The BEGi MazdaSpeed Miata XEDE Installation Manual

The BEGi MazdaSpeed Miata
XEDE Installation Manual
Installation and operations manual
Applicable to all 2004 to 2005
MazdaSpeed Miatas
Revised 5-14-10
Rev 1.2
1
Thank you for purchasing the XEDE Engine Management System. We regard your installation as a mutual project
and will be pleased to offer help at any time. If clarification of these instructions is required, please call BEGi at
830-438-2890. Suggestions for improvements of these instructions are welcome. Send an e-mail to
info@bellengineering.net. Or, write notes on the instruction set and mail / fax to: BEGi, 203 Kestrel Dr., Spring
Branch, Texas. 78070. Fax: 530-438-8361
The success of this installation will be determined by a variety of factors. These instructions should be adhered to
unless reasonable cause for deviation exists. The vehicle must be in excellent condition and proper tune prior to
starting the installation. Care and attention to detail by the installer are of extreme importance.
It is not necessary that the installer has any previous experience with engine management computers. The
mechanical skills required for a successful install are roughly equivalent to that needed to properly remove and
replace the radio. If one has no mechanical experience, it is strongly suggested that help be sought from a hobbyist
or professional mechanic.
All left or right directional references will be from the driver viewpoint. For example, the turbo mounts on the left
side.
These instructions and the operational requirements for this system must be reviewed with the owner-driver prior
to delivery of the vehicle to the end user. Please read the statement of warranty at the end of these instructions prior
to starting the installation.
THE INSTALLER SHOULD PASS THESE INSTRUCTIONS
ON TO THE OWNER-DRIVER.
Tool and Equipment Requirements
The following tools and equipment will be required to conveniently accomplish this install:
General metric open/box wrenches
Wire Cutter
Assorted slot and phillips screw drivers
Wire Splicer and Crimper
General metric socket set
Clean rags
Heat Gun
WD-40 Spray or Similar
Preliminary
•
A clean engine is pleasant to work on. If needed, wash both top side and bottom very thoroughly. The high
pressure car wash does a good job. Wearing latex gloves, can help keep the installer as clean as a nice
engine.
2
STOP!
It is VERY important
that you return the car
to stock timing setting.
If this is not done, bad
things will happen.
3
Installing Injectors
Remove the gas cap to release pressure. There will still be
some gasoline spilled so have some absorbent rags handy.
Wearing eye protection is recommended.
Remove the strut tower brace. Refer to picture # 1.
Remove hoses connected to the piping on the strut tower
brace. These are air hoses and do not contain fluids.
Locate the seven, 12 mm bolts on the Intake Manifold to be
removed. There are three on the right side (passenger) and
two on the left (driver) side. The two remaining bolts are
located under the throttle body. Since space is limited, an
open ended wrench works best on the bolts under the
throttle body. Refer to picture # 2, 3 & 4.
Picture # 1
Picture # 3
Picture # 2
Picture # 4
4
Picture # 5
Picture # 6
Remove the 10 mm bolt holding the ground wire, and the bolt on a bracket. Refer to picture # 5.
Remove the top of the intake manifold. Push the intake manifold back towards the passenger fender well, exposing
the fuel rail. Move the wire bundle that is on top of the fuel rail. Move all vacuum lines and wires in the way of the
fuel rail. Refer to picture # 6.
Place a shop rag next to the fuel rail to absorb any fuel that is spilled. Loosen the bolts holding the fuel rail to the
cylinder head, but do not remove them. Refer to picture # 7. Pull the fuel rail out as far as possible, without
removing bolts. Slide the spacer upwards towards the fuel rail and apply a piece of tape to hold them in place. It is
very important that you do not lose these spacers. Remove the bolts completely.
Lift the fuel rail up until you can unplug and remove the injectors. Remove the injectors. Remove the plastic rings
on the injector tips and save them. It is, also, very important that you do not lose these injector tip seals.
Unplug the stock injector wire clip, by pushing the tab down and pulling out. Expose the wires on the stock injector
wires near the clip. Refer to picture # 9.
Picture # 7
Picture # 8
5
Picture # 9
Picture # 10
Plug the PNP Injector clips into the stock harness connector.
Refer to picture # 10.
NOTE: Before connecting the stock injector wires onto
the new wire clips be sure that they are running to the
correct injector! For example, do not attach the stock
wires for injector number three to the new injector wire
clip on injector number four.
Push a plastic injector seal (o-ring) onto the end of each
injector, and push it all the way up. Use a small amount of
motor oil to lubricate the rubber o-rings on the inlet side of the
injectors. Insert the 440 cc injectors into the four seats. Refer to
picture # 11.
Connect the PNP injector clip to the injectors. Refer to picture
# 10 & 11.
Picture # 11
Align the fuel rail with the injectors but do not push it on yet.
Line up the fuel rail mounting tabs and spacers with the bolt
holes. Replace the mounting bolts into the cylinder head.
Remove the tape holding the spacer to the fuel rail. Refer to
picture # 12. Push the fuel rail into place. Tighten the bolts.
Make sure that the injector wires are clear of danger.
Conceal all the wires. Replace all vacuum lines and wire
bundles that were moved out of the way.
Replace the top of the intake manifold with stock fasteners.
Replace the ground wire and bolt. Replace the bolt into the
bracket next to the ground wire.
Picture # 12
6
Replace the strut bar and re-connect all hoses. Replace the gas cap.
XEDE Installation
The stock ECU is located under the driver side dash,
directly behind the fuse panel. If you are a contortionist,
it is possible to reach the ECU by pushing the seat back
as far as possible. Or, it might be easier to remove the
driver seat. We recommend placing something on the
ground to avoid skinned knees. ☺
Un-plug all wires going into the stock ECU. The wire
harness assembly consists of two components: 1. White
wire harness adapter; 2. A black Xede wire harness,
wired into the white wire harness. It is very important
that you do not pull on the wires and loosen the
connections.
Plug the white wire harness in to the ECU. Plug the Picture # 13
connector on the black XEDE wire harness into the
Xede unit. Hanging loose is a serial port connection
should you need to hook the XEDE up to a laptop. Refer to
picture # 13.
Using the zip/cable ties provided, secure the XEDE unit to the
steering column under the dash.
Locate the black terminal on th Xede. There should be a loose
wire from pin # 5. This is the ground wire for the boost
solenoid. Crimp on an eyelet to the end of the wire. Run the
eyelet to a bolt under the dash. The easiest bolt to reach is
located below the hood release, next to the interior wall of the
car. Secure eyelet under the stock screw. Make sure it has metal
Picture # 14
contact on both sides of the eyelet. Refer to picture # 14.
The “Pill”
Locate and remove the factory hose with a restrictor installed. Refer to picture # 14. Replace the hose with the 1/4"
hose supplied. The 1/4" hose contains a “pill” or restrictor. Take care not to damage the restrictor inside the hose.
Refer to picture # 15.
*** This Vacuum line with the restrictor pill MUST BE INSTALLED. If it is not installed
the car will over boost. ***
7
Picture # 14
Picture # 15
Boost Solenoid Wire
Locate the red and white wire next to the strut tower brace. Refer to
picture # 16. Clip the blue scotch lock overlap to the wire as shown.
This is a 12V power supply.
Strip 1/4" off of one end of the black wire provided. Crimp a male
spade onto the end of the black wire. Insert the male spade and black
wire assembly into the end of the scotch lock overlap. Refer to picture
# 17.
Route the wire thru a clip (adjacent to the throttle cable), behind the
throttle body inlet tube, and ending at the boost solenoid. Refer to
picture # 18. Leaving a little extra length to the wire, cut it to an
appropriate length. Strip 1/4" off of the end of the wire and crimp on
a male spade. Refer to picture # 19, wire # 3.
Picture # 16
Locate the black and red wire coming out of the solenoid. Cut it about
3" away from the solenoid. Strip 1/4" off of the end of each wire. Look
at picture # 19. Crimp on a female spade to wire # 2, coming out of the
boost solenoid. Crimp on a male spade to wire #1, going into the stock
wire harness. Connect wires # 2 & 3. Wrap the connection with
electrical tape or use heat shrink tubing provided. Wire # 1 will hang
loose until it is needed again, usually for OBD II testing. Route it away
from any potential problems. Refer to picture # 20.
Picture # 17
8
Picture # 18
Picture # 19
Picture # 20
9
Starting The Car for the First Time
•
•
•
•
•
Replace the gas cap.
Turn ignition on, do not start the car. A red light will illuminate on the XEDE unit. Use a mirror, if
necessary, to view the LED light under the dash.
Start the car. Rev the engine to 1200 rpm for 2 to 4 seconds. The light on the XEDE will briefly flash red,
then turn solid green. If the light does not turn green, review the instructions and make sure all items are
installed properly. If that does not turn the LED green, please see below for loading the timing pattern file.
If that does not work, call the office.
Drive the car for a few miles before applying boost. If the car idles well and runs smoothly you may start
applying boost.
The check engine light will come on after a few miles.
Troubleshooting
•
•
•
•
•
•
•
If the red light does not illuminate, recheck all connections at ECU.
If the car stalls frequently, check the LED light on the Xede Unit and/or replace the 02 Sensors. Call for
more information
If the car starts to act differently, remember that the stock ECU still reads and compensates for
environmental and some driving conditions. If the problem persists for a few days, please call for assistance.
Some check engine light codes are normal. If illuminated, have the codes read to see if it is a mechanical
problem or the XEDE. Most problems with the car will not be Xede related.
A P0300 MIL / CEL code is NORMAL! The Xede maps advance the timing beyond what the stock ECU
thinks is “normal”. It gets confused and throws out the Random Cylinder Misfire code. To get rid of the
code, simply zero out any timing advance (any positive number) in the Timing map.
If the car surges at idle clean the MAF with MAF Cleaner. If that does not work, clean your idle air
controller. It is located beneath the throttle body. If that does not work, chances are the Idle air controller
is bad.
Some check engine light codes are normal. If illuminated, have the codes read to see if it is a mechanical
problem or the XEDE. Most problems with the car will not be Xede related. Normal MIL/CEL codes include
one or two for TPS, one or two for the wastegate / boost solenoid, and the P0300. These are normal CEL
codes.
Tuning the XEDE
Please call BEGi for assistance. Tuning will depend on the injectors, i.e. Bosch vs. RC’s. The basic principle is to
tune for a Long Term Fuel Trim (LTFT) of “0” at cruise speeds, when the car operates in closed loop fuel
conditions. This will optimize fuel economy. When under boost, in open loop conditions, tune for an Air / Fuel
Ratio of 12.0 to 12.5. Depending upon the injectors used, the car will typically need to be tuned for a LTFT of -10
to -16 at idle. This will ensure good hot start conditions, and the use of a/c at idle.
Connecting to the XEDE to Load a New Map
Attached to the Xede harness is a serial port. Plug a serial cable or a Serial/USB adapter in here. If your are going
to use a Serial/ USB adapter cable, WE STRONGLY RECOMMEND that you go to Radio Shack and buy cable
# 26-949. It is a Gigaware Brand cable and includes a CD with the cable drivers. If you do not have a good
cable with the proper drivers installed, you will corrupt the map you are working on!
10
Version 3.2
This version will come on a CD with the Xede unit. Install the version 3.2.0.7 from the CD. Or it can be downloaded
from: http://www.bellengineering.net/.
> Copy the version 3.2.0.16 zip file from the CD to your desktop.
> Double click on it and extract all files. Extract the folder and place it on your desktop.
> Open the folder and move the XMAP 3.2.0.16.exe file icon to the desktop.
> Double click the following icons: my computer >> C: drive >> program files >> Xede.
> Leave the Xede folder open and move it off to the side.
> On your desktop: click and hold on the XMAP 3.2.0.16.exe icon and drag it into the Xede folder.
> Right click on the icon just moved, and place a shortcut on your desktop.
> Delete the zip file and zip folder from the desktop.
Serial Cables
Plug in serial cable to Xede harness and computer. Open XMAP. Turn the ignition key to the “ON” position. The
Xede status will display in the lower left hand corner of the XMAP window. Once the key is turned on the status
should read connected. If not, turn key off and back on. If still not connected, reboot computer, double check that
all cables are plugged in, turn key on and open XMAP. If this does not work, please call for assistance.
USB / Serial Cables
Insert the CD that came with the USB / Serial cable into your computer. **Do Not plug the cable into the computer
yet**. Follow the instructions to install the drivers on the CD. Once installation is complete, then you may plug
the USB / Serial cable into the computer. Plug the serial end of the cable into the Xede Serial port.
To determine which Port the USB / Serial cable will be connected to, open the device manager:
> Start
> Control panel
> Switch to classic view (on blue bar)
> System
> Hardware tab
> Device manager >
> + sign next to “Ports”. The USB / Serial cable will be listed here with the recognized COM port at the
end. (For now we will use the example COM5).
> Close the device manager and control panel.
Open XMAP. If any other USB cables are plugged in you will get an error message said the COM port is in use.
Click on “okay” and ignore for now.
In XMap, click on:
> Options
> Comm Port Setup.
> From the drop down menu click on the appropriate COM port. (For example, COM5.)
> Click on Okay.
Turn the ignition key to the “On” position. Look to the lower left hand corner of the XMAP window for the Xede
status. It should read connected. If not, turn key off and back on. If still not connected, reboot computer, double
check that all cables are plugged in, turn key on and open XMAP. If it is still not connected, you will need to
manually reset your COM port. Turn key off.
11
To Manual Reset the COM Port:
> Go back to the device manager from the directions above.
> Right click on the USB to Serial Comm. Port.
> Click on properties.
> Click on port settings tab
> Click on Advanced. In the advanced settings window at the bottom there is a drop down menu at COM
port number. From the drop down menu choose COM1.
> Click OK here and at the serial cable properties window.
> Close device manager and control panel.
Open XMAP. Click on Options >> Comm Port Setup. From the drop down menu click on COM1 port. Click on
Okay. Turn key back on and check Xede status in lower left part of the window. It should now read connected. If
not, please call for assistance.
Setting Default Printer
XMap has a quirk in the software. There must be a printer installed on the computer and/or laptop in order for the
software to run and operate. Even if you do not use a printer, please install a driver for one and set it as the default
printer.
Downloading a Map off of the Xede:
Once connected, hit the F8 button. This is the short cut to Download and show maps.
The long way is to click on:
> Maps
> Download and Show Maps.
The maps will download and automatically display on the screen.
Loading Map
In order to load a map, you must have one saved to the computer already. Once connected click on:
> File
> Open. Find and click on the new map you want to upload.
> Xmap will ask if you want to upload the Map. Click on Yes. Xmap will ask if you want to Burn the Map.
Click on Yes. Once the map is burned, a small window will pop up and say the store was successful or not.
If it takes longer than two minutes to upload the new map, chances are you have a bad cable. Stop the transfer and
go buy a RADIO SHACK cable!
Connecting to the XEDE to load a Timing Pattern File
This is not the Timing Map. It does not retard or advance timing. It is a waveform pattern file that the Xede
recognizes so that it can control the ignition timing.
From XMap screen click on Setup and Configure Timing Signal. This screen will appear.
12
Click on Select pattern file. Open the pattern file for your car. If you are unsure, please verify with the office prior
to using. Once the pattern file has been selected, click on ok. XMap will return to this screen.
Notice the name of the file now displays in the lower portion of the window. Also there is a waveform pattern
displayed also. Click on ‘Configure Xede to use this Pattern’. Another window will pop up asking if you want to
continue. Select ‘Yes’. It will tell you if the configuration was successful or if the data was not stored.
13
Viewing the Current Timing Pattern File
If you want to verify that the pattern file being used is correct, there a few methods of doing so.
First Method: Connect the Xede to the computer via cable and turn the ignition key to the ‘On’ position. When you
open XMap look at the first screen that pops up. In YELLOW letters, it will display the timing pattern file being
used. See the photo below for the approximate location.
Second Method: From the main Xmap screen, click on Diagnosis and Xede Information. The serial number, map
name, and timing pattern file will be displayed.
Shortcut Keys
While you do not have to use the shortcut keys, using this software will be much easier if you do.
Ctrl + U = Upload a Map
Ctrl + B = Burn Map to EEPROM
F8 = Download and Show all Maps loaded on the Xede unit.
F10 = Tile Maps. Use this if a map does not display on the screen.
Less and More Buttons
** the best shortcut you will use!!**
14
Maps Missing - Off the screen
If you are missing maps off the screen, press ‘F10' to tile maps. This will arrange all of the maps for view within
the desktop area.
If the Title of the Map Is Missing
For use if the Menu Bar does not contain the name of the map and only the map number. Click on the map in
question. Right click on this map. Click on ‘Edit the Map’. In the first and fifth tabs, type in the Map description
(MAF, Timing, O2 Offset, Load Predict, Boost) in two places. Click on ‘Ok’.
15
Highlighting Maps
To highlight the map, click an hold the mouse button over one corner of the map. Drag it to the opposite corner. The
active cells are yellow. As the active cells move throughout the table, the text in the cells will remain yellow. This
is called ‘tracing’. What to know exactly where the lean spot was? Highlight the map. Make a run. Make note of
the rpm at the onset of the lean condition. If the lean spot is at about 4000 rpm, see which cells remained yellow in
the 4000 rpm range on the table. Alter those cells.
Tracing is your friend! Use it frequently and on all maps at the same time. Just make sure that the XMAP is the
active program on the desktop. The alternative is to do a data log file.
Checking Output Scaling Value
If you call for assistance with the Xede, we WILL ask you what the offset value is. We need to verify that it is
correct prior to making any changes in the map.
Click on ‘Features’ then ‘Output Scaling’. AN0 should be set to ‘0.891' and AN1, AN2 and Freq should display
‘1.0'. The output scaling may be less. It will depend solely on the injector type being used. For example, RC injectors
will have more scaling than a Denso or Ford injector.
Viewing 3D maps
To view the 3D graph of the Map, click on the Blue arrow in the bottom left corner of the map. See the red circle
in the picture below. To return the map to normal, click on the same arrow. As you can see, the map below shows
a spike in it. Find the spike (incorrect content in a cell) and fix as needed.
16
Adding Offsets
If a cell, or block of highlighted cells, currently reads “0" and you want it to read ‘9'. There are two ways of changing
the contents. Click on the cell and hit the number ‘9' button, and press enter. This will automatically change all
highlighted cells to ‘9'. If you are changing more than one cell, I would recommend the second method. That is to
right click on the map and click on add offset. Type in the amount of offset you want to ADD. If you want to
subtract, remember you need to add in a negative number. Another method is to highlight the cells that need to be
changed. Use the arrow keys (as pictured above) to make changes. That will change all of the cells highlighted by
the minimum amount of change possible.
17
What Interpolate Does
Interpolate will average the cells, on either axis, to be even gaps between the selected cells. The interpolation works
independently in each direction. So if you interpolate on the y-axis it interpolates only in the y direction (bottom to
top) and if you interpolate on the x-axis it interpolates only in the x direction (left to right).
Take a look at the map below. It has been interpolated on the ‘y’ axis. Above, the first map is normal, the second
is highlighted area to be interpolated on the y axis. The third is the interpolation result. It will average between the
lower left and upper right cell contents.
Adding Load Points & RPM Points
There are two ways of adding rpm and load values/points into a map. The first is to right click on the map. Click
on ‘edit this map’. There is a line for RPM points and Load Points. You can change them here, add in or subtract
values, then click on ok. See the picture on page 18.
The second method is to right click on the map, and click on ‘Insert Column’ or ‘Insert Row’. If the small window
does not show up on the screen, move the map window up to view the new point window.
18
What the Live Data Display Tells You
The Live Data Window will visually tell you the changes
being made by the Xede.
For regular Miatas:
AN0 = MAF
AN1 = O2 Sensor
For MazdaSpeed Miatas:
AN0 = MAF
AN1 = TPS
It will show the incoming voltage and the outgoing voltage.
For example if the incoming signal is 10%. The map
indicates a change of -7%. So the live data display of AN0
Out should read 3%.
Wideband Map
If your wideband O2 sensor has an Analog Out wire, it can be wired into the Xede to make additional corrections.
However, the car MUST be tuned very well prior to doing this. It does it thru a nested map feature and makes
corrections based off of the voltage from the wideband O2 sensor.
Please call us for help with this feature.
19
Recovery Console
DO NOT EVER use the recovery console. This feature is for Xedes using V2 firmware. 99.9% of all Mazdas
will be using V3 or V3.2 firmware, so it is not necessary. If the recovery console is run, there are significant
risks that the Xede losing its programming. If that unit loses it hard coded programming, it has to be sent to
Chip Torque in Australia to fix it.
The Car Will Not Start
The engine is cold, and will not turn over. Check the Fuel Injection fuse under the hood. Chances are it has blown
and needs to be replaced. It is a 30 amp, pink fuse. It would not be a bad idea to have one of these in the glove box,
just in case.
If the fuse is intact, look at a mechanical reason the car will not work. Only 1% of the time will it be the Xede.
How to Intentionally Disable the Car
It is very easy to intentionally disable the car. This comes in handy if you are parking the car at the airport, or
something of that nature. Unplug the Xede unit from the wire harness. The car will crank but will never start. Short
of being towed or stolen, the motor will not start and the car cannot be driven.
If you come across some other short cuts or handy tips, please let us know!
General Rules of Operation
•
•
•
Do not remove the Xede unit unless absolutely necessary.
If your car quits operating normally, please take note of the lights & patterns illuminated on the Xede
unit.
Also, if your car quits operating normally, it is usually do to a mechanical failure not an Xede failure.
Getting the codes read off of the OBD II port can help to diagnose the problem. Certain MIL codes are
normal with the Xede unit. If any other codes exist, please call for assistance or clarification.
20
Warranty Information
•
•
•
•
•
•
•
•
All items made by BEGi are warranted for workmanship and function for one year from the date of
receipt. All other items are subject to manufacturer’s warranty.
If problems arise from using a BEGi part in a manner other than intended, or a part is installed
incorrectly, BEGi reserves the right to refuse warranty coverage for damages.
BEGi will not warranty any kits, parts or items purchased thru an online auction that is not purchased
from an authorized dealer. The customer must be able to provide proof of purchase for any warranty
repairs.
BEGi reserves the right to inspect any item before any warranty will be granted. BEGi will not reimburse
for any labor charges on warranty items that occur without prior, written consent.
BEGi extends no warranty nor accepts liability to any original, stock, or replacement components on the
vehicle.
BEGi does not pay any towing expenses.
Warranty may transfer. BEGi must be notified within twenty days of sale to continue warranty coverage.
Shipping / freight charges are the responsibility of the end user for all warranty consideration.
Terms of Sale
•
•
•
•
•
•
•
•
All shortages from the parts list must be reported to BEGi within 20 days of receipt.
BEGi does not pay any towing expenses.
All returned items are subject to a 25% re-stocking fee.
BEGi accepts no liability for death or injury to any person or persons under any circumstance.
The re-seller assumes all responsibility for the end user’s knowledge of this warranty.
Turbo Kits sold by BEGi or by a BEGi authorized distributor must be registered with BEGi within
twenty days of receipt by the end user.
BEGi does not guarantee that turbo kits will pass smog tests. For California residents, some BEGI kits
have been provided a C.A.R.B. Executive Order Number. However, BEGi does not guarantee that the
end user’s car will pass.
Acceptance, re-sell, or use of any BEGi part constitutes full agreement by the re-seller/end user, that the
terms of sale and warranty are fully understood and accepted in full.
© Copyright BEGi 2006-2010
21