VCN-1000 Venom Computerized Nitrous System Installation and Operation Manual COMPLETELY READ THIS MANUAL BEFORE STARTING INSTALLATION Revised July, 2001 2001 Python Injection, Inc. All rights reserved.
TABLE OF CONTENTS 1.0 General Information 1.1 Warranty Information 1.2 What Is Included 1.3 Necessary Tools 1.4 Product Registration 1.5 Technical Assistance 1.6 Precautions 1.7 Vehicle Requirements 2.0 System Operation 2.1 Basic Overview 2.2 Nitrous Tuning 3.0 Installation Instructions 3.1 Installation Precautions 3.2 Locating the Module 3.3 Main Harness Installation 3.4 Connecting Power and Ground 3.5 Connecting Switched Power 3.6 Mounting the Nitrous Solenoid 3.7 Sensor Connections 3.7.1 Throttle Position Sensor 3.7.2 Oxygen Sensor 3.8 Injector Harness Installation 3.9 Hose and Bottle Installation 3.10 Testing The System 4.0 Appendices 4.1 Appendix A Throttle Position Sensor Connection 4.2 Appendix B Oxygen Sensor Connection, LEV, ULEV Vehicles 4.3 Appendix C Connecting To Shielded Cables 4.4 Appendix D Frequently Asked Questions (FAQ) 5.0 Special Procedures 5.1 Procedure 1 Injector Ground Circuit Identification 5.2 Procedure 2 Injector Connection Verification 5.3 Troubleshooting System Flashes Code 2 System Flashes Code 3 System Will Not Activate No System Power Lean LED Lit At All Times Rich LED Lit At All Times Lean LED Lit During Activation Status LED Remains Off System Activates Then Shuts Off Fuse Blows
1.0 GENERAL INFORMATION 1.1 WARRANTY INFORMATION With the statements below, the term Nitrous Oxide System shall refer to the complete VENOM VCN-1000 Nitrous Oxide System, including any hoses, wires, connectors, bottles, displays or modules. LIMITED WARRANTY Every Nitrous Oxide System is rigorously tested at the factory. Python Injection warrants the Nitrous Oxide System to be free from manufacturer s defects for a period of 90 days from the date of purchase. During this period, if any of the Nitrous Oxide System components are found to be defective by Python Injection, we, at our option, will repair or replace the defective Nitrous Oxide System components. No allowances will be made for labor or other installation charges. Consequential damages are not covered. There will be no warranty coverage for engine damage. LIMITATION OF LIABILITY TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL PYTHON INJECTION, INC. OR ITS SUPPLIERS BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT, OR CONSEQUENTIAL DAMAGES WHATSOEVER (INCLUDING BUT NOT LIMITED TO CITATIONS, DAMAGE TO VEHICLE, VEHICLE ENGINE, OR COMPONENTS OR ANY OTHER PECUNIARY LOSS) ARISING OUT OF THE USE/INSTALLATION OR INABILITY TO USE/INSTALL THE NITROUS OXIDE SYSTEM OR THE FAILURE OF PYTHON INJECTION, INC OR ITS SUPPLIERS TO PROVIDE SUPPORT SERVICES, EVEN IF PYTHON INJECTION, INC. HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE ENTIRE LIABILITY OF PYTHON INJECTION, INC. UNDER THE WARRANTY SHALL BE LIMITED TO THE AMOUNT PAID BY THE PURCHASER FOR THE NITROUS OXIDE SYSTEM. BECAUSE SOME STATES/JURISDICTIONS DO NOT ALLOW EXCLUSION OR LIMITATION OF LIABILITY, THE ABOVE LIMITATION MAY NOT APPLY TO YOU. PURCHASER MUST NOTIFY PYTHON INJECTION, INC. OF ANY DEFECT OR MALFUNCTION OF THE NITROUS OXIDE SYSTEM PROMPTLY UPON DISCOVERY. CONDITIONS THAT WILL VOID THE WARRANTY The following conditions will void the VCN-1000 Warranty: Incorrectly installing the VCN-1000. Opening the VCN-1000 Module, the LED display or performing any unauthorized modifications to the VCN-1000 Module or its components. Damage caused by heat, water, improper electrical connection, physical damage or improper installation. Modifying (shortening, lengthening, cutting, etc.) the VCN harness.
1.2 WHAT IS INCLUDED The VCN-1000 kit includes all of the necessary parts to perform a professional installation of the VCN-1000 Nitrous System. Check the contents of the kit prior to beginning the installation. If any part of the kit is missing, contact the place of purchase for replacement. The VCN-1000 kit should include: Installation Manual The VCN-1000 Module The VCN-1000 Main Wiring Harness with LED Display & Switch The VCN-1000 Injector Wiring Harness Nitrous Solenoid with Mounting Hardware Nitrous Bottle with Valve and Valve Fitting Bottle Brackets with Bolts 20 Nitrous Hose 2 ½ Nitrous Hose Connector Splices Nitrous Nozzles (4) Product and Warranty Registration Card Wire Ties and Adhesive Mounting Bases 1.3 NECESSARY TOOLS Basic hand tools, I.E. screw drivers, wrenches, pliers, etc. The VCN-1000 includes a dash-mounted display and switch. A drill and drill bit will be necessary to provide passage between the engine compartment and the passenger cabin. A drill and drill bit may also be necessary to tap into the air intake. A Digital Volt/Ohm Meter. This may be obtained at any electronics store (such as Radio Shack) for about $25.00. 1.4 PRODUCT REGISTRATION A product and warranty registration card is included with the VCN-2000 kit. This card must be filled out and received by Python Injection to activate the warranty. Have this information available if you call for technical assistance. Online registration is also available at http://www.venom-performance.com. 1.5 TECHNICAL ASSISTANCE Technical assistance regarding the installation process is available Monday through Friday between 8 A.M. to 5 P.M. Pacific Standard Time. Assistance is provided directly by Python Injection by calling 714-828-1406. Be prepared to have your serial number ready when calling. Do not call the place of purchase for technical assistance questions. Online Technical Support is also available at http://www.venom-performance.com.
1.6 PRECAUTIONS Observe the following precautions while installing the VCN-2000 Wire Harness and Injector Harness: Never install the Wire Harness or Injector Harness or work under the hood of a vehicle with the engine running. Some engine parts become extremely hot. Use caution when working under the hood. Read over the entire installation manual prior to starting the installation. Familiarize yourself with the procedures. Installation is very easy if the procedures are followed. Wear safety glasses at all times during the installation process. Nitrous is a gas that is under extreme pressure and can cause frostbite if it comes in contact with the skin. If you are unfamiliar with working on or around automobiles it is suggested you have the system professional installed. 1.7 VEHICLE REQUIREMENTS In order for the VCN-1000 system to operate your vehicle must have the following features and equipment: Port Electronic Fuel Injection (One Injector Per Cylinder) Return-Less Fuel Systems Are Okay. (Neon, Focus) Linear Throttle Position Sensor (Voltage Increases or Decreases with Throttle Movement) 1 A Standard Oxygen Sensor (0-1 Volt) 2. Use of High Octane fuel (92 Octane or Greater) and/or use of a pour in Octane booster. 1 If your vehicle is a European vehicle or uses a Throttle Position Sensor that decreases in voltage with an increase in throttle angle refer to Appendix D. 2 Refer to Appendix B for LEV or ULEV vehicles. Your vehicle may require the installation of a standard oxygen sensor.
2.0 SYSTEM OPERATION 2.1 BASIC OVERVIEW The VCN-1000 Nitrous System is a computer controlled nitrous system. The heart of the system is the VCN-1000 control module, which controls the flow of nitrous and fuel to the engine when the system is active. Most importantly, the module maintains the proper air fuel ratio at any bottle pressure and will terminate the flow of nitrous to the engine should the air fuel ratio become too lean. The VCN-1000 module is designed so that when the ignition is turned on the system will power up, when this occurs the Blue LED will light up for 2 seconds then go out. Once the engine is started the module will perform an Oxygen Sensor test. This process takes place regardless of the position of the enable switch. During the Oxygen Sensor Test the Blue Light will be off. After the module has determined the Oxygen sensor is warmed-up and functional, which can take up to 2 minutes 3, it will go into ready mode. When this occurs the Blue LED will flash on and off continuously. In this mode the module will continually monitor the throttle position. If the module senses that the throttle is wide open and the enable switch is enabled it will activate the nitrous solenoid and nitrous will flow into the engine. The Blue LED will come on solid when the nitrous is being injected. The amount of nitrous is controlled by the installation of different sized nozzles at the throttle body. As nitrous is injected into the engine the module will monitor the Oxygen Sensor and will maintain the proper air fuel mixture. The nitrous will continue to flow into the engine until the throttle is released or the enable switch is switched to disable. Once the nitrous is deactivated the Blue LED should return to a flashing state. If the module automatically terminates the nitrous because the air fuel mixture is too lean the module will flash a trouble code 3 using the Blue LED. This will be indicated by 3 flashes followed by a pause, which will repeat continually. If this occurs the ignition will need to be cycled off and then back on in order to reset the module. If this occurs refer to the troubleshooting section for instructions. 2.2 NITROUS TUNING The amount of nitrous introduced into the engine is determined by the size of nozzle you are using. Although there are seven different sized nozzles, your kit contains four nozzles depending on whether it is a four, six or eight cylinder engine. The nozzles are color coded for quick reference. Other nozzles as well as custom nozzles may be purchased for a nominal charge. Color Orifice Size Included In Kit Blue.025 4 Cyl Red.030 4 Cyl Green.035 4 Cyl, 6 Cyl Purple.040 4 Cyl, 6 Cyl, 8 Cyl Gold.045 6 Cyl, 8 Cyl Black.050 6 Cyl, 8 Cyl Clear (aluminum).055 8 Cyl 3 If after 4 minutes the module cannot determine the Oxygen Sensor is working it will begin flashing a code 2 using the Blue LED. If this occurs refer to the troubleshooting section.
Always start off using the smallest nozzle included in your kit! Increase the size of the nozzle only after you have determined that the fuel system and engine can handle the additional flow of nitrous (no code 3 termination, no detonation or overheating). The Switch and LED Display has a Red and Green LED to indicate the air fuel mixture. This measurement is taken off of the vehicles Oxygen Sensor and processed by the VCN-1000 Module. When the Red LED is lit the air fuel mixture is LEAN, when the Green LED is lit the air fuel mixture is RICH. During normal operation the Red and Green LEDs should alternate back and forth indicating proper Oxygen Sensor and fuel system operation. On deceleration, such as when coming to a stop the Red LED should light. On heavy acceleration the Green LED should light. The Red and Green LEDs are for your reference only and have no affect on the operation of the nitrous system but can be a good troubleshooting and tuning tool. For instance if the LEDs do not switch back and forth there is a fuel control problem on your vehicle or poor or incorrect connection to the vehicles oxygen sensor. During the introduction of nitrous the Green LED should be lit more than the red. Engines are very rarely damaged as a result of too rich and air fuel mixture, however too lean an air fuel mixture is deadly to an engine. If you have just switched to a larger nozzle and notice the Red LED is starting to remain on longer or more frequently it is a good idea to switch back to the smaller nozzle. This indicates that you are approaching the limits of your fuel system. If the Red LED comes on as soon as the nitrous engages and remains on you should immediately disengage the nitrous by letting your foot off of the gas or by switching the switch to the disabled position. You should then check the connections to the injectors and switch back to the smallest possible nozzle.
3.0 INSTALLATION INSTRUCTIONS 3.1 INSTALLATION PRECAUTIONS NOTE: The VENOM module is susceptible to electrical noise. You must maintain 8 of clearance between VENOM harness and module and any of the following components: Spark Plug Wires Ignition Coil(s) Alternator Stereo Amplifiers Stereo Speakers 3.2 LOCATING THE MODULE Decide where the module will be located. The module should be located beneath the hood, however avoid locating the module near any of the following; rotating engine parts, the Alternator, radiator or where water intrusion may occur (I.E. near the front of the engine compartment) or where excessive heat build up may occur. Do not mount near the exhaust manifold(s) or on the engine. 3.3 MAIN HARNESS INSTALLATION Locate a path for the wiring harness and drill any necessary holes. The LED display and switch assembly should be routed through the firewall where it can be mounted on the dash. Secure the harness with the supplied wire ties and adhesive mounting bases. Use alcohol to clean the area to which the adhesive base will be installed to ensure secure mounting. Mount the LED/Switch Assembly on the dash where it is easily viewable and accessible to the driver. WARNING: The Gray wires on the VCN Main Harness are shielded cables do not cut the cable to shorten or lengthen it. If the harness is too long route the cable to utilize the entire cable. Looping the wire and securing it with a wire tie is acceptable. If the harness is too short, you may obtain and extension cable in various lengths for a nominal charge. Two wiring harnesses are included with the kit, a main harness (16 pin connector) and injector connector (8 pin connector with orange wires). Locate the main harness. Make the following connections: 3.4 CONNECTING POWER AND GROUND Connect the RED wire with the 20 Amp in-line fuse from the main harness directly to the vehicles positive battery cable. This wire should have power even when the engine is off. NOTE: do not bypass the fuse or connect to the wire past the fuse, doing so could cause an electrical fire if the system becomes shorted. Only replace the fuse with a 20 Amp Fuse. If the fuse blows repeatedly there is a short in the system and all wiring should be inspected. Connect both BLACK wires to the negative side of the battery (ground).
3.5 CONNECTING SWITCHED POWER The GREEN wire with the 3 Amp in-line fuse will be connected to a power source that is only hot when the vehicles ignition switch is turned to the on position (switched power). The most common location to obtain a switched power is off the POSITIVE side of one of the fuel injectors. REFER TO PROCEDURE 1A. This connection should be made using one of the supplied blue splice connectors. The splice connector is folded and snapped over the existing wire on the vehicle. The blue connector on the GREEN wire is then plugged into the splice. This effectively taps into the existing wire on the vehicle. NOTE: DO NOT cut the existing wire on the vehicle. DO NOT connect the green wire directly to the positive battery terminal or a wire that has voltage all times. Doing so will cause improper operation and will drain the vehicles battery. 3.6 MOUNTING THE NITROUS SOLENOID Using the supplied hardware, mount the Nitrous Solenoid within 2 feet of the throttle body. Locate the wire on the main harness that has the mating connector to the solenoid and plug the solenoid into the harness. NOTE: Use caution when mounting the solenoid and wiring to ensure it is away from the throttle body linkage to avoid entanglement. Failure to do so could result in a sticking throttle and uncontrollable vehicle acceleration. 3.7 SENSOR CONNECTIONS 3.7.1 Throttle Position Sensor (Also See Appendix A/C) Note: Refer to the vehicle specific wiring instructions to obtain the proper wire color codes for your vehicle or use the digital volt-ohm meter and the procedure below. Locate the Gray wire with the YELLOW heat shrink tubing on the end. This wire will be connected to the output of the vehicles Throttle Position Sensor (TPS). The TPS will be located on the throttle body on the opposite side of the throttle linkage. The sensor is usually a three-wire sensor. The output wire will usually have between.5-1.2 volts at closed throttle and 3.5-4.75 volts at wide-open throttle (some European vehicles are different, refer to appendix A). Using the digital volt-ohm-meter (VOM), check the voltage on each wire of the TPS with the ignition in the ON position and the engine OFF. One wire will be ground (0 Volts). One wire will be near 5 volts (DO NOT CONNECT TO THIS WIRE) while the other will be the output wire. Probe the wire while manually opening the throttle (have an assistant press the accelerator pedal). The voltage should increase proportionate to throttle angle. Using the blue splice, tap into the OUTPUT wire and plug the Gray wire with the YELLOW heat shrink onto the splice until it is fully seated. CAUTION: The module must be connected to the output of the Throttle Position Sensor. Connecting to the reference wire (the wire with nearly 5 volts or more) will cause the nitrous to activate at idle causing severe engine damage and possible loss of vehicle control, which could lead to possible injury or death. If you are unsure consult with a qualified professional.
3.7.2 Oxygen Sensor (Also See Appendix B/C) Note: Refer to the vehicle specific wiring instructions to obtain the proper wire color codes for your vehicle or use the digital volt-ohm meter and the procedure below. Locate the Gray wire with the WHITE heat shrink tubing on the end. This wire will be connected to the output of the vehicles Oxygen Sensor, which is located in the exhaust stream or in the exhaust manifold. Some vehicles use multiple oxygen sensors. The connection must be made to the oxygen sensor that is located between the engine and catalytic converter. Connecting to the oxygen sensor after the catalytic converter will lead to improper operation and possible engine damage. The output of the oxygen sensor is 0-1 volt. The system uses this input to control the amount of fuel injected into the engine while nitrous is being injected. If this connection is poor or incorrect engine damage can result. The oxygen sensors output is result of the oxygen content in the exhaust. A signal below.45 volts indicates the engine is lean while a signal of.45 to 1.0 volts indicates a rich condition. During normal operation the signal should swing back and forth. This is called closed loop operation and is controlled by your vehicles on board computer to keep emissions low. The oxygen sensor must heat up to almost 600 degrees before it begins to work. Some oxygen sensors have heaters in them that assist in getting them to operating temperature quickly. These sensors will have more than one wire attached to them. In order to determine which wire is the output the oxygen sensor must be at operating temperature (the engine running at operating temperature). Each wire can be probed with the digital volt-ohm meter until the wire with the proper voltage is detected. The voltage should be swinging back-and-forth between 0 and 1 volt. If the voltage is 12 volts or 0 volts at all times you have probably probed the voltage supply to the heater or the sensor ground. Once the proper signal has been located use the blue wire splice to tap into the signal wire. 3.8 INJECTOR HARNESS INSTALLATION NOTE: The VCN-1000 Module provides additional fuel to support the addition of nitrous through the existing injectors. It accomplishes this by pulsing the injectors. This procedure deals with the connection to each injector. If the connection to the injector is not complete or secure, the cylinder associated with that injector will run lean, causing engine damage. If the wire from the VENOM Injector Harness is connected to the wrong side of the vehicle harness at the injector, the module will be permanently damaged, causing incorrect operation and engine damage. Follow Procedures 1A and 1B to ensure proper connection! Locate the fuel injector harness. The injector harness (8 pin connector with orange wires) will be connected to the negative side of each fuel injector. The harness should have the same number of wires as your engine has injectors, I.E. 4 cylinder, 4 injectors, 4 orange wires. Perform procedures 1A, 1B and refer to the vehicle specific wiring instructions. Secure the harness using the supplied wire ties and adhesive mounting bases. 3.9 HOSE & BOTTLE INSTALLATION
NOTE: Since installation of the bottle brackets will vary from vehicle to vehicle, mounting hardware to mount the bottle brackets to the floor of the truck is not included. This hardware may be obtained from any local hardware store. Mount the nitrous bottle in the trunk of the vehicle. Using the supplied bottle brackets mount the bottle so that the valve end of the bottle is elevated and uses the longer bracket. Position the bottle so that it mounts sideways in the truck (valve NOT facing the front or rear of the vehicle). Rotate the bottle in the brackets so that the outlet of the valve is facing the floor of the truck. Route the 20 nitrous hose from the trunk beneath the vehicle into the engine compartment. Avoid the exhaust system, braking components, suspension and steering components. If there is excess hose make sure the hose is coiled inside the trunk rather than beneath the vehicle or inside the engine compartment. NOTE: Use a rubber grommet when routing the hose from the truck floor to the outside of the vehicle. Failure to do so will cause the hose to wear and eventually fail causing high-pressure nitrous gas leakage. Do not cut the nitrous hose or modify the fittings. Connect the end of the hose in the engine compartment to fitting on the nitrous solenoid marked IN. Do not use any Teflon tape or other sealants. CAUTION: Connecting the hoses backwards on the solenoid will cause solenoid to leak resulting in engine damage. Ensure you connect the hose from the nitrous bottle to the fitting on the solenoid marked IN. Ensure the hose is pulled snuggly so that it will not drag on the ground. Excess hose should be coiled inside the trunk. Secure the hose using the supplied wire ties or other suitable mounting hardware. Connect and tighten the hose fitting to the outlet of the nitrous valve. Do not use any Teflon tape or other sealants. Locate the 2.5 foot nitrous hose. Connect one end of the 2.5 hose to the other side of the nitrous solenoid marked OUT. Do not use any Teflon tape or other sealants. Locate the smallest orifice nitrous nozzle in your kit. Refer to the color code chart at the beginning of the manual. The nozzle should be mounted approximate 3 before the throttle body between the air filter and throttle body. If your vehicle uses an airflow sensor it should be mounted between the airflow sensor and the throttle body. In most applications it is suitable to drill a ¼ hole into the rubber boot just before the throttle body. Remove the boot when drilling to ensure no rubber shavings are ingested into the engine. Push the nozzle into the rubber boot ensuring that the outlet of the nozzle is aligned with the intake of the throttle body. Connect and tighten the other end of the 2.5 hose to the nozzle. Do not use any Teflon tape or other sealants. Secure the hose using the supplied wire ties. 3.10 TESTING THE SYSTEM Because nitrous bottles are shipped empty you will need to have the nitrous bottle filled prior to testing. Turn the enable switch to the ENABLED position. Turn the ignition key on. The BLUE LED should come on for 2 seconds then go out. Start the engine. Revving the engine to
about 2,000 RPM will help the oxygen sensor warm-up. After about 10-40 seconds of operation the RED and GREEN LED s should start to flash back and fourth. This may take longer if the engine is cold. Once the module has determined the oxygen sensor is switching and warmed up the BLUE LED begin to flash indicating the system is ready. The system will now activate once it sees wide-open throttle. When the system is active the BLUE LED will come on solid, once the throttle is released the BLUE LED will return to flashing. The system will not activate if the switch is in the DISABLE position, although the system will still perform the oxygen sensor test and the BLUE LED will still flash indicating the system is ready. 4 4.0 Appendices 4.1 Appendix A - Throttle Position Sensor Connection The Throttle Position Sensor (TPS) is a three-wire sensor located on the throttle body on the opposite side of the throttle linkage. On most vehicles the voltage output of the TPS increases as the throttle is opened although some European vehicles such as the VW New Beetle has Throttle Position Sensor that decreases as the throttle is opened. If the module is to be installed on this type of vehicle the module will need to have a special software version designed to interface with this type of TPS. Consult you re your part number and software version on the back of this manual to determine if the letter E or e is contained in the software version number. If it is, the module is designed to interface with this type of TPS. The Throttle Position Sensor is used as an input to the VCN Module to determine when to inject Nitrous into the engine. The module looks for a near wide-open throttle condition prior to activating the nitrous solenoid. The voltage at which the Module must see prior to injecting the nitrous is calibrated at the factory and is not user adjustable. The factory can modify this adjustment if it not specifically suited for your needs. CAUTION: The module must be connected to the output of the Throttle Position Sensor. Connecting to the reference wire (the wire with nearly 5 volts or more) will cause the nitrous to activate at idle causing severe engine damage and possible loss of vehicle control, which could lead to possible injury or death. If you are unsure consult with a qualified professional. 4.2 Appendix B Oxygen Sensor Connection, LEV, ULEV Vehicles The VCN Module uses the input from the oxygen sensor to control the air fuel ratio when nitrous is injected into the engine. Therefore it is critical that this connection is made correctly. The Oxygen Sensor (O2S) is a sensor located in the exhaust stream of the engine. The sensor determines the oxygen content of the exhaust, which in turn determines the air fuel ration of the engine. On most vehicles the oxygen sensor is located on the exhaust manifold or the header pipe just after the manifold. If the engine is a V6 or V8 multiple oxygen sensors may be used, such as one for each side of the engine. The oxygen sensor generates a very low voltage output of 0-1 volt which is dependent upon the oxygen content of the exhaust. When the oxygen content of 4 The engine must be running in order for the module to perform the oxygen sensor test. If the engine is off and the key is on the BLUE LED will remain off and the system will be in stand-by until the engine is started and the module has determined the oxygen sensor is functional.
the exhaust is high (lean condition) the output of the sensor will be low (below.45 volts). When the oxygen content of the exhaust is low (rich condition) the output of the sensor will be high (.45-1.0 Volt). In order for the oxygen sensor to function it must be heated to over 600 degrees Fahrenheit. This occurs as the hot exhaust gases pass over the sensor. In order for emissions to remain low, manufacturers desire that the sensor heat up quickly so that your on board computer can control the air fuel mixture precisely. Because of this some manufacturers use an oxygen sensor that has a built in heater. This heater helps the oxygen sensor heat up quicker. These sensors will have multiple wires. It is imperative that the VCN Module be connected to the output of the sensor. Connecting it to the heater circuit of the oxygen sensor will damage the module. Late model vehicles (post 1996) equipped with On-Board Diagnostics II (OBDII) use multiple oxygen sensors. These vehicles utilize an oxygen sensor in front and in the rear of the catalytic converter. Sometimes up to 4 oxygen sensors are used. It is critical that the VCN Module be connected to one of the oxygen sensors before the catalytic converter. Connecting the module to the oxygen sensor behind the catalyst can lead to improper fuel control and engine damage. Some 1999 to current vehicles that are ULEV (Ultra Low Emission Vehicle) and LEV use a different style oxygen sensor that is not able to interface with the VCN Module. If your vehicle is ULEV or LEV and you are having trouble identifying the 0-1 volt signal on the vehicle you should contact technical support. To verify your vehicle is ULEV or LEV consult the under hood emissions label. On these vehicles you will need to install a standard oxygen sensor, which is available for a nominal charge. If your kit came with vehicle specific instructions that identify the color of wires on your vehicle, the colors indicated are the colors of wires prior to any pigtail connector that may be present on the sensor. Refer to Figure 1. 4.3 Appendix C Connecting To Shielded Cables Some vehicles use shielded sensor cables for the Oxygen Sensor and Throttle Position Sensor. This type of cable is used to eliminate electrical noise and interference that could interfere with the operation of your vehicles on-board computer system. These shielded cables are similar to the coax cable found in your home audio or TV wiring. A shielded cable contains two conductors the signal wire and the shield. The shield is the outer conductor and use usually made of a steel braid or foil that is connected to the ground of your vehicle. This allows any interference that is induced on wire to be shorted ground rather than being introduced onto the signal wire. If the Blue wire splice provided is applied to a shielded cable your vehicles wiring harness will be permanently damaged. In addition, the signal will be shorted to ground, which could damage your vehicles computer system. Examining the wire at the sensor connection can identify a shielded wire. If the wire is larger than the others and is a single color such as gray or black without any color tracers or you see braided shielding or foil protruding out of the wire, the sensor wire is a shielded cable. In order to tap into this wire you will need to use a razor blade and trim the outer shielding away to access the inner connector. Do this as close to the sensor as possible.
5.0 Special Procedures 5.1 Procedure 1 Injector Ground Circuit Identification This procedure is used to determine which wire on each injector is the ground circuit and which is the power circuit. Each one of the orange wires on the injector circuits will need to be tapped into each injectors ground circuit. It doesn t matter which orange wire is connected to which injector, however all the injector s ground circuits and orange wires must be connected. Failure to properly connect to each injector will cause one or more cylinders to run lean which will result in engine damage. Step 1 - Disconnect EVERY injector. Step 2 Locate a Digital Volt Ohm Meter, set the meter to read DC Volts. Ensure the meter will read up to 13 volts (this usually requires the meter to be set on the 20-volt scale. Some meters may be auto ranging which will not require you to set the voltage scale). Step 3 SECURLY connect the Black (negative) probe to the vehicles negative battery terminal or ground. Step 4 Turn the ignition key on but do not attempt to start the engine. Step 5 Using the Red probe (positive), probe each of the two terminals on one of the injector connectors. One terminal should have battery voltage of 12.00 volts or more while the other terminal should have 0 volts present. Record which terminal has 0 volts as this is the wire that the Orange wire from the VCN Injector Harness will need to be tapped into. Step 6 Repeat Step 5 for each of the other injectors ensuring you are connecting the Orange wire to the wire on the injector that has 0 Volts present when the key is on. Step 7 Reconnect every injector, proceed to procedure 2. NOTE: You may connect the Green wire (Ignition On Voltage) from the VCN Main Harness to one of the injector wires that has voltage present. This will provide key on power to the module. This is the only injector that will have two connections to it. 5.2 Procedure 2 Injector Connection Verification This procedure is used to verify that the connection to each injector is correct. If one or more of the injectors are not connected engine damage could result. Procedure 1 should be performed prior to this procedure. Step 1 Locate 8 pin plastic connector end of the Orange VCN Injector Harness. Step 2 Locate a Digital Volt Ohm Meter, set the meter to read DC Volts. Ensure the meter will read up to 13 volts (this usually requires the meter to be set on the 20-volt scale. Some meters may be auto ranging which will not require you to set the voltage scale).
Step 3 - Step 3 SECURLY connect the Black (negative) probe to the vehicles negative battery terminal or ground. Step 4 Turn the ignition key on but do not attempt to start the engine. Step 5 Using the Red probe (positive), probe the back of the connector (where the wire enters) touching the metal part of the terminal. Ensure 12.00 volts or greater is present for EACH and EVERY Orange wire. This will verify the connection to the injector. NOTE: There will only be voltage present once the injector is plugged back into the injector from procedure 1. If the injector is still unplugged there will be no voltage present. This procedure should only be performed with the key on ENGINE OFF. NOTE: Although it may be easier, do not probe the front of the connector. This can distort the fragile terminals inside the connector. When plugged into the module a poor connection could lead to engine damage.
6.0 Troubleshooting As a general rule most malfunctions are the result of improper or poor electrical connections. If you are experiencing erratic operation or the system is not functioning as designed you should recheck all electrical connections. In particular the blue splice connections should be inspected to ensure they are piercing the wire that they are connected to. System Will Not Power Up The Blue LED should come on for two seconds then go out as soon as the key is turned on. Either the Red or Green LED should be on as soon as the key is turned on. If this does not occur check the following: System Fuse Inspect to make sure the 20 amp fuse is not blown. If the fuse is blown check for electrical shorts and make sure you have installed the correct rating fuse. Green Wire It must be connected to a switched power. Red Wire It must be connected to the battery positive terminal or suitable junction box. Black Wires Ensure BOTH black wires are connected to the NEGATIVE battery terminal (Ground). Fuse Blows Repeatedly After Activation Check for incorrect fuse rating. Ensure fuse is a 20 amp fuse. If fuse is okay the most likely cause is a shorted solenoid. Disconnect solenoid and retry (there will be no nitrous flow) if the fuse remains good the solenoid will need to be replaced. System Flashes Code 2 Oxygen Sensor Failure If the system cannot determine the oxygen sensor is functional after 90 seconds of operation, the Blue LED will flash a code 2 and the system will be disabled. When this occurs the Blue LED will flash twice, then pause and then repeat the sequence until the modules power is cycled (key off then back on). This is usually the result of a poor or improper connection to the vehicles oxygen sensor. Recheck your connections and make sure the blue splice as connected to the correct wire of the oxygen sensor, refer to Appendix B. If the problem persist you may need to replace your vehicles oxygen sensor. This problem will also be evident because the Green and Red LEDs will not fluctuate back and fourth. If the Green LED is lit at all times check to make sure you are not connected to the power circuit of the oxygen sensor s heater circuit, if you have this may have damaged the module. If the Red LED is lit at all times make sure the wire to the oxygen sensor is not grounded or connected to the oxygen sensor ground. NOTE: It is normal for the Red or Green LED to remain lit for an extended period of time if the vehicle is started cold. This is because the oxygen sensor had not reached operating temperature. Do not confuse this with the problem above. NOTE: The system will not activate until this problem is corrected.
System Flashes Code 3 System Too Lean If the system cannot correct the air fuel mixture during nitrous injection it will terminate the flow of nitrous and flash a code 3. When this occurs the Blue LED will flash three times, then pause and then repeat the sequence until the modules power is cycled (key off then back on). This is a result of too lean of an air fuel mixture. You should do the following: Check the connections to EVERY injector; the Orange wires should be connected to each injector s ground circuit. Refer to procedure 1 and 2. If the connection to even one injector is poor the entire air fuel balance can be thrown off causing improper operation. If you are using one of the larger nozzles that came with the kit it may be too large for your engines fuel system. Verify this by switching to the smallest nozzle. If system functions normally you need to switch to a smaller nozzle. Increase nozzle sizes by only one step at a time. If the Red LED starts to remain on more than half of the time during the injection of nitrous, switch back to the next smaller nozzle. You have reached the limits of your fuel system. At this point you should consider larger injectors or an adjustable regulator. Most stock fuel systems will support an addition 40-60% of your vehicles stock horsepower, although this will vary from vehicle to vehicle. Status LED Remains Off, Red or Green LED Lit Oxygen Sensor Test If the Status LED came on when the ignition key was turned on and then when out the system is performing an oxygen sensor test. The engine must be running in order for the oxygen sensor test to begin. This is normal operation and can take up to 90 seconds. On a warm engine the test usually takes about 10-15 seconds while on a cold engine in cold weather the test can take 30-90 seconds. During this time the system will not engage the nitrous at wide open throttle. Once the test is completed the Status LED will begin blinking indicating it is ready. At this point if the throttle reaches wide open and the switch is in the Enable position the nitrous will activate. Green LED lit at All Times The module is seeing a rich condition or the oxygen sensor wire on the VCN harness is not connected to the proper wire on the oxygen sensor. Refer to Appendix B and Code 2 troubleshooting. Red LED lit at All Times The module is seeing a lean condition or the oxygen sensor wire on the VCN harness is not connected to the proper wire on the oxygen sensor. Refer to Appendix B and Code 2 troubleshooting. Ensure the oxygen sensor wire on the VCN Harness is not grounded. Engine Pings or Detonates You may be running too much nitrous, consider reducing the size of the nozzle you are using.
Use of high-octane fuel is required when nitrous is used. Use premium grade pump gas of 92 octane or higher. Consider the use of a pour in octane booster. Check the connections to EVERY injector; the Orange wires should be connected to each injector s ground circuit. Refer to procedure 1 and 2. If the connection to even one injector is poor the entire air fuel balance can be thrown off causing improper operation. If you are using one of the larger nozzles that came with the kit consider using a colder temperature range spark plug. Engine Surges Low Bottle Pressure The bottle pressure is low. Also check to ensure the bottle is installed properly. Installing the bottle with the valve facing the rear of the vehicle will cause the liquid nitrous in the bottle to move to the top of the bottle during acceleration. This can cause a surging condition. System Will Not Activate at Wide Open Throttle If the system is ready (Blue LED flashing) but will not activate at wide-open throttle you should check your connection to the Throttle Position Sensor. Refer to the Refer to the back of this manual for calibration information for your module. The Throttle Position sensor voltage must reach the voltage indicated in the TPS field. Check to ensure your vehicles TPS output reaches at least that voltage at wide-open throttle. Verify this with the key on, engine off using a digital volt ohm meter. If it does not your module will need to be recalibrated by the Venom Service Department. Contact Venom Technical Support for assistance. System Activates At Idle or Part Throttle Connection to Throttle Position sensor is incorrect. Refer to section 3.7.1 and Appendix A.
6.0 Quick Reference Electrical Connections VCN Main Harness Function Connection to Vehicle Red Wire w/fuse Main Power, Solenoid Positive Battery Hot At All Times Green Wire Key On Power, Module Switch Power Hot With Key On Only Black Wires (2) System Ground, Injector Ground Battery Negative (Ground) Gray w/yellow End TPS Input Voltage Output of Throttle Position Sensor Gray w/white End Oxygen Sensor Voltage Input Output of Upstream Oxygen Sensor VCN Injector Harness Function Connection to Vehicle Orange Wires (4,6 or 8) Injector Ground Switching Negative Injector Circuit VCN-1000 Module Information Filled Out By VENOM: Part Number Software Version TPS Calibration Volts Serial Number Filled Out By Purchaser: Date of Purchase Place of Purchase