3 903
2 002-2 005 V W 1 .8 T A W P
I N FIN IT Y-6 /8 H *
P nP A DAPTE R H A RNESS
AEM P erfo rm ance E le ctr o nic s
A EM P erfo rm ance E le ctr o nic s, 2 205 1 26th S tr e et U nit A , H aw th orn e, C A 9 0250
P hone: ( 3 10) 4 84-2 322 F a x: ( 3 10) 4 84-0 152
h ttp ://w ww.a em ele ctr o nic s.c om
I n str u ctio n P art N um ber: 1 0-3 903
D ocum ent B uild 1 /6 /2 015
I
n str u ctio n
M an ual
W ARNIN G : T his in sta lla tio n is n ot fo r th e tu nin g n ovic e ! U se th is s y ste m w ith E X TR EM E c a utio n! T he A EM
I n fin ity P ro gra m mable E M S a llo w s fo r to ta l fle xib ility in e ngin e tu nin g. M is u se o r im pro per tu nin g o f th is
p ro duct c a n d estr o y y o ur e ngin e! If y o u a re n ot w ell v e rs e d in e ngin e d yn am ic s a nd th e tu nin g o f e ngin e
m anagem ent s y ste m s D O N O T a tte m pt th e in sta lla tio n. R efe r th e in sta lla tio n to a n A EM -tr a in ed tu nin g
s h op o r c a ll 8 00-4 23-0 046 fo r te ch nic a l a ssis ta nce .
N O TE: A ll s u pplie d A EM c a lib ra tio ns, W iz a rd s a nd o th er tu nin g in fo rm atio n a re o ffe re d a s p ote ntia l
s ta rtin g p oin ts o nly . IT IS T H E R ES PO NSIB IL IT Y O F T H E E N G IN E T U NER T O U LTIM ATELY C O NFIR M IF T H E
C ALIB RATIO N IS S AFE F O R IT S IN TEN DED U SE. A EM h old s n o r e sp onsib ility fo r a ny e ngin e d am age th at
r e su lts fr o m th e m is u se o r m is tu nin g o f th is p ro duct!
STO P!
T HIS P RO DUC T H AS L E G AL R ESTRIC TIO NS.
R EAD T HIS B EFO RE IN STALLIN G /U SIN G !
T H IS P R O DUCT M AY B E U SED S O LELY
O N V EH IC LES U SED IN S A NCTIO NED C O MPETIT IO N W HIC H M AY N EV ER B E U SED U PO N A
P U BLIC R O AD O R H IG HW AY, U NLES S P ER M IT TED B Y S PEC IF IC R EG ULA TO RY E X EM PTIO N. ( V IS IT T H E “ E M IS SIO NS” P A GE A T H TTP://
W WW.S EM ASA N.C O M/E M IS SIO NS
F O R S TA TE B Y S TA TE D ETA IL S .)
I T IS T H E R ES PO NSIB IL IT Y O F T H E IN STA LLER A ND/O R U SER O F T H IS P R O DUCT T O E N SURE T H A T IT IS U SED IN C O MPLIA NCE W IT H
A LL A PPLIC A BLE L A W S A ND R EG ULA TIO NS. IF T H IS P R O DUCT W AS P U RCHA SED IN E R RO R, D O N O T
IN STA LL A ND/O R U SE IT . T H E
P U RCHA SER M UST
A RRA NG E T O R ETU RN T H E P R O DUCT F O R A F U LL R EFU ND.
T H IS P O LIC Y O NLY A PPLIE S T O IN STA LLER S A ND/O R U SER S W HO A RE L O CA TED IN T H E U NIT ED S TA TES ; H O W EV ER C USTO MER S
W HO R ES ID E IN O TH ER C O UNTR IE S S HO ULD A CT IN A CCO RDA NCE W IT H T H EIR L O CA L L A W S A ND R EG ULA TIO NS.
3903-M KIV 1 .8 T 2 © 2 015 A EM P erfo rm ance E le ctr o nic s Overv ie w T he 3 0-3 903 A EM In fin it y A dapte r k it w as d esig ned fo r 2 002-2 005 V olk sw agen 1 .8 T G olf/ J e tta /G TI c ars w it h A W P e ngin e c ode a nd m anual tra nsm is sio n. T his is a tru e s ta ndalo ne s yste m th at e lim in ate s th e u se o f th e fa cto ry E CU. T he k it is “p lu g a nd p la y” s o n o c uttin g o r s plic in g is n ecessary . T he b ase c onfig ura tio n file s a va ila ble fo r th e I n fin it y E CU a re s ta rtin g p oin ts o nly a nd w ill n eed to b e m odifie d fo r y our s pecific a pplic atio n. P le ase r e ad th is d ocu m ent in its e ntir e ty b efo re a tte m ptin g to s ta rt o r r u n a n e ngin e. T he a va ila ble A EM In fin it y E M S p art n um bers fo r th is a dapte r k it a re : 30-7 106 In fin it y -6 30-7 108 In fin it y -8 h** S uggeste d a ddit io nal c om ponents : 30-3 903-0 0 B oost-to -M AP S ensor A dapte r H arn ess 30-2 130-5 0 S ta in le ss S te el 3 .5 B ar M AP S ensor Im porta n t A pplic atio n N ote s T he te st v e hic le u sed fo r d eve lo pm ent o f th is a pp w as a 2 003 G TI th at w as m ostly s to ck e xcept fo r a n A EM c old a ir in ta ke a nd 3 c at-le ss d ow npip e. T he A W P e ngin e d oes h ave v a ria ble v a lv e c ontro l (V VC) o n th e in ta ke c am o nly th at a ppears to o nly b e u tiliz ed d urin g c old s ta rts w hen th e s econdary a ir in je ctio n p um p is a ctiv e . T he a dapte r in th is k it h as b een b uilt to g iv e th e In fin it y c am c ontro l, h ow eve r th e b ase s essio n d oes n ot h ave a ny V VC c ontro ls c onfig ure d a s a dva ncin g th e in ta ke c am d urin g d yno te stin g s how ed th at p ow er w as a lw ays d ecre ased. T he s to ck E CU u ses m ass a ir flo w (M AF) fu elin g c ontro l u sin g a M AF s ensor in th e in ta ke p ip in g a head o f th e t u rb o. T he In fin it y o nly u ses S peed D ensit y fu elin g c ontro l fo r th is a pplic atio n a nd th e M AF s ensor is n ot u tiliz ed in t h e a dapte r s o th e s ensor c an b e re m ove d if d esir e d. T he s to ck E CU re fe re nces a b oost s ensor th at is lo cate d in t h e s to ck s id e-m ount in te rc oole r a head o f th e th ro ttle b ody. B ecause th e In fin it y o nly u ses S peed D ensit y fu elin g c ontro l, a m anifo ld a bsolu te p re ssure (M AP) s ensor in put is n ecessary th at is re fe re ncin g m anifo ld p re ssure a ft e r t h e th ro ttle b la de. T here is a n a va ila ble b oost-to -M AP s ensor a dapte r h arn ess a va ila ble (A EM p art n um ber 3 0- 3 903-0 0) th at a llo w s a n A EM s ta in le ss s te el M AP s ensor (3 .5 B ar M AP s ensor s uggeste d, P N 3 0-2 130-5 0) to b e p lu gged in to th e s to ck b oost s ensor c onnecto r m akin g fo r s eam le ss in te gra tio n. S ee M AP s ensor in sta lla tio n i n stru ctio n fu rth er in th is m anual. T he s to ck d riv e -b y-w ir e (D BW ) th ro ttle b ody h as b een fu lly c hara cte riz ed a nd th e p ro vid ed b ase s essio n is c onfig ure d fo r it s u se. L arg er th ro ttle s iz e D BW th ro ttle b odie s m ay b e u sed h ow eve r u se o f th ose th ro ttle b odie s w ill re quir e fu ll c hara cte riz atio n a nd P ID c ontro ls tu nin g. N one o f th e s to ck e m is sio ns c ontro ls (s econdary a ir i n je ctio n, E G R, E va p, e tc ) a re s upporte d. A ddit io nally , th e N 249 b ypass v a lv e a ctiv a tio n s ole noid is a ls o n ot s upporte d. T he A W P u ses a B osch w id eband O 2 s ensor fr o m th e fa cto ry w hic h is u tiliz ed b y th e In fin it y th ro ugh t h e c ars w ir in g h arn ess th us a n a ddit io nal O 2 s ensor is n ot re quir e d. N ote th at th e O 2 s ensor is nt p ow ere d b y th e c ar u ntil th e e ngin e is ru nnin g. C ru is e c ontro l is n ot s upporte d b y th e In fin it y a nd th e s te erin g w heel c ru is e c ontro l b utto ns a re n ot u tiliz ed in a ny w ay. T he c ars C AN d ata stre am is s upporte d b y th e In fin it y a nd a llo w s fo r th e f a cto ry g auges to fu nctio n c orre ctly a s w ell a s th e In fin it y to re fe re nce a ll fo ur w heel s peeds a s w ell a s s te erin g a ngle .
Im porta nt A pplic a tio n N ote s 3 © 2 015 A EM P erfo rm ance E le ctr o nic s Gettin g S ta rte d Y our In fin it y E M S w ill b e p ackaged w it h fo ur im porta nt d ocum ents : U sage L egalit y D is cla im er, S oft w are D ow nlo ad N otic e, S ecurit y C ode N otic e, a nd a n In fin it y Q uic k S ta rt G uid e. F ir s t, re ad a nd a cknow le dge th e U sage L egalit y D is cla im er. S econd, re fe r to th e In fin it y Q uic k S ta rt G uid e (Q SG ). T hir d , fo llo w th e S oft w are D ow nlo ad N otic e a nd d ow nlo ad th e In fin it y T uner s oft w are , w iz ard s, a nd d riv e rs fr o m th e A EM E le ctro nic s w eb s it e (s ectio n 2 .1 in Q SG ). F ourth , v is it w ww.a em in fin it y .c om to re gis te r y our E M S (s ectio n 3 .2 in Q SG ). O nce th e re gis tra tio n p ro cess is c om ple te , y oul l b e a ble to d ow nlo ad th e la te st fir m ware fo r y our E M S. T he fin al s etu p p ro cess is to o pen th e In fin it y T uner s oft w are a nd c onnect to y our E M S to u pdate th e f ir m ware (s ectio n 3 .3 in Q SG ). T his c an b e d one o nce th e E M S is in sta lle d in to y our v e hic le - s ee In fin it y E M S I n sta lla tio n. O nce th e In fin it y is in sta lle d in to y our v e hic le a nd it h as b een lo aded w it h th e la te st fir m ware , s etu p a nd tu nin g m ay c om mence. R efe r to th e Q SG fo r a ddit io nal in fo rm atio n o n g ettin g th e e ngin e re ady fo r tu nin g w it h th e In fin it y E M S. A ddit io nally , th e fu ll In fin it y U ser M anual c an b e re fe re nced fo r m ore in -d epth in fo rm atio n p erta in in g to th e i n sta ll, s etu p, a nd u sage o f th e In fin it y E M S.
3903-M KIV 1 .8 T 4 © 2 015 A EM P erfo rm ance E le ctr o nic s **Im porta n t In fin it y -8 h In fo rm atio n T his p lu g a nd p la y a dapte r k it h as s pecific ally b een d esig ned to b e u sed w it h th e 3 0-7 106 In fin it y -6 . W hile th e 3 0- 7 108 In fin it y -8 h c an b e u sed, it w ill re sult in th e lo ss o f Id le A /C O ffs et c om pensatio n a nd th e a ddit io nal d ig it a l f r e quency in put in th e A ux c onnecto r. P in s C 1-3 1 a nd C 1-3 2 M UST b e re m ove d fr o m th e 8 0 p in c onnecto r if u sin g t h is a dapte r h arn ess w it h a n In fin it y -8 h. A ls o, th e In fin it y -8 h d oes n ot h ave P eak & H old in je cto r d riv e rs to ru n lo w i m pedance fu el in je cto rs . H ig h im pedance (s atu ra te d, h ig h-z ) fu el in je cto rs M UST b e u sed w it h th e In fin it y -8 h. In fin it y P in In fin it y -6 F unctio n In fin it y -8 h F unctio n VW 1 .8 T A dapte r P in /F unctio n In fin it y -6 N ote s In fin it y -8 h N ote s C1-3 Low sid e6 In je cto r7 No C onnect/N ot U sed Availa ble L S o utp ut Availa ble in je cto r o utp ut C1-4 Low sid e7 In je cto r8 No C onnect/N ot U sed Availa ble L S o utp ut Availa ble in je cto r o utp ut C1-3 1 Dig it a l6 Coil7 Aux 7 /F re q In put Spare f re q in put in A ux Loss o f s pare f re q in put, M UST r e m ove p in f ro m In fin it y 8 0 p in c onnecto r C1-3 2 Dig it a l7 Coil8 40/A /C R eq S w it c h A/C R eq s w it c h in put Loss o f A /C id le c om pensatio n, M UST r e m ove p in f ro m In fin it y 8 0 p in c onnecto r In fin it y C onnecto rs T he A EM In fin it y E M S u ses th e M X123 S eale d C onnectio n S yste m fr o m M ole x. A EM s tro ngly re com mends th at u sers b ecom e fa m ilia r w it h th e p ro per to ols a nd p ro cedure s b efo re a tte m ptin g a ny m odific atio ns. T he e ntir e u ser m anual c an b e d ow nlo aded d ir e ct fr o m M ole x a t: h ttp ://w ww.m ole x.c om /m x_uplo ad/fa m ily //M X123U serM anual. p df
In fin ity C onnecto rs 5 © 2 015 A EM P erfo rm ance E le ctr o nic s In fin it y A dap te r H arn ess T he b asis o f th e V W 1 .8 T In fin it y k it is th e a dapte r h arn ess th at m ate s th e In fin it y E CU w it h th e c ars fa cto ry w ir in g h arn ess. T his a dapte r a llo w s fo r s eam le ss in te gra tio n o f th e In fin it y E M S o nto y our v e hic le . A EM Net is a n o pen a rc hit e ctu re b ased o n C AN 2 .0 w hic h p ro vid es th e a bilit y fo r m ult ip le e nable d d evic es, s uch a s d ashboard s, d ata lo ggers , e tc . to e asily c om munic ate w it h o ne a noth er th ro ugh tw o tw is te d c able s (C AN+/C AN-). T he 2 p in F la sh E nable c onnecto r is u sed a s a s econdary h ard w are fla shin g o ptio n b y ju m pin g th e tw o w ir e s t o geth er u sin g th e in clu ded s hunt c onnecto r. N ote : F la shin g w ill n orm ally b e p erfo rm ed in th e s oft w are n ot u sin g t h is c onnecto r. I n te gra te d in th e 1 .8 T a dapte r h arn ess is a n “a uxilia ry ” c onnecto r. T his is a D euts ch D TM 1 2P c onnecto r a nd is u sed to a dapt m any c om mon a ncilla ry in puts a nd o utp uts e asily . In clu ded in th e k it a re a D TM 1 2P m atin g c onnecto r, 1 2 D TM te rm in als , a nd a D TM 1 2P w edgelo ck. If u sed, th ese c om ponents w ill n eed to b e te rm in ate d b y t h e in sta lle r o r e nd u ser w it h 1 6-2 2aw g w ir e (n ot in clu ded). N ote : th e p in n um berin g is b ased o n th e n um bers m old ed in to th e c onnecto r. D euts ch P in In fin it y P in Pin D escrip tio n Defa ult P in F unctio n Note s 1 C1-5 3 Analo g 9 Fuel P re ssure Can b e u sed to m onit o r f u el p re ssure f o r f u el d eliv ery c alc ula tio n. U se A EM s ta in le ss s te el 1 00psig o r 1 50psig s ensor. C onnect d ir e ctly to s ig nal w ir e o f p re ssure s ensor. S ee S etu p W iz ard . A nalo g in put N O T r e assig nable . 2 C1-7 5 Analo g 1 0 Baro Can b e u sed to m onit o r b aro m etr ic p re ssure . U se A EM s ta in le ss s te el M AP s ensor. C onnect d ir e ctly to s ig nal w ir e o f M AP s ensor. S ee S etu p W iz ard . A nalo g in put is a ls o r e assig nable to o th er f u nctio ns. 3 C1-7 4 Analo g 1 1 Shif t S w it c h Can b e u sed to a ctiv ate S hif t C ut f o r n o-lif t- s hif tin g. S ee S etu p W iz ard . A nalo g in put is a ls o r e assig nable to o th er f u nctio ns. 4 C1-7 3 Analo g 1 3 Oil P re ssure Can b e u sed to m onit o r o il p re ssure f o r E ngin e P ro te ctio n. S ee S etu p W iz ard . A nalo g in put is a ls o r e assig nable to o th er f u nctio ns. 5 C1-4 0 Tem p 3 Oil T em p Can b e u sed to m onit o r o il te m pera tu re . S ee S etu p W iz ard . C an a ls o b e u sed t o m onit o r o th er te m p in put.
3903-M KIV 1 .8 T 6 © 2 015 A EM P erfo rm ance E le ctr o nic s 6 C1-2 9 Dig it a l 4 Spare F re q I n put Can b e u sed to m easure f re quency in put s uch a s F le x F uel S ensor o r tu rb o s peed o r w heel s peed, e tc . S ee S etu p W iz ard . 7 C1-3 1 Dig it a l 6 Spare F re q I n put Can b e u sed to m easure f re quency in put s uch a s F le x F uel S ensor o r tu rb o s peed o r w heel s peed, e tc . S ee S etu p W iz ard . 8 C1-1 LS 4 Low S id e O utp ut Can b e u sed a s a c onfig ura ble lo w s id e o utp ut to c ontr o l a v arie ty o f f u nctio ns. O utp ut is p ulle d u p to 1 2v a nd r a te d to 1 .7 A . D o n ot u se to P W M h ig h c urre nt lo ads. 9 C1-2 LS 5 Low S id e O utp ut Can b e u sed a s a c onfig ura ble lo w s id e o utp ut to c ontr o l a v arie ty o f f u nctio ns. O utp ut is p ulle d u p to 1 2v a nd r a te d to 6 A . O k to P W M h ig h c urre nt l o ads. 10 C1-2 3 Sensor G ro und Sensor G ro und Used a s 0 v r e fe re nce f o r s ensors . D o N O T u se a s p ow er o r c hassis g ro und. C onnect to s ensor g ro und p in s o n a uxilia ry s ensors . 11 C1-4 9 5v Sensor P ow er Used a s 5 v r e fe re nce f o r s ensors . D o N O T u se to p ow er a ny h ig h c urre nt l o ads. C onnect to s ensor p ow er p in s o n a uxilia ry s ensor. 12 C1-6 3 12v +12v P ow er Used a s 1 2v p ow er f o r a uxilia ry d evic es. In fin it y E M S In sta lla tio n T he fo llo w in g p ro cedure d escrib es h ow to re m ove th e p la stic c ow l th ats b elo w th e b otto m o f th e w in dshie ld a nd t h en in sta ll th e In fin it y E M S u sin g th e p ro vid ed a dapte r h arn ess. F ir s t, ra is e th e h ood a nd d is connect t h e g ro und c able fr o m th e b atte ry . R em ove th e p la stic c ap fr o m th e p iv o t e nd o f e ach w ip er a rm . R em ove th e 1 3m m n ut th at s ecure s e ach w ip er a rm to it s d riv e s haft .
In fin ity E M S In sta lla tio n 7 © 2 015 A EM P erfo rm ance E le ctr o nic s R em ove e ach w ip er a rm fr o m it s d riv e s haft . R em ova l is u sually b est a chie ve d b y g ra spin g th e w ip er a rm i m media te ly b elo w th e b la de p iv o t p oin t a nd w ork in g th e w ip er a rm a w ay a nd to w ard s th e w in dshie ld r e peate dly u ntil th e a rm c om es l o ose. T he w ip er a rm m ountin g h ole i s ta pere d a nd s plin ed s o re m ova l c an b e d iffic ult . R em ove th e e ntir e re ar h ood s eal b y p ullin g u p o n it . R em ove th e c abin a ir filt e r c ove r b y r e m ovin g th e fo ur s cre w s a nd lift in g t h e c ove r u p w hile p ullin g it to w ard s t h e fr o nt o f th e c ar.
3903-M KIV 1 .8 T 8 © 2 015 A EM P erfo rm ance E le ctr o nic s R em ove th e c ow l b y s ta rtin g a t o ne e nd a nd p ullin g th e e nd o f th e c ow l s tra ig ht o ut fr o m th e w in dshie ld to d is engage it fr o m it s re ta in in g c lip . R em ove th e w ir in g h arn ess c onnecto rs fr o m th e E CU b y s lid in g t h e c onnecto r lo cks o ut to th e s id e a nd th en p ullin g th e c onnecto rs o ut o f th e E CU. P ry u p o n m eta l ta bs th at a re h old in g E CU in p la ce u sin g a fla t tip s cre w driv e r. R em ove E CU.
In fin ity E M S In sta lla tio n 9 © 2 015 A EM P erfo rm ance E le ctr o nic s T he In fin it y is to b e p la ced in to th e c ow l c avit y a s s how n. T horo ughly c le an th e a re a b elo w th e E M S to a llo w fo r th e v e lc ro to b e a pplie d a nd t h en in sta ll th e E M S. D o n ot a pply v e lc ro to b otto m o f E M S o r to th e c ow l s heet m eta l u ntil th e a dapte r h arn ess h as b een in sta lle d a nd th e l o catio n o f th e E M S h as b een f in aliz ed. C are fu lly in sta ll th e In fin it y a dapte r h arn ess. T his is m ost e asily d one b y in sertin g th e In fin it y c onnecto r e nd o f th e h arn ess in to th e c ow l c avit y fir s t a nd th en ro ta tin g th e h arn ess to th e rig ht w hile p assin g u nder th e s heet m eta l ta b th at s tic ks o ut. P la ce th e e nclo sed E CU c onnecto r in to th e s pot w here th e s to ck E CU w as o rig in ally lo cate d b ein g m in dfu l o f m eta l ta bs th at m ay b e s tic kin g u p.
3903-M KIV 1 .8 T 1 0 © 2 015 A EM P erfo rm ance E le ctr o nic s C onnect th e In fin it y e nd o f th e h arn ess to th e In fin it y E M S. C onnect th e fa cto ry w ir in g h arn ess c onnecto rs to th e o ve rm old ed E CU c onnecto r. E nsure th at th e c onnecto rs a re fu lly s eate d w it h t h eir lo cks c om ple te ly p ushed in . W it h th e lo catio n o f th e E M S f in aliz ed, a pply v e lc ro th e h old th e E M S in p la ce. C onnect th e s upplie d U SB c om ms c able a nd U SB lo ggin g c able to th e I n fin it y a nd ro ute a s d esir e d.