AEM CoilOnPlug COP Conversion Kit 302860 User Manual
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WARNING: ! WARNING: This installation is not for the tuning novice! Use this system with EXTREME caution! If you are not well versed in engine dynamics and the tuning of engine management systems DO NOT attempt the installation. Refer the installation to an AEM trained tuning shop. A list of AEM trained tuning shops is available at www.aemelectronics.com/dealer_locator.php or by calling 800 -423- 0046. NOTE: All supplied AEM calibrations, Wizards and other tuning information are offered as potential starting points only. IT IS THE RESPONSIBILITY OF THE ENGINE TUNER TO ULTIMATELY CONFIRM THE CALIBRATION IS SAFE FOR ITS INTENDED USE. AEM holds no responsibility for any engine damage that results from the misuse or mistuning of this product! AEM Performance Electronics 2205 126th Street Unit A, Hawthorne, CA. 90250 Phone: (310) 484- 2322 Fax: (310) 484- 0152 http://www.aemelectronics.com Instruc tion Part Number: 10- 2860 Rev B 2011 AEM Performance Electronics P/N 30-2860 B Series COP Conversion Kit Instruction Manual This product is legal in California for racing vehicles only and should never be used on public highways. WARNING: IT IS RECOMMENDED THAT TIMI NG BE CONFIRMED ON EACH CYLINDER BEFORE ATTEMPTING TO START THE ENGINE !
Page 2 10-2860 B Series COP Instructions RevB 111117 KIT CONTENTS 1 x 35- 2840 IGNITER W/ B RACKET 1 x 30-3 255 HONDA EPM 4 x 30-2 854 COIL 1 x 35- 3860 B SER IES COP HARNESS 1 x 35- 3861 E PM HARNESS 2 x #6 M OUNTING S CREW 2 x DI ELECTRI C GREASE INSTALLATION TIPS 1.R ead through the entire manual and instructions before beginning the installation. 2. Disconnect the negative battery cable(s) before beginning any work. 3. Maintain a c lean and neat work area throughout the installation. 4. When raising or working under a vehicle, use properly rated s tands/jacks. 5. Make sure all connectors are fully seated and inserted. 6. Make sure all components and cables are routed and installed away from any direct heat sources or sharp objects. TABLE OF CONTENTS •I nstallation 2 • EMS/ECU Configuration 8 • Jumper Settings 12 • Syncing The EMS Timing 17 • EMS Pin Locations 18 • Connector Pinout s 19 • Factory Tachometer Setup 20 • Specifications 21 • Recommended Parts 21 • Replacement Parts 21 • Warra nty 22 INSTALLATION R emoving the Factory Ignition R emove the spark plug wires from the distributor and cylinder head. Unplug the distributor from the factory wiring harness and remove the distributor from the engine. The d istributor is held in place by three mounting bolts. See Figure 1 below.
Page 3 10-2860 B Series COP Instructions RevB 111117 Remove the retaining clip from the drive gear and remove the pin, drive gear, and shim. Save the parts as they will be reused on the EPM. See Figure s 2 and 3 below. Figure 1. Factory Distributor Figure 2. Factory Distributor
Page 4 10-2860 B Series COP Instructions RevB 111117 AEM Engine Position Module (EPM) Apply a small amount of clean engine oil to the shaft on the EPM and install the shim, drive gear, pin, and retaining clip. See Figure 4 below. Apply a small amount of clean engine oil to the O -ring on the EP M and install the EPM as shown below in Figure 5. Secure the EPM using one of the stock distributor bolts and washers. Figure 3. Retaining Clip, Pin, Drive Gear, and Shim (left to right) Removed from Distributor Figure 4. EPM with Shim, Drive Gear, Pin, and Retaining Clip Installed
Page 5 10-2860 B Series COP Instructions RevB 111117 Coils With the factory plug wires removed, apply a small amount of dielectric grease inside the boot of the coils and install the coils on the spark plugs. Make sure the coils are fully seated in the head and o n the spark plugs. See Figure 6 below. Figure 5. EPM Installed on B Series Engine Figure 6. Coils Installed in Cylinder Head
Page 6 10-2860 B Series COP Instructions RevB 111117 B Series COP Harness Lay the B Series COP harness over the cylinder head and connect the coil connectors to the coils. See Figure 7 below. Make sure the connectors are fully seated and locked into position. Route the harness through the engine bay, away from any high heat sources and sharp objects. The branch labeled “EMS” should be routed towards the ECU. The branch labeled “Power” should be routed towards the power source. Igniter With the harness routed, find a suitable mounting location for the igniter and mount the igniter. Two #6 screws are supplied for mounting the igniter to the firewall or engine bay. Connect the two igniter connectors from the harness to the igniter. Make sure the connectors are fully seated and locked into position. See Figure 8 below. Figure 7. B Series COP Harness Connected to Coils Figure 8. Igniter Mounted and Connected to B Series COP Harness
Page 7 10-2860 B Series COP Instructions RevB 111117 EPM Harness Connect the 4- pin connector on the EPM harness to the mating con nector on the EPM. Make sure the connector is fully seated and locked into position. Route the harness through the engine bay, away from any high heat sources and sharp objects, towards the ECU. See Figure 9 below. Wiring EPM Harness RED – EPM Power, Connect to 12 volts BLACK – EPM Ground, connect to ground GREEN – Crank Signal , connect to crank input on EMS/ECU WHITE – Cam Signal , connect to cam input in EMS/ECU DRAIN WIRE – Conne ct to power ground/drain in EMS/ECU Figure 9. EPM Harness Connected to EPM
Page 8 10-2860 B Series COP Instructions RevB 111117 B Series COP Harness RED (IGN) – Connect to s witched, fused ( 15 A or greater) 12 volts BLACK (GND) – Connect to ground ORANGE (COIL 1) – Connect to Coil 1 Trigger in EMS/ECU BLUE (COIL 2) – Connect to Coil 2 Trigger in EMS/ECU PINK (COIL 3) – Connect to Coil 3 Trigger in EMS/ECU GREY (COIL 4) – Connect to Coil 4 Trigger in EMS/ECU EMS/ECU CONFIGURATION Timing Patten The EPM has a 24 and 1 timing pattern. There are 24 crank signals and one cam signal for every engine cycle. Both output signals are 12 volt square waves . See Figure 10 below. EMS Wizard The AEM EMS must be configured to accept the timing pattern from the EPM. In AEMTuner, go to Wizards > Setup Wizard and select the AEM EPM. See Figure 11 below. Figure 10. EPM Timing Pattern
Page 9 10-2860 B Series COP Instructions RevB 111117 Coil Firing In order for the EMS to fire each coil individually, the coils must be activated and configured correctly in AEM Tuner. Click on the Coils and Injectors tab labeled Coils/Inj and acti vate Coils 1 – 4. See Figure 12 below. Figure 11. Selecting the AEM EPM Figure 12. Coil and Injector Tab Showing Coil Settings
Page 10 10-2860 B Series COP Instructions RevB 111117 The Coil Phasing sets the firing order of the coi ls and must match the Injector phasing. For the example shown above in Figure 12, Coil 1 and Injector 1 both have a value of 12. The corresponding values for Coils and Injectors 2- 4 also match. See the advanced calibration notes on phasing included wit h the EMS for more information on Coil and Injector phasing. NOTE: IT IS RECOMMENDED THAT TIMING BE CONFIRMED ON ALL CYLINDERS BEFORE ATTEMPTING TO START THE ENGINE! Series 2 EMS Coil Dwell The coil dwell settings are listed below in Table 1. Dwell tim es in excess of those listed in Table 1 will not improve spark performance and may cause the igniter and/or coil to overheat. Click on the coil dwell tab labeled Coil Dwell in AEM Tuner and adjust the tables as shown i n Figure 13 below . The values in Table 1 should be entered in the Dwell vs Battery table. The Dwell vs RPM table should remain at 100% for all engine speeds. Voltage Dwell Time (mS) 16 2.2 15 2.2 14 2.4 13 2.7 12 3.0 11 3.1 10 3.5 9 3.8 8 4.1 7 4.1 6 4.1 Table 1. Series 2 Coil Dwell Settings for Dwell vs Battery V Table