TXS. Tuner User Manual. Version 1.1

TXS Tuner User Manual Version 1.1 1

TABLE OF CONTENTS 1. INTRODUCTION...3 1.1 Tuner package contents...3 1.2 Technical Support...4 1.4 ESD (Electrostatic Discharge) Precautions...4 2. INSTALLATION & SETUP...5 2.1 Wiring & Tuner Installation...5 2.1.1 Installing the O2 Sensor...5 2.1.2 Installing the Knock Sensor...5 2.1.3 Connecting the Tuner...5 2.1 DIP Switch Setup...7 2.2 Terminal Program...7 2.2.1 Using HyperTerminal...7 2.2.2 Changing the Software Setup...10 OPERATION...12 2.3 Standalone Operation (not used in conjunction with UTEC)...12 2.3.1 Normal Operation...12 2.3.2 Very Lean and Very Rich readings...12 Gasoline AFR display...12 LPG AFR display...13 Lambda display...13 2.3.3 Sensor Temperature Warnings...13 2.4 Standalone with PC Terminal...13 2.4.1 Home Menu...15 2.4.2 Main Data display...15 2.4.3 Palm Display...18 2.4.4 Replay...19 2.4.5 User Settings...21 2.5 UTEC Operation...24 2.5.1 UTEC dashboard with wideband...26 2.5.2 UTEC logger with wideband...26 2.5.3 UTEC replay with wideband...27 2.6 Free Air Calibration...29 2.6.1 Calibration via DIP Switches...29 2.6.2 Calibration via PC Terminal...29 3. UPGRADING THE TUNER SOFTWARE VERSION...30 3.1 REPROGRAMMING TROUBLESHOOTING...32 4. APPENDIX A:...33 4.1 DC Socket...33 4.2 Serial Connector...33 4.3 Aux Input Plug...33 5. APPENDIX B INPUT ELECTRICAL SPECS...34 6. APPENDIX C: OUTPUT ELECTRICAL SPECS...34 7. APPENDIX D: BOSCH LSU 4 INSTALL DOCUMENT...35 8. NOTES...37 2

1. INTRODUCTION Congratulations on your TXS Tuner purchase. We hope this tool will help you get the most out of your high performance vehicle and maximise your ability to make informed decisions about its state of tune. Please take a few minutes to familiarise yourself with the contents of the tuner package. 1.1 Tuner package contents O2 Sensor Bung Tuner Bosch Knock Sensor Tuner Harnes s Serial Cable Tuner Tuner Cable (Bosch LSU4 or VW Sensor) Bosch O2 Sensor Bosch Knock Sensor (Delete option) Serial Cable O2 Sensor Weld On Bung This Instruction Manual 3

1.2 Technical Support TOLL FREE AT 877.887.2679 1.4 (Also see our web site at www.turboxs.com/tuner.htm) ESD (Electrostatic Discharge) Precautions ESD is the multi thousand volt zap you feel when get out of your car on a dry day. This ESD zap can damage electronic devices and should be discharged prior to handling any electronic device. To prevent ESD, follow the steps below when installing, removing or handling the Tuner: 1. Always turn off the ignition before removing or installing the Tuner. 2. Handle the Tuner as little as possible. 3. Transport and store the Tuner in a static-protected bag or container. 4. Do not slide the Tuner over any surface. 5. Wear a grounded antistatic wrist strap to discharge the static voltage from your body while installing or removing the Tuner or, discharge yourself by touching an exposed metal chassis point which is grounded. 6. Do not touch the connector pins of the Tuner. 7. Avoid handling the Tuner in areas that have floor or work-surface covering capable of generating a static charge. 4

2. INSTALLATION & SETUP 2.1 Wiring & Tuner Installation 2.1.1 Installing the O2 Sensor Guidelines on locating and installing the sensor Do not install the sensor where condensation may pool in the exhaust pipe. Install the sensor at the side of the pipe to avoid having excessive moisture enter into the sensor. Avoid mounting the sensor where the cables may get damaged from scraping moving parts, or contacting the ground while the vehicle is in motion. Keep cables away from hot exhaust parts. The O2 sensor is equipped with a heater circuit that will maintain a 750c internal temperature. If the sensor is too hot or too cold it will loose accuracy. Take note of exhaust gas temperatures and ensure that the sensor is installed in a location where those exhaust temperatures are significantly less then the required 750c internal operating temperature. There should not be any catalytic converters between the O2 sensor and the exhaust ports on the head. If the vehicle is turbocharged the o2 sensor should be installed after the turbine discharge, but before the first catalytic converter. Take note of the long flexible tube that is attached to the O2 sensor and ends just before the main connector. This must not be crimped. When installed in the exhaust system the O2 sensor must be connected and powered via the Tuner. If installed without the heater circuit powered the O2 sensor will be damaged. When used with leaded racing gasoline you will greatly shorten the life of the O2 sensor. See Appendix D for further installation instructions as taken from the Bosch LSU4 install document. 2.1.2 Installing the Knock Sensor Guidelines on installing the knock sensor Ensure the knock sensor is in contact with the engine block. Avoid locating sensor near mechanical parts that could generate noise that may mask the sound of detonation. Ideally you should install the knock sensor in close proximity to the stock knock sensor. Do not replace your stock knock sensor with the supplied sensor. 2.1.3 Connecting the Tuner Item Number Connector Description 1 Headphone socket Headphones for audible knock detection 2 Volume Headphone volume control 3 LDR Light sensor used to automatically control LED display intensity 4 LED Display For AFR and Lambda readings and Tuner 5

message display 5 Knock LED s LED s used to indicate knock detection 6 PC Serial Port PC Terminal connection 7 Output Analogue output (use with accessories option) 8 DIP Switches Tuner configuration 9 DC Power Socket Used for battery option* 10 Analogue Input 1 + Digital Input 1 Used with accessories option 11 Analogue Input 2 + Digital Input 2 Used with accessories option 12 Handheld Terminal Port For future use 13 DB15 Sensor connector Power Connection O2 Sensor Connection Knock Sensor Connection 14 UTEC serial port For connection to UTEC * Battery operation is only needed when you wish to view or re-flash the Tuner software from your desktop computer. The sensors are not powered by the attached battery and the tuner will have limited functionality to conserve battery life. 14 13 12 11 10 9 8 Top of Tuner 7 LED Display 1 2 3 4 5 6 1. Ensure that the power to the car or Tuner is OFF. 2. Connect the red lead on the POWER lead to a switched and fused +12V supply (2 amps). Connect the black lead on the POWER lead to a good earth. Note: It is highly recommended that a hardwired connection to a switched +12V power supply and ground be used. The use of the cigarette lighter is not recommended due to the possibility of a poor connection. 3. Connect the knock and O2 sensors to their harnesses 4. Ensure that all the Dipswitches are in the UP position. 6

2.1 DIP Switch Setup The DIP switch settings are used to configure the operation of the Tuner. The following table describes the function of each DIP switch. DIP Switch Up Position Down Position 1 AFR Mode. Air/Fuel mixtures will be displayed as an Air Fuel Ratio Number. Lambda Mode. Air/Fuel mixtures will be displayed as a Lambda reading. 2 Normal Operation Display Fr.A on LED when DOWN, otherwise will not display Fr.A on LED. 3* Normal Operation Free Air Calibration Mode 4* Normal Operation Used for Tuner Software Update functions. *The functions of DIP Switches 3 & 4 will be explained in further detail in later sections relating to each of their functions. 2.2 Terminal Program Ensure that HyperTerminal or a VT100 emulator program is installed on your PC or laptop. If you are using HyperTerminal, it is typically located in the Programs\Accessories\Communications folder that is accessed from the Start menu. HyperTerminal is included as part of your Windows Operating System. If it is not installed, you may need to install it from your Windows CD or download the freeware from http://www.hilgraeve.com/htpe/download.html. Note: The Tuner uses the same HyperTerminal connection as the TurboXS UTEC. If you already have a shortcut that works with the UTEC, you do not need to setup another HyperTerminal session. 2.2.1 1. Using HyperTerminal Start up HyperTerminal from the Start menu as shown in the following figure. 7

2. HyperTerminal should ask you whether you want to create a new connection as shown in the following figure. 8

3. Enter a name for the new connection as shown in the following figure. 4. HyperTerminal will ask you what you want to connect to. Select the appropriate serial communications port as shown in the following figure and click OK. Note: Most USB to serial Adaptors use Com4. Check your USB to serial port adaptor documentation for further information. 5. Configure the serial port to 19200 baud, 8 bit, one stop bits, no parity, no control flow as shown in the following figure. 9

6. Save this setup by using the File menu. If you place a shortcut to this on your desktop then you will be able to easily access this in the future. 2.2.2 Changing the Software Setup 1. If you want to change the settings then click on Disconnect on HyperTerminal as shown in the following figure. 2. Click on properties as shown in the following figure. 10

3. Change Connect using from COM1 to your desired COM port as shown in the following figure. 4. The COM port properties should be as shown in the following figure. Note: If you have connection problems, many times they can be resolved by simply trying a different emulation setup. If VT100 doesn t work try ANSIW or Auto Detect. Further, if HyperTerminal is stuck on a blank screen and there is power to the Tuner try hitting the ESC key to refresh the HyperTerminal session. 11

5. Click on Call on HyperTerminal as shown in the following figure to re-establish contact. 6. Press the ESC key to refresh the HyperTerminal session and bring up the home menu. OPERATION 2.3 Standalone Operation (not used in conjunction with UTEC) 2.3.1 Normal Operation 1. Turn the +12V power ON. 2. The three LED s (Red, Yellow, Green) should all light. The LED display should start a count down sequence. During the countdown, the Tuner is heating the sensor up to operating temperature of 750 C (1382 F). 3. Once the Tuner has reached zero, it will switch to normal operation. The display will show the air-fuel ratio in either AFR or Lambda readings. The display mode is setup using DIP Switch 1. See Section. After the warm-up display, the LED display will show what type of fuel will be used for the AFR calibration, or will show if the display is set to Lambda mode. DIP Switch Up Position gas AFR mode. Gasoline fuel. Stoichiometric = 14.70 : 1 LPg AFR mode. LPG fuel. Stoichiometric = 15.80 USr AFR mode. User set value for stoichiometric mixture. LA Lambda mode. 2.3.2 Very Lean and Very Rich readings Gasoline AFR display Leanest gasoline AFR is 24.99:1 Richest gasoline AFR is 9.00:1 Lean readings leaner than 24.99 shows. Rich readings richer than 9.00, shows._ 12

LPG AFR display Leanest LPG AFR is 26.86:1 Richest LPG AFR is 9.67:1 Lean readings leaner than 26.86 shows Rich readings richer than 9.67, shows._. Lambda display Leanest Lambda is 1.70 Richest Lambda is 0.61 Lean readings leaner than 1.70 shows. Rich readings richer than 0.61, shows _. 2.3.3 Sensor Temperature Warnings The Bosch LSU4 sensor is calibrated to give accurate air-fuel ratio readings when the sensor is within its operating temperature. In normal operation, an internal heater element in the sensor controls the temperature. If the sensor is placed in an environment where the internal heater cannot regulate the temperature correctly, the accuracy of the air-fuel ratio readings may be compromised. When the sensor falls outside of the temperature range, the tuner will give and indication by flashing the decimal point. The decimal point will flash quickly (approximately twice a second) when the sensor is above its recommended temperature threshold. The decimal point will flash slowly (approximately once a second) when the sensor is below its recommended temperature threshold. 2.4 Standalone with PC Terminal 1. Startup HyperTerminal. 2. Connect the serial cable attached to the serial connection on the Tuner marked HT to the serial connector on the PC or Laptop. 3. Turn the +12V power ON. 13

4. The three LEDs (Red, Yellow, Blue/Green) should all light. The LED Display should start a count down sequence. A similar countdown will be displayed on HyperTerminal. This is the warming up mode of the Tuner. 5. Once the Tuner has reached zero it will then switch to normal mode and the LED display will read the AFR. The display can be switched to display Lambda in the User Constants Menu accessed using a Laptop and HyperTerminal. 6. The HyperTerminal screen will show the Home Menu. 14

2.4.1 Home Menu 2.4.2 Main Data display 15

2.4.2.1 Analogue Inputs The Tuner Analogue inputs can accommodate a voltage signal from 0 to 16V. The analogue input voltage is displayed only on the Data Display page. On all other pages, a scaled value is displayed that is scaled according to the input voltage. To display input voltage in the scaled value, set the 0V scaling value to 0, and the 5V scaling value to 5. For example; If you have a 3 bar absolute 5V MAP sensor and you want to display it in gauge pressure. i.e. with the engine off the reading should be approximately 0 bar. Set 0V scale to 1, set 5V to 2. 2.4.2.2 Digital Inputs The Tuner digital input can accommodate digital signals ranging from 0 to 5V however signals up to 12V can be used. Digital Input 1 is reserved for RPM measurement. It is suggested that one of the following common ECU signals be used; Engine speed or Tacho Ignition signal (NOT HIGH VOLTAGE SIDE) Crank or cam signal Three values are displayed for each digital input: 1. State The state of the input. An H state is displayed when a voltage higher than approximately 2.7V is present on the input. An L state is displayed when a voltage lower than 2.5V is present on the input. 2. Frequency When the digital input is a pulsed signal, the frequency of the signal is displayed. The minimum frequency is 5Hz and the maximum is 12kHz. 3. Duty When the digital input is a pulsed square wave input, the duty cycle of the input waveform is displayed. The Data Display page shows both the percentage of when the signal is low as well as high. When only one duty cycle figure is displayed (such as in the data log or replay), the value represents the percentage of time that the signal is low. 2.4.2.3 AFR and Lambda Displays When AFR readings are within the range of 0.61 Lambda to 1.7 Lambda, the AFR and Lambda readings will display the value measured. Condition AFR Message Lambda Message Out of range, Rich < 9:1 (if gasoline selected), <0.6 rich (for all other fuels) > 25:1 (if gasoline selected), lean (for all other fuels) Out of range, Lean >1.7 2.4.2.4 Free Air Display The PC Terminal displays will give a free air indication in the Data Display when the sensor is in free air. This is used to assess if a free air calibration is required. If the sensor is placed into free air for approx. 30 seconds, and the Fr.A message does not display, then the Tuner may require a Free Air Calibration. The Fr.A indication is available on the LED display when DIP SW 2 is in the down position. 16

This is not displayed in the data logger or replay, which will show the appropriate lean indication. 2.4.2.5 Error and Diagnostics Displays 17

The Sensor field shows the following error and messages. Message Description Normal Sensor is operating normally. Disconnected Sensor is disconnected, or not fuctioning. Too Cold Sensor is under the operating temperature range. Too Hot Sensor is over the operating temperature range. 2.4.3 Palm Display When using a Palm pilot with a HyperTerminal emulator it is recommended that you use the Palm formatted data display. 18

2.4.4 Replay 19

2.4.4.1 When in Replay mode press a to display an AFR vs. RPM plot 2.4.4.2 Data Listing This is useful for displaying/downloading the entire replay log. When in replay mode, press l (lowercase L) to display a listing of the full replay log. Pressing L will display a listing of the replay log with comma-separated fields 20

2.4.5 User Settings 2.4.5.1 User Settings 1 21

Setting Description Baud Rate Sets the baud rate for serial communications. The baud rate changes on the next reboot. RPM Calibration The number of pulses per revolution. Analogue Output Minimum (0V) AFR The AFR value that will correspond to 0V output of the D/A output. This is used when in AFR mode (DIP SW1 Up). Analogue Output Maximum (5V) AFR The AFR value that will correspond to 5V output of the D/A output. This is used when in AFR mode (DIP SW1 Up). Analogue Output Minimum (0V) Lambda The Lambda value that will correspond to 0V output of the D/A output. This is used when in Lambda mode (DIP SW1 DOWN). Analogue Output Maximum (5V) Lambda The Lambda value that will correspond to 5V output of the D/A output. This is used when in Lambda mode (DIP SW1 DOWN). Analogue Output Mode (0=Wideband, 1=Narrowband) When set to 0, the above scaling values are used. Free Air Calibration Value The current from the sensor when in free air. This is typically between 235 and 275. This does not need to be set from user settings it is set by the free air calibration. Offset Calibration Value This is set to 0 under normal conditions and should not require changing except under special circumstances. When set to 1, a simulated narrow band signal is output. When richer than stoichiometric, approximately 0.9V is set on the output. When leaner than stoichiometric, the output is set to 0V. Do not change this value unless specifically directed to by 22

TurboXS. AFR Fuel Selection 0 = User setting - The setting for stoichiometric mixtures is defined by the user in the following field. 1 = Gasoline The stoichiometric value is preset to 14.70 for displaying AFR for gasoline. (Default). 2 = LPG The stoichiometric value is preset to 15.80 for displaying AFR for LPG (Liquefied Petroleum Gas). AFR Fuel User Setting The value of the stoichiometric mixture for the given fuel being used. Analogue 1 Scaling Minimum (0V) The value displayed in the Analogue 1 Scaled field when analogue input 1 is at 0V Analogue 1 Scaling Maximum (5V) The value displayed in the Analogue 1 Scaled field when analogue input 1 is at 5V. When input voltage exceeds 5V, the value is extrapolated from 5V up to a maximum of 12V input. Analogue 2 Scaling Minimum (0V) Similar to Analogue 1 Scaling Minimum (0V), but for analogue input 2. Analogue 2 Scaling Maximum (5V) Similar to Analogue 1 Scaling Maximum (5V), but for analogue input 2. 2.4.5.2 User Settings 2 Setting Description Knock Threshold idle to 2000 RPM Threshold for knock signal for the given RPM range. Knock Threshold 2000 to Threshold for knock signal for the given RPM range. 23

3000 RPM Knock Threshold 3000 to 4000 RPM Threshold for knock signal for the given RPM range. Knock Threshold 4000 to 5000 RPM Threshold for knock signal for the given RPM range. Knock Threshold 5000 to 6000 RPM Threshold for knock signal for the given RPM range. Knock Threshold 2000 + Threshold for knock signal for the given RPM range. Knock Light Threshold (Green) Number of knock events per time unit before the LED will light. Knock Light Threshold (Orange) Number of knock events per time unit before the LED will light. Knock Light Threshold (Red) Number of knock events per time unit before the LED will light. Knock Indicator (0=Time, 1=RPM) Time The time interval over which the knock count is accumulated is fixed at 100ms. RPM The time interval is the time between each RPM pulse. Knock Threshold Time based knock detection The threshold used when Time based knock detection is selected. To adjust the knock threshold set the threshold at the RPM or time range to 127. Return to the dashboard menu. Free rev the engine to the appropriate RPM and verify that the knock count is greater than 0. Adjust the knock threshold down by 5 and repeat the test. Once you find a threshold level that keeps the knock count at 0 reduce that value by 5 to 10. 2.5 UTEC Operation In UTEC Operation mode, the Tuner must be connected to the UTEC using a regular RS232 serial cable via the UTEC serial port on the back of the Tuner. The UTEC must be booted and running before the Tuner warm-up phase finishes. The Tuner will then detect the presence of a UTEC if it is connected and functioning. An additional option to switch between the Tuner and the UTEC will be available on the screen when the UTEC has been detected. 24

The Tuner will start with the user interface in UTEC mode. In this mode, all the screens and controls will be that of the UTEC, with additional Tuner information displayed in the Dashboard, Logger and Replay. Pressing t will switch the user interface to display the Tuner menus and Tuner user interface. This interface is similar to standalone Tuner operation. 25

When in Tuner mode, the menu will change to display an option to switch back to UTEC mode. Pressing u will change the mode back to UTEC mode, and all the UTEC menu options will be available. 2.5.1 UTEC dashboard with wideband When in UTEC mode, displaying the UTEC dashboard will show the usual UTEC Dashboard data, along with the wideband AFR reading from the Tuner in the row labelled WB AFR. The Tuner wideband value is displayed on the Dashboard in AFR mode only (not Lambda). When the Tuner WB O2 sensor is installed and operating correctly, the UTEC AFR row will read W/B. If a sensor fault is detected, the Tuner display ----- in the WB AFR row. The UTEC data will be displayed in the AFR row and will not be overwritten with W/B since no valid wideband data is available. A C or a H character will flash next to the WB AFR value if the sensor is overly cold or overly hot. 2.5.2 UTEC logger with wideband When in UTEC mode, displaying the UTEC dashboard will show the usual UTEC Dashboard data, along with the wideband AFR reading from the Tuner. 26

The UTEC logger displays with the wideband AFR in the last column. If an existing UTEC AFR value exists, it is overwritten with W/B to avoid confusion. If a sensor fault is detected, the UTEC data will be displayed while the Tuner will fill in ----- for the invalid wideband data. The UTEC data will be displayed instead and will not be overwritten with W/B when no wideband data is available. 2.5.3 UTEC replay with wideband While the Logger (data1) or Dashboard is running, the UTEC will log its data, while the Tuner will log the wideband AFR data. When Replay is selected while in UTEC mode, the data is combined and displayed in the replay logger. 27

If the Tuner is reset without the UTEC being reset, then logged data in the UTEC will be available, but the corresponding wideband data in the Tuner will be lost. In this situation, the UTEC data will be displayed while the Tuner will fill in ----- for the invalid wideband data. The UTEC data will be displayed instead and will not be overwritten with W/B when no wideband data is available. 28

2.6 Free Air Calibration The Tuner utilizes the calibration resistor fitted to the Bosch sensor however for the best accuracy the Tuner and O2 Sensor should be given a free air calibration when you first receive it. A free air calibration must be performed if you have performed a free air calibration previously and have a need to change the O2 sensor. As the O2 sensor ages (over several months), the Tuner can perform a Free Air Calibration to help bring the calibration back into alignment with the sensor. The calibration is performed with the sensor warmed up in Free Air that has a known quantity of oxygen under normal atmospheric conditions. For best results with a free air calibration, the sensor must be removed from any exhaust and be completely in free air and at operating temperature. It is important that the surrounding air is not contaminated with exhaust air such as in a workshop with running engines. Allow the sensor to warm up, and allow at least 1 minute after sensor warm-up before performing a free air calibration to ensure the best temperature stability for taking the reading. Be careful when handling the sensor while it warming up as it can get quite hot (remember that the sensor itself is heated to over 700 C). It is best to rest the sensor on something that is heat resistant or let it hang in the air. 2.6.1 1. Calibration via DIP Switches Free air calibration is initiated using DIP Switch 3. In normal operation this should be in the UP position. When switched to the DOWN position, Free Air calibration starts. 2. The LED display shows C.A.L. with dots flashing. The dots flash while the Tuner checks for the temperature to be stable. 3. The Tuner will wait up to 30 seconds for the temperature to stabilize 4. If the temperature stabilizes, then the LED display will show the calibration value. This value is typically between 235 and 275. Returning the switch to the up position will return to normal operation. 5. If the temperature fails to stabilize, Er1 will be displayed. 6. If the temperature stabilizes, but the sensor gives a reading less than 200, then the calibration will fail with Er2. This is typically because the sensor is not in pure free air, such as the case if it is left in an exhaust, even if the engine is not running. Breathing on the sensor will alter its reading, so free air calibration is quite sensitive. 2.6.2 Calibration via PC Terminal 1. Free air calibration is selected from the menu Edit->User Settings->Free Air Calibration. 2. Screen shows instructions and flashes the twirly character while it waits for temperature to stabilize. 3. Conditions are the same as for DIP Switch initiated calibrations. Errors will be displayed on screen in plain text with description of the errors. 4. Successful calibration will display a value that is the same value that would have been displayed on the LED display in a DIP Switch initiated calibration. 29

3. UPGRADING THE TUNER SOFTWARE VERSION The initial software release of the Tuner was Version 1.3. Your current software version is displayed at the top right hand portion of the Tuner Home Menu. Periodically, we will release new software versions for the Tuner. These upgrades could be to add new features or functionality or to eliminate any known software bugs. The latest software revision will be available for download from our internet site (www.turboxs.com/tuner.htm). 1. Ensure that the Tuner is powered off. 2. Switch Dipswitch 4 to the DOWN position. 3. Save the new software file to a known location on your hard drive. 4. Connect the supplied serial cable to your PC or laptop. 5. Connect the supplied serial cable to the serial port on the Tuner marked HT. 6. Apply power to the Tuner 7. Run the m16c_flash_v105.exe program (note you can download this software from our website www.turboxs.com/tuner.htm). 8. Click on Select File and locate the new program <Tuner_xx.mot> that was saved in step #3 above. 9. Tick the Verify box: 30

10. Click on the Upload Now button. 31

11. The program should now load; when complete it will tell you that you have been successful. If not, please see the trouble shooting section at the end of these instructions and repeat this process. 12. Turn the power to the Tuner OFF. 13. Switch Dipswitch 4 UP. 14. The reprogramming is complete. 3.1 REPROGRAMMING TROUBLESHOOTING 1. Most programming errors are due to the following: A. The serial cable being loose or defective. Replace or secure cable. B. Another program, such as HyperTerminal, HotSync, M16 Flash or other communication program is using the serial port. Close all other programs before trying to reprogram your UTEC. C. Dipswitch 4 has not been switched to the DOWN position prior to power up. Shut car off, reset dipswitch, restart reprogramming. 2. If the program fails to load, try reducing the maximum baud rate on the serial flash loader program. 32

4. APPENDIX A: 4.1 DC Socket 2.5mm x 10mm long Centre positive 9V to 12V DC 4.2 Serial Connector 9 way D type socket Pin 2 TxD Pin 3 RxD Pin 5 GND 4.3 Aux Input Plug 4 2 3 7 1 Aux. Input Plug (Fitted to TUNER) The previous figure shows the pinout of the Aux Input Plug as viewed from the Tuner (front of the plug). Pin 1 +5V (20mA) Pin 2 Analogue In (0 to 10V) Pin 3 Digital In Pin 4 Ground 33

5. APPENDIX B INPUT ELECTRICAL SPECS Input Specification Analogue Input 1 0 16V Analogue Input 2 0 16V Analogue Input 1 Scaled 0 12V, Display value 100 to 1300. Analogue Input 2 Scaled 0 12V, Display value 100 to 1300. Digital Input 1 0 5V, 0V = L state, 5V = H state Max Frequency = 12kHz Digital Input 2 0 5V, 0V = L state, 5V = H state Max Frequency = 12kHz 6. APPENDIX C: OUTPUT ELECTRICAL SPECS Output Specification Analogue Output 0V 5V 34

7. APPENDIX D: BOSCH LSU 4 INSTALL DOCUMENT 35

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8. NOTES HyperTerminal is a trademark of Hilgraeve Inc. Notepad, Wordpad and Windows are trademarks of Microsoft Corporation WRX is a trademark of Fuji Heavy Industries 37