Installation Instructions for: EMS P/N 30-1500 1996-02 Dodge Viper V-10! 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. Misuse of this product can destroy your engine! If you are not well versed in engine dynamics and the tuning of management systems or are not PC literate, please do not attempt the installation. Refer the installation to a AEM trained tuning shop or call 800-423-0046 for technical assistance. You should also visit the AEM EMS Tech Forum at http://www.aempower.com NOTE: AEM holds no responsibility for any engine damage that results from the misuse of this product! This product is legal in California for racing vehicles only and should never be used on public highways. 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: 10-1500 2003 Advanced Engine Management, Inc. Page 1 of 12
Congratulations! You have just purchased the finest Engine Management system for your car at any price! The AEM Engine Management System (EMS) is the result 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 EMS is an all new stand alone system, which completely replaces the factory ECU and features unique Plug and Play Technology, which means that each system is configured especially for your make and model of car. There is no need to modify your factory wiring harness and in most cases your car may be returned to stock in a matter of minutes. The AEMPro software is configured to work with the factory sensors and equipment, so that there is no need for expensive or hard to find sensors, making replacement and repairs as simple as with an unmodified car. For stock and some slightly modified cars, the AEMPro software will be preprogrammed with a set of base parameters, providing a starting point for individual tuning. For more heavily modified cars, the EMS has many spare inputs and outputs allowing the elimination of separate rev-limiters, boost controllers, nitrous controllers, and fuel computers. It will also allow programmable control over all automatic transmission functions, and includes a configurable onboard data logger capable of recording 512kb of information. Every EMS comes with all functions installed and activated, and there are no expensive options or upgrades to be performed. The installation of the AEM ECU on the 1996-2002 Dodge Viper V-10 uses the stock sensors and actuators. The base map is automatically installed in the base calibrations directory in the AEMPro directory on your computer. It is named 1500 Stock MAP.VX.XX.cal. Full details of the test vehicle used to generate this map can be found in the files notes section. However, while the base map is a good starting point and may save you considerable time and money, it will not replace the need to tune your specific application. It is not intended to be driven aggressively. Ignoring this can and will damage your engine. Please visit the AEM EMS Tech Forum at http://www.aempower.com/bbs and register your EMS before you start to use it. Make sure you enter your EMS serial number when you register as doing this grants access to the calibration files. We always post the most current strategy release, PC Software and base calibrations online. On the forum, you will find many helpful hints/tips to make your EMS perform it s best. Also, we may make available EMS maps for engines running speed density, larger turbo, etc NOTE: IF YOUR VEHICLE CURRENTLY USES REAR O2 SENSOR SIMULATORS, THEY MUST BE UNPLUGGED OR REMOVED BEFORE INSTALLING THE AEM EMS. THE SIMULATORS CREATE NOISE ON THE 0-5V SENSOR GROUND AND WILL ADVERSELY AFFECT ENGINE OPERATION. Read and understand these instructions BEFORE attempting to install this product. 1) Removing the Stock Engine Unit Page 2 of 12
a) Access the stock Engine Unit (PCM). The location of the PCM on the Dodge Viper is inside the engine compartment on the driver s side below the battery charging location. b) Remove the factory heatshield by removing the four 8 mm bolts and two screws. c) Carefully disconnect the wiring harness from the PCM. Avoid excessive stress or pulling on the wires, as this may damage the wiring harness. Do not cut any of the wires in the factory wiring harness to remove them. d) Remove the fasteners securing the PCM to the vehicle, and set it aside. Do not destroy or discard the factory PCM. 2) Installing and routing the AEM UEGO Sensors a) Remove the forward most O2 sensors and replace them with the supplied UEGO sensors. b) Install the supplied UEGO harness by plugging the single 14 terminal connector into the ECU and each 6 terminal connector into the UEGO sensor connectors. The long lead is intended for installation of the passengers side forward most O2 sensor. 3) Install the AEM Engine Management System. a) Plug the factory wiring harness into the AEM EMS and position it so the wires are not pulled tight or stressed in any manner. Secure the EMS with the provided 10 screws and spacers. b) Install the supplied AEM CD and open the AEMPro software. c) Turn the ignition on but do not attempt to start the engine. d) Go to: ECU Send New Calibration. Upload the base calibration file (.cal) that most closely matches the vehicle s configuration to be tuned. Full details of the test vehicle used to generate each map can be found in the Notes section in the Setup window of the AEMPro software. The base maps can be found in the Dodge folder located in: My Computer Local Disk (C:) Program Files AEM AEMPro Startup Calibrations e) Set the throttle range: Select the Configure drop down menu, then ECU Setup Set Throttle Range and then follow the instructions given on the screen. f) Calibrate the lambda sensor channel: With the ignition on and the sensor unplugged, change the O2 #1 Gain ( Setup Sensors Oxygen Sensor Oxygen Sensor #1 Options - O2 Sensor #1 ) until the O2 #1 Volts parameter displays 4.00 Volts (+/- 0.02 Volts). This should yield an O2 #1 Gain near 1.3. Set the appropriate UEGO calibration: Enter the calibration on page 8 of this manual into Setup Sensors Oxygen Sensors Oxygen Sensor #1 O2 Sensor #1 Cal Table. Note, this is different than that used for the external AEM UEGO sensor. 4) Stock PCM and EEM function: a) The Viper Coupe and Roadster utilize an Electronic Entry Module (EEM). The Entry Module provides remote keyless entry functions as well as vehicle theft alarm functions. Installation of the AEM EMS removes communication between the Chrysler PCM and the EEM. Because of this, the red LED on top of the dash will be lit while the EMS is installed. b) Alarm function is not disabled with the EMS installed. The effect from this condition is that the automatic door locks will no longer function as they would with the stock PCM installed. If the key is left in the RUN position and the doors are closed, the automatic locks will be activated. Under these conditions, the Page 3 of 12
doors can be opened from inside the vehicle by using the manual release latches ONLY. The door opening levers will not work. With the key in the OFF position, the door opening levers will function correctly from inside or outside the vehicle. c) THE VEHICLE CANNOT BE ENTERED FROM THE OUTSIDE IF THE KEYS ARE LEFT IN THE RUN POSITION. YOU MUST MAINTAIN THE FACTORY PCM AFTER INSTALLING THE AEM EMS FOR PROPER COMMUNICATION OVER THE CCD BUS AND OPERATION OF THE EEM. IF THIS IS NOT DONE, THE DOORS WILL NOT BE ABLE TO BE OPENED USING THE DOOR OPENING LEVERS WITH THE KEY IN THE RUN POSITION. 5) PCM Relocation: a) Remove the passenger side knee panel as shown. b) Remove the passenger side knee panel support brace as shown. c) Repeat this same procedure on the driver s side as well. Page 4 of 12
d) Plug supplied harness connectors into PCM and install the controller into the pocket under the dash as shown. Secure controller with Velcro. e) Feed harness across toward the driver s side behind console. To gain access to the EEM, remove the rubber retaining strap holding it and allow it to hang down. f) Five connections are required at the EEM. Tap the circuits as shown in the following table. Page 5 of 12
Circuit PCM Pin EEM Pin Wire Color Fused Ign. (St-Run) A2 Conn. C1 Dark Blue / White Orange Pin D15 Fused B(+) A22 Red Conn. C2 Red Pin C Ground A32 Black Conn. C2 Black / White Pin D CCD (-) C28 Gray Conn. C1 Pin C5 White / Brown or White / Black CCD (+) C30 Lt Green Conn. C1 Pin C4 Violet / Brown g) Soldered and heat shrinked connections are recommended for each circuit tap as shown. h) When all required connections are complete, re-install the EEM using the rubber retaining strap. i) Secure all wires under the dash and be sure to avoid any sharp edges or corners. j) Re-install the knee panel support braces and knee panels on both sides of the vehicle. 6) Idle Tuning a) The Viper idle air control motor is sometimes susceptible to drift and/or sticking. If your idle control hangs abnormally high or low during operation, turn the key to the ON position and wait approximately 10 seconds before starting. The EMS will reset the idle motor and store the new position references. Page 6 of 12
Application Notes for EMS P/N 30-1500 1996-02 Dodge Viper V-10 Make: Dodge Supplied Connectors: Model: Viper Spare Injector Drivers: --- Years Covered: 1996-2002 Spare Injector Drivers: --- Engine Displacement: 8.0 Liters (488 in 3 ) Spare Injector Drivers: --- Engine Configuration: V10 Spare Injector Drivers: --- Firing Order: 1-10-9-4-3-6-5-8-7-2 Spare Injector Drivers: --- N/A, S/C or T/C: N/A Spare Injector Drivers: --- Load Sensor Type: MAP Spare Coil Drivers: --- Ignition System: Inductive Spare Coil Drivers: --- # Coils: 5 Spare Coil Drivers: --- Ignition driver type: 0-12V Internal Drivers Spare Coil Drivers: --- How to hook up MSD: Install between ECU and Boost Solenoid: PW2, Pin A12 Coil # Injectors: 10 EGT 1 Location: B22 1 Injection Mode: Sequential EGT 2 Location: B23 Injector Size: 30 lb/hr at 55 psi EGT 3 Location: A14 Injector Resistance: 12 Ω EGT 4 Location: A29 Knock Sensors used: None Spare 0-5V Channels: ADCR14, Pin A25 Lambda Sensors used: 1 & 2 Spare 0-5V Channels: ADCR11, Pin C15 Idle Motor Type: Stepper Spare 0-5V Channels: ADCR13, Pin C26 Main Relay : No Spare LS Driver: LS#12, Pin C10 Crank Pickup Type: Hall Effect Spare HS Driver: HS#1, Pin B17 Crank Teeth/Cycle: 10 Spare HS Driver: HS#2, Pin B18 Cam Pickup Type: Hall Effect Spare HS Driver: HS#3, Pin B19 Cam Teeth/Cycle: 1 Spare HS Driver: --- Trans Supported: M/T Check Engine Light: LS#10, Pin C17 Drive Options: RWD Spare Switch Input: Switch #5, Pin C24 Spare 0 5V MAF MAF, Pin B7 Spare Switch Input: Switch #6, Pin C14 Spare Knock Input Knock 1, Pin C7 A/C Switch Input: Switch #3, Pin C22 Spare Knock Input Available PWM IAC Motor Notes: Knock 2, Pin C8 PW1, Pin B8 1. EGT Inputs set from factory for 470 ohm pull-up. Thermistor temp type (2k2 pull-up) and analog input (100k pull-up) available through internal hardware jumper change. Page 7 of 12
Connection Diagram for EMS P/N 30-1500 1996-02 Dodge Viper PnP Available Dedicated The Plug and Play system comes with this configured for proper operation of this device. Is still available for reassignment by the end user. The function is not currently allocated and is available for use The location is fixed and can not be changed Pin # 96-02 Dodge Viper AEM PEMS P/N 30-1500 I/O Availability A1 Ignition Coil Driver #4 Coil #4 Output PnP for Coil #4 A2 Fused Ignition Switch Output PWR Input Dedicated A3 Ignition Coil Driver #3 Coil #3 Output PnP for Coil #3 A4 Sensor Ground AGND Output Dedicated A5 Ignition Coil Driver #5 Coil #5 Output PnP for Coil #5 A6 Not Used Not Used --- --- A7 Ignition Coil Driver #1 Coil #1 Output PnP for Coil #1 A8 Crank Position Sensor Signal Crank Input Dedicated A9 Ignition Coil Driver #2 Coil #2 Output PnP for Coil #2 A10 Idle Air #2 Driver Idle #4 Output PnP for Idle #4 Driver A11 Idle Air #1 Driver Idle #3 Output PnP for Idle #3 Driver A12 Not Used PW2 Output Available PWM Output (Boost ) A13 Not Used Not Used --- --- A14 Not Used EGT #3 Input Available RTD/Thermistor/0-5V Analog 1 A15 Intake Air Temperature AIT Input PnP for AIT Sensor Sensor Signal A16 ECT Sensor Signal Coolant Input PnP for Coolant Sensor A17 5-Volt Supply RefV Output Dedicated A18 Camshaft Position Sensor Signal Cam Input Dedicated A19 Idle Air #3 Driver Idle #2 Output PnP for Idle #2 Driver A20 Idle Air #4 Driver Idle #1 Output PnP for Idle #1 Driver A21 Not Used Not Used --- --- A22 Fused B(+) Perm Input Dedicated A23 Throttle Position Sensor TPS Input PnP for TPS Sensor Signal A24 Left Upstream O2 Not Used --- --- Sensor Signal A25 Left Downstream O2 ADCR14 Input Available 0-5V Analog input Sensor Signal A26 Right Upstream O2 Not Used --- --- Sensor Signal A27 MAP Sensor Signal MAP Input PnP for MAP Sensor A28 Not Used RefV Output Available 5 Volt Reference A29 Right Downstream O2 Sensor Signal EGT #4 Input Available RTD/Thermistor/0-5V Analog 1 A30 Not Used AGND Output Available Analog Ground A31 Ground PGND Input Dedicated A32 Ground PGND Input Dedicated B1 Not Used Not Used --- --- B2 Injector #7 Driver Injector #7 Output PnP for Injector #7 B3 Injector #9 Driver Injector #9 Output PnP for Injector #9 Page 8 of 12
B4 Injector #1 Driver Injector #1 Output PnP for Injector #1 B5 Injector #3 Driver Injector #3 Output PnP for Injector #3 B6 Injector #5 Driver Injector #5 Output PnP for Injector #5 B7 Not Used MAF Input Available 0-5V MAF Sensor Input B8 Not Used PW1 Output Available PWM Output (IAC) B9 Not Used Not Used --- --- B10 Generator Field Driver Alt Reg Output Dedicated (except 96 Roadster) B11 Shift Indicator Lamp LS#2 Output PnP for Shift Indicator Lamp B12 Injector #6 Driver Injector #6 Output PnP for Injector #6 B13 Injector #8 Driver Injector #8 Output PnP for Injector #8 B14 Injector #10 Driver Injector #10 Output PnP for Injector #10 B15 Injector #2 Driver Injector #2 Output PnP for Injector #2 B16 Injector #4 Driver Injector #4 Output PnP for Injector #4 B17 Not Used HS#1 Output Available Switched 12 Volt Output, 1.5A Max B18 Not Used HS#2 Output Available Switched 12 Volt Output, 1.5A Max B19 Not Used HS#3 Output Available Switched 12 Volt Output, 1.5A Max B20 Not Used FM Output Available +/- 5 Volt Output 5mA max B21 Reverse Lock Out Solenoid LS#5 Output PnP for Reverse Lock Out Solenoid B22 Not Used EGT #1 Input Available RTD/Thermistor/0-5V Analog 1 B23 Not Used EGT #2 Input Available RTD/Thermistor/0-5V Analog 1 B24 Not Used RefV Output Available 5 Volt Reference B25 Not Used AGND Output Available Analog Ground B26 Not Used Not Used --- --- B27 Speedometer Signal Speedometer Output Dedicated B28 Vehicle Speed Sensor Signal Car Speed Input PnP for Vehicle Speed Sensor B29 Not Used Idle #5 Output Available Stepper Motor or 12 Volt 1.2A output B30 Not Used Idle #6 Output Available Stepper Motor or 12 Volt 1.2A output B31 5 Volt Supply RefV Output Dedicated B32 Not Used Idle #7 Output Available Stepper Motor or 12 Volt 1.2A output C1 A/C Comp Clutch Relay LS#4 Output PnP for Compressor Clutch Relay C2 Lo-Spd Radiator Fan LS#8 Output PnP for Lo-Spd Radiator Fan C3 Auto Shutdown Relay LS#3 Output PnP for Auto Shutdown Relay 2 C4 Not Used HS#4 Output Available Switched 12 Volt Output, 1.5A Max C5 Not Used Not Used --- --- C6 2-3 Skip Shift Solenoid LS#6 Output PnP for 2-3 Skip Shift Solenoid C7 Not Used Knock #1 Input Available Knock Sensor Input C8 Not Used Knock #2 Input Available Knock Sensor Input C9 Not Used AGND Output Available Analog Ground C10 Leak Detect Pump LS#12 Output Available Switched Ground, 1.5A Max Solenoid (98-02 Only) C11 Not Used RefV Output Available 5 Volt Reference Page 9 of 12
C12 Auto Shutdown Relay Switch #1 Input PnP for Auto Shutdown Relay Output Output C13 Not Used Not Used --- --- C14 Leak Detect Pump Switch #6 Input Available Switched or Speed Input Switch Sense (98-02 Only) C15 Ambient Temp Sensor Signal ADCR11 Input Available 0-5V Analog input C16 Gen Lamp Driver (98-02 Only) Idle #8 Output Available Stepper Motor or 12 Volt 1.2A output C17 MIL Lamp Driver LS#10 Output Available Switched Ground, 1.5A Max C18 Not Used Not Used --- --- C19 Fuel Pump Relay LS#11 Output PnP for Fuel Pump Relay C20 Evap Emission Solenoid LS#1 Output PnP for Evap Solenoid C21 Hi-Spd Radiator Fan Relay LS#9 Output PnP for Hi-Spd Radiator Fan C22 A/C Request Signal Switch #3 Input PnP for A/C Request Signal C23 A/C Select Signal Switch #4 Input PnP for A/C Select Signal C24 Brake Switch Sense Switch #5 Input Available Switched or Speed Input C25 Not Used Not Used --- --- C26 Low Fuel Sense / Fuel level Sensor Signal ADCR13 Input Available 0-5V Analog Input C27 SCI Transmit PCRX Output Dedicated (Comms Transmit) C28 CCD Bus(-) Not Used --- --- C29 SCI Receive PCTX Input Dedicated (Comms Receive) C30 CCD Bus(+) Not Used --- --- C31 Tachometer Signal Tacho Output PnP for Tachometer Drive Signal C32 Not Used Not Used --- --- A - Black B - White C - Grey Notes: 1. EGT Inputs set from factory for 470 ohm pull-up. Thermistor temp type (2k2 pull-up) and analog input (100k pull-up) available through internal hardware jumper change. Page 10 of 12
Oxygen Sensor #1 Calibrations (30-1500 ONLY) O2 (V) AFR (GAS) LAMBDA 0.000 9.950 0.679 0.156 10.070 0.687 0.312 10.180 0.695 0.468 10.350 0.706 0.624 10.520 0.718 0.780 10.690 0.730 0.936 10.810 0.738 1.092 10.920 0.745 1.248 11.090 0.757 1.404 11.270 0.769 1.560 11.380 0.777 1.716 11.550 0.788 1.872 11.720 0.800 2.028 11.900 0.812 2.184 12.070 0.824 2.340 12.240 0.835 2.496 12.410 0.847 2.652 12.640 0.863 2.808 12.810 0.874 2.964 13.040 0.890 3.120 13.210 0.902 3.276 13.440 0.917 3.432 13.670 0.933 3.588 13.950 0.952 3.744 14.240 0.972 3.900 14.580 0.995 4.056 14.980 1.023 4.212 15.440 1.054 4.368 16.010 1.093 4.524 16.580 1.132 4.680 17.210 1.175 4.836 17.840 1.218 4.992 18.470 1.261 Calculating the Air Fuel Ratio of common fuels from the Lambda value Gasoline AFR = Lambda * 14.65 Methanol AFR = Lambda * 6.47 Diesel AFR = Lambda * 14.5 Propane AFR = Lambda * 15.7 Ethanol AFR = Lambda * 9.00 CNG AFR = Lambda * 14.5 Page 11 of 12
UEGO ler/sensor Specifications (30-1500 Only) Supply Voltage (nominal): 9 to 18 Volts Measuring range: 0.75 to 1.22 Lambda Type: Bosch UEGO LSU4.2 Accuracy: +/- 1% Temperature Limit: 930C Initial Warm-up Time: Less than 20 seconds Weight: 80 grams Heater Current: 1.1A at 12.0V Mounting: M18 X 1.5 thread, Torque to 30 ft-lbs Nominal Service Life: 100,000 km for Unleaded Fuel 60,000 km for Leaded Fuel 0.15g Pb/l 30,000 km for Leaded Fuel 0.40g Pb/l 20,000 km for Leaded Fuel 0.60g Pb/l Notes: The sensor should not be subject to mechanical or thermal shock or it may be damaged. The sensor is not designed for operation on leaded fuels, doing so will dramatically shorten sensor life. Long term running in the rich region (Lambda < 0.95) will shorten sensor life. High exhaust temperatures (over 850C) will shorten sensor life. Engine oil consumption at a rate greater than 1 quart per 1,000 miles will shorten sensor life. Do not run the engine with the UEGO sensor installed without power applied to the controller and the sensor plugged in. Replacement Oxygen Sensor Components (1500 Only) 30-2001 Replacement UEGO Sensor 35-4005 O2 Sensor Bung, mild steel, welding required 35-4001 O2 Sensor Plug, mild steel Page 12 of 12