INSTALLATION INSTRUCTIONS. Revision 4.0.3

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1 INSTALLATION INSTRUCTIONS Revision 4.0.3

2 Table of Contents INTRODUCTION... 3 INSTALLATION OVERVIEW... 4 Included Parts... 5 DEVICE WIRING... 6 Required Parts... 6 Guidelines... 6 Wiring Diagram... 7 Engine Speed Input... 7 Vehicle Speed Input... 8 Outputs... 8 General-Purpose Input... 8 PRESSURE PORT Required Parts Guidelines BCS Required Parts Guidelines Port BCS Internal Wastegate/Actuator Configuration Port BCS External Wastegate Primary Configuration Port BCS External Wastegate Alternate Configuration Port BCS External Wastegate Configuration APPENDIX 1: OUTPUT WIRING DIAGRAMS General Solenoid or Pump Wiring Single WMI Pump or IC Spray Pump Wiring WMI Pump and Solenoid Wiring WMI Pump and IC Spray Pump Wiring Single Stage Nitrous Wiring Secondary Fuel Pump Wiring Cortex EBC Installation Instructions SIRHC Labs LLC

3 INTRODUCTION This manual provides detailed instructions for installing your Cortex EBC device. Complete documentation for the Cortex EBC (including the instructions found in this document) can be accessed from Cortex EBC Help Navigator, which is incorporated into the Cortex Config PC software. To access the Cortex EBC Help Navigator, first install and launch the Cortex Config software on your PC. The Cortex Config software can be downloaded from: Next, select Help Launch Cortex EBC Help Navigator from the menu at the top of the Cortex Config Editor window. Cortex EBC Installation Instructions SIRHC Labs LLC

4 INSTALLATION OVERVIEW It is strongly recommended that the Cortex EBC be installed by an automotive professional. Use an appropriate metering device to ensure engine speed, vehicle speed, and general-purpose input signals are within the specified operating range for the Cortex EBC device. Improper installation may result in damage to your vehicle and/or the Cortex EBC device. The Cortex EBC device should be mounted in the interior of the vehicle in a location where it will not be exposed to dirt, moisture, excessive heat, or other environmental elements. The Cortex EBC is not waterproof and exposure to moisture will damage the device. After installing the Cortex EBC device you MUST correctly configure the Cortex EBC Vehicle Configuration settings to correctly interpret your vehicle s electrical signals using the Cortex Config software application. The Cortex EBC installation process requires the completion of 5 steps: 1. Connect the Cortex EBC wiring harness to the correct signals in your vehicle s electrical system. 2. Connect the Cortex EBC device to a suitable intake manifold pressure reference. 3. Connect the 3-Port or 4-Port BCS to the vehicle s turbocharger and wastegate. Rear Panel of Cortex EBC Device Cortex EBC Installation Instructions SIRHC Labs LLC

5 Included Parts Cortex EBC Part Identification Table Cortex EBC Installation Instructions SIRHC Labs LLC

6 DEVICE WIRING The Cortex EBC requires five connections to be made between the Cortex EBC wiring harness and your vehicle s electrical system. On many cars manufactured between 1988 and 2007, the necessary signals can easily be found in a common location at the ECU/ECM/PCM. On vehicles manufactured after 2007 some of these signals may no longer be available at the ECU/ECM/PCM, but can usually still be found elsewhere in the electrical system (gauge panel, other control units, sensors outputs, etc.). Required Parts Cortex EBC Wiring Harness Fuse Holder and 2 Amp Fuse Guidelines 1. Disconnect the negative battery terminal. 2. Place the 10-pin connector of the Cortex EBC wiring harness near the Cortex EBC device. 3. Connect the wiring harness to +12 V power and chassis ground. 4. Connect the wiring harness to appropriate engine speed, vehicle speed, and TPS or WBO2 signals. 5. Cover the ends of the wires for the programmable outputs and tuck them away in a safe place until installation process is complete and the Cortex EBC has been setup for your vehicle. 6. Route the black sub-harness/connector into the engine bay to the location you plan to mount the 3-Port or 4-Port BCS. 7. Plug the 10-pin wiring harness connector into the back of the Cortex EBC device. The harness should be plugged in such that the purple, red, orange, and black wires are towards the TOP of the Cortex EBC device. Cortex EBC Wiring Harness Orientation (empty pin should be on top) Cortex EBC Installation Instructions SIRHC Labs LLC

7 Wiring Diagram WARNING: IMPROPER ELECTRICAL CONNECTIONS CAN RESULT IN UNPREDICTABLE BEHAVIOR AND/OR DAMAGE TO THE CORTEX EBC DEVICE OR THE VEHICLE S ELECTRICAL SYSTEM. SOLDER ANY CONNECTIONS AND INSULATE WITH HEAT SHRINK (PREFERRED) OR ELECTRICAL TAPE. WARNING: PIN 3 OF THE CORTEX EBC WIRING HARNESS MUST BE CONNECTED TO A FUSED POWER SOURCE (5A OR SMALLER FUSE). FAILURE TO USE A FUSED POWER SOURCE MAY RESULT IN DAMAGE TO THE CORTEX EBC DEVICE. WARNING: DO NOT CONNECT THE ENGINE SPEED INPUT TO THE SECONDARY (HIGH VOLTAGE) SIDE OF AN IGNITION COIL. Wire Side of 10-Pin Wiring Harness Connector with Pins Labeled Wiring Harness Diagram PIN COLOR SIGNAL TYPE REQUIREMENTS Pin 1 PURPLE BCS Power Supply Plugs into BCS connector. Pin 2 BLUE BCS Drive Switch to Ground Plugs into BCS connector. Pin 3 RED Switched/Fused + 12V Supply Connect to FUSED +12V power source (fuse rating 5A or less). Pin 4 TAN Output 1 Drive Switch to Ground Resistive load, 200 ma max current. Pin 5 ORANGE General-Purpose Input Analog or Digital Input Voltage Range: 0 V to +12 V Pin 6 GRAY Output 2 Drive Switch to Ground Resistive load, 200 ma max current. EMPTY Pin 8 PINK Engine Speed Digital Input Connect to frequency based engine speed signal. Pin 9 BLACK Chassis Ground Ground Connect directly to clean chassis ground. Pin 10 GREEN Vehicle Speed Digital Input Connect to frequency based vehicle speed signal. Electrical Signal Descriptions Engine Speed Input The Cortex EBC is compatible with a wide variety of engine speed signals, and most vehicles will have several options to choose from when selecting an RPM source. The following signal types can be used (in order of preference): Tach signal from ECU/ECM/PCM Cam or crank position sensor Transmission input shaft speed sensor (auto trans applications only) Coil trigger signal from ECU/ECM/PCM or negative (-) terminal on primary (LOW VOLTAGE) side of ignition coil Fuel injector trigger signal from ECU/ECM/PCM (not compatible with gasoline direct injection) Cortex EBC Installation Instructions SIRHC Labs LLC

8 Electrical noise on coil and fuel injector trigger signals may make it impossible for the Cortex EBC to accurately determine RPM. In these cases it will be necessary to switch to a different RPM source as the device will not be able to determine gear without a smooth RPM signal. All 3-wire hall-effect and most 2-wire magnetic/inductive/vr cam and crank position sensors can be detected by the Cortex EBC without any additional components. The device can handle any virtually any trigger wheel pattern as long as it has 60 teeth or less. Vehicle Speed Input Obtaining a speed signal that can be detected by the Cortex EBC can be a bit of a challenge on certain applications. The following signal types can be used (in order of preference): Digital speed pulse signal from ECU/ECM/PCM or gauge cluster Transmission output shaft speed sensor (may require Speed Sensor Adapter) Most ABS wheel speed sensors (requires Speed Sensor Adapter) CAN bus (requires third-party adapter) Most vehicles manufactured from 1988 to 2007 will have a digital speed pulse signal that can be obtained from the ECU/ECM/PCM, gauge cluster, or cruise control module. If a digital speed pulse is not available a transmission output shaft speed sensor is the next best option. 3-wire hall-effect type sensors can be connected directly to the Cortex EBC without any additional hardware. 2-wire magnetic/inductive/vr type sensors will need to use a Speed Sensor Adapter. If a transmission output shaft speed signal is not available an ABS wheel speed sensor is the next best option. A Speed Sensor Adapter will be required for this configuration. The Speed Sensor Adapters are compatible with all magnetic/inductive/vr type ABS wheel speed sensors and most 2-wire hall-effect type ABS wheel speed sensors. If none of the above options will work and your vehicle is equipped with a CAN bus a third-party adapter can be used to obtain a speed pulse signal from CAN bus data. Please see our website for additional information on the Speed Sensor Adapter and CAN bus modules. Outputs See Appendix 1 for output wiring diagrams. General-Purpose Input The general-purpose input available on the Cortex EBC can be connected to several different sensor types to add additional boost control, output, and/or fail-safe capabilites. The following signal types are currently supported: Analog throttle position signal Analog Wideband O2 sensor controller output GM flex fuel sensors Cortex EBC Water/Methanol Flow Sensor Trans Brake Switch Under no circumstances should any sensor type other than the ones listed above be connected to the general-purpose input. Cortex EBC Installation Instructions SIRHC Labs LLC

9 Flex Fuel Sensor Wiring The GPI input can be connected directly to the output of your flex fuel sensor if your vehicle is equipped with a factory sensor or if your sensor is currently wired to your ECU/ECM/PCM or other device. If your flex fuel sensor is not connected to any other devices you will want to use the following diagram when installing your sensor. For the Cortex EBC to be able to detect the output of the flex fuel sensor it is necessary to connect a pull-up resistor between the sensor power and output wires, as shown in the diagram. WMI Flow Sensor Wiring WMI flow sensors should be wired as shown in the following diagram. Do not forget to connect the included pull-up resistor between the sensor power and output wires. Transbrake Switch Wiring Transbrake switches should be wired to the Cortex EBC as shown in the following diagram. You MUST use a diode protected relay such as the Hella or the relay will damage the Cortex EBC device. Cortex EBC Installation Instructions SIRHC Labs LLC

10 PRESSURE PORT To monitor and control boost pressure the Cortex EBC must be connected to an intake manifold pressure reference. Required Parts 1/8 Silicone Vacuum Hose Zip Ties 1/8 Hose Tee (optional) 1/8 Hose Barb (optional) 3/16 Hose Tee (optional) 3/16 to 1/8 Hose Reducer (optional) Guidelines 1. Connect one end of the 1/8 ID Silicone Vacuum Hose to the pressure port on the back of the Cortex EBC device. 2. Route the other end of the hose into the engine bay of the vehicle and connect it to a pressure source after the throttle-plate. Suitable sources include vacuum ports on the throttle-body, intake manifold, or fuel pressure regulator. A variety of hose fittings are supplied to assist in making a connection in the engine bay. 3. Use the supplied zip ties to secure all hose connections. Cortex EBC Installation Instructions SIRHC Labs LLC

11 BCS The Cortex EBC has been designed to be compatible with both internal (actuator type) and external wastegate configurations. The manner in which the BCS is connected to your turbocharger system depends on your wastegate type. WARNING: FAILURE TO FOLLOW THE DIAGRAM CORRESPONDING TO YOUR WASTEGATE TYPE WILL RESULT IN UNPREDICTABLE BOOST BEHAVIOR AND POSSIBLE DAMAGE TO YOUR ENGINE. Required Parts 3-Port or 4-Port BCS Zip Ties 3/16 Silicone Vacuum Hose 3/16 Hose Barbs 3/16 Hose Tee (optional) Guidelines 1. Thread the 3/16 Hose Barbs into the BCS. 2. Connect the BCS to turbocharger system using the supplied 3/16 Vacuum Hose. 3. Plug the BCS into the connector on the Cortex EBC wiring harness. 4. Use the supplied zip ties to secure all hose connections. Cortex EBC Installation Instructions SIRHC Labs LLC

12 3-Port BCS Internal Wastegate/Actuator Configuration BCS Port 1 BCS Port 2 BCS Port 3 Leave open or connect to pre-turbocharger intake tract. Connect to wastegate actuator pressure port. Connect to compressor outlet on turbocharger. Cortex EBC Installation Instructions SIRHC Labs LLC

13 3-Port BCS External Wastegate Primary Configuration BCS Port 1 BCS Port 2 BCS Port 3 Leave open or connect to pre-turbocharger intake tract. Connect to side port on external wastegate. Connect to compressor outlet on turbocharger. Cortex EBC Installation Instructions SIRHC Labs LLC

14 3-Port BCS External Wastegate Alternate Configuration This configuration will allow the Cortex EBC to apply equal pressure to the top and bottom ports of the external wastegate. Using this configuration can help increase the maximum boost pressure that can be achieved and also improve the responsiveness of the wastegate valve. BCS Port 1 BCS Port 2 BCS Port 3 Connect to compressor outlet on turbocharger AND side-port of external wastegate using 3/16 hose tee. Connect to top-port of external wastegate. Leave open. Cortex EBC Installation Instructions SIRHC Labs LLC

15 4-Port BCS External Wastegate Configuration BCS Port 1 BCS Port 2 BCS Port 3 BCS Port 4 Connect to compressor outlet on turbocharger. Connect to side-port of external wastegate. Leave open. Connect to top-port of external wastegate. Cortex EBC Installation Instructions SIRHC Labs LLC

16 APPENDIX 1: OUTPUT WIRING DIAGRAMS This section provides example wiring diagrams for the programmable outputs available on the Cortex EBC. Most applications will require the use of a standard automotive relay and master override switch, which are available at most automotive parts stores or online. General Solenoid or Pump Wiring

17 Single WMI Pump or IC Spray Pump Wiring Cortex EBC Installation Instructions SIRHC Labs LLC

18 WMI Pump and Solenoid Wiring Cortex EBC Installation Instructions SIRHC Labs LLC

19 WMI Pump and IC Spray Pump Wiring Cortex EBC Installation Instructions SIRHC Labs LLC

20 Single Stage Nitrous Wiring Cortex EBC Installation Instructions SIRHC Labs LLC

21 Secondary Fuel Pump Wiring Cortex EBC Installation Instructions SIRHC Labs LLC

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