Installation guide for cars

Installation guide for cars
TDI‐tuning‐set
VW / Audi / Seat / Skoda group
Ford
Volvo
VW / Audi / Seat / Skoda group
1.7 SDI 44 kW
1.9 SDI 47 kW
1.9 TDI 55 kW / 66 kW / 81 kW
2 5 TDI 65 kW / 75 / 103 kW /111 kW
2.5 TDI 65 kW / 75 / 103 kW /111 kW
Ford 1.9 TDI 66 kW / 81 kW
Volvo
2.5 D 103 kW
Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
General instructions
Read this installation guide carefully before starting the installation
so that you will be able to use all the technical advantages of the
systems and do not start with the installation before you have read
and understood the instructions.
Your tuning system was designed and manufactured with great care and therefore should
be also handled with care. If you comply with the advice given below you will avoid an
early termination of the product guarantee and you will be enjoying your product for years
to come.
Never install the system if the ignition is on. Pull the ignition key. After switching off the
ignition, wait for 5 minutes until all electric devices are turned off.
5 MIN.
Please absolutely consider these references. Ignition switch off . Wait after switching the ignition off 5 min.
If possible, install the module in a dry area in the engine compartment. Humidity and wetness
contain minerals which cause corrosion to the electronic circuits. Fix the harness and protect it
from humidity. Before every engine wash, remove the entire tuning system.
Install splash‐proof
Attention with engine washing. No installation on hot engine parts.
Do not fix tuning systems to engine parts that could heat up. Never fix the module directly or close
to the engine (engine block). High temperatures can reduce the lifespan of electronic devices and
can deform
d f
or melt
l specific
ifi plastics
l i materials.
i l
Take care that the harness does not touch the parts in motion and the metal parts to avoid friction.
Do not make any changes to the harness (do not make it any longer or shorter).
In case of the malfunctioning of the system due to any non‐compliance with the instructions during
the installation of the tuning modules, the product guarantee will be terminated.
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Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Settings
Installation
Switch off the ignition. Remove if necessary the engine
cover. Near the injection pump a 8/10 pin connector is in
the supply line of the pump. Open this plug connection.
Connect the adapter between the original plugs.
plugs Connect
then the reference signal (black cable) from the adapter
cable with the air flow meter.
If enhancement of power performance is too low, the
potentiometer should be turned clockwise (+) by one or
two units. If enhancement of power performance is too
high the engine switches to emergency operation.
high,
operation If so,
so
the potentiometer must be turned anti‐clockwise (‐) by
one or two units. Should the filament in the speedo‐
meter lighten up as a warning signal, then the power
performance is also set too high and should be reduced.
The signal turns off automatically. In no case at all should
soot exhaust be higher than in the standard condition.
condition
Should the filament in the speedometer lighten up as a
warning signal, then the power performance is also set
too high and should be reduced. The signal turns off
automatically. In no case at all should soot exhaust be
higher than in the standard condition
TDI System TDI‐X8 / TDI‐X10 installation principle
air flow meter
flat
TDI module
driving direction
oval
TDI‐X8 / TDI‐X10
connector
3
Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Installation example: VW Golf IV 1.9 TDI 110 hp
A
Switch off the ignition of the vehicle. Remove the engine
cover. Near the injection pump a 8/10 pole connector (P) is in
the supply line of the pump.
P
P
Open this plug‐connection. Connect the adapter between the
original plugs.
Localise the air flow meter plug (A) at the air filter box.
A
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Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Installation example: VW Golf IV 1.9 TDI 110 hp
Connect the black wire from the TDI‐System at the highest
connected pin at the plug (A) from the air flow meter
(stripping / solder). Here it is pin 4. You can see the pin
assignment under the rubber / plastic grommet. Connect it
always at the highest pin number. If there is a cable on pin 5
you must connect the black wire on pin 5.
Sometimes the air flow meter is an oval plug. Connect here
the black wire at the same highest, connected pin.
A
Backside: TDI module
‐
+
P1
Settings:
Keep ignition off and connect the setting (extension) cable to
vehicle interface. Take the other end of the cable into the
vehicle interior. Connect the TDI‐System to the cable.
The TDI plug has a standard setting for approx. + 25 % power
performance and torque. You can change the settings with a
potentiometer (P1). To get the standard settings (ex works)
turn the potentiometer to the right until it clicks, then back
approximately three to four rotations.
If enhancement of power performance is too low, the
potentiometer should be turned clockwise ((+)) by one or two
units. If enhancement of power performance is too high, the
engine switches to emergency operation. If so, the
potentiometer must be turned anti‐clockwise (‐) by one or
two units.
Should the filament in the speedometer lighten up as a
warning signal, then the power performance is also set too
high and should be reduced. The signal turns off
automatically. In no case at all should soot exhaust be higher
than in the standard condition
5
Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Final installation:
The settings are now complete and the TDI‐System can finally
be installed. You only need to lay the entire cable, including
the TDI plug inside the engine compartment. We recommend
attaching the TDI plug next to the air flow sensor connector,
protected from splash water.
You still have questions or you are not quite sure?
Contact us, a technician will gladly help you!
Only for SDI vehicles:
Should your vehicle not have an airflow sensor (SDI), then the
cable should be connected directly to the plug of the
controller.
Installation of vehicle interface:
1.
Turn off vehicle ignition.
2.
Remove all necessary coverings and uncover the
controller.
3.
Pull out big multipolar plug from controller.
4.
Open
p p
plug.
g
5.
Now solder the short black wire of the connector
cable, according to the pin assignment of the
controller, onto the respective wire of the controller
plug.
6.
Check assignments once more. A wrong assignment
may lead to destruction of the controller and/or the
power electronics.
Insulate all bare soldering joints and close the plug.
Now reinstall the controller.
7.
8.
Controller 55 Pin Æ Cable to Number 37
Controller 68 Pin Æ Cable to Number 15
Controller 80 Pin Æ Cable to Number 24
Controller 121 Pin Æ Cable to Number 69
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Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Installation example: VW T4 TDI 150 PS:
In the Volkswagen T4, this connection is situated at the
bottom of the engine compartment. Remove the guard
plate only partly. In order to reach the plug connection, it
is sufficient to remove the four front screws of the guard
plate, and to simply pull down the guard plate a little.
The original plug (P) connection is situated slightly to the left
of the center. Open this plug‐connection. Connect the
adapter
p between the original
g
plugs.
p
g
P
Localise the air flow meter plug (A) at the air filter box.
A
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Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Installation example: VW T4 TDI 150 PS:
A
Backside: TDI module
‐
+
P1
Connect the black wire from the TDI‐System at the highest
connected pin at the plug (A) from the air flow meter
(stripping / solder). Here it is pin 5. You can see the pin
assignment under the rubber / plastic grommet. Connect it
always at the highest pin number.
Settings:
Keep ignition off and connect the setting (extension) cable to
vehicle interface. Take the other end of the cable into the
vehicle interior. Connect the TDI‐System to the cable.
The TDI plug has a standard setting for approx. + 25 % power
performance and torque. You can change the settings with a
potentiometer (P1). To get the standard settings (ex works)
turn the potentiometer to the right until it clicks, then back
approximately three to four rotations.
If enhancement of power performance is too low, the
potentiometer should be turned clockwise ((+)) by one or two
units. If enhancement of power performance is too high, the
engine switches to emergency operation. If so, the
potentiometer must be turned anti‐clockwise (‐) by one or
two units.
Should the filament in the speedometer lighten up as a
warning signal, then the power performance is also set too
high and should be reduced. The signal turns off
automatically. In no case at all should soot exhaust be higher
than in the standard condition
8
Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Installation example: Volvo V70 2.5 TDI 140 hp
Switch off the ignition of the vehicle. Remove the engine
cover.
P
Near the injection pump a 8 pole connector (P) is in
the supply line of the pump.
P
Open this plug‐connection. Connect the adapter between the
original plugs.
P
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Version1.2 ‐14.11.2008‐ENG
Installation guide for cars
TDI‐tuning‐set
Installation example: Volvo V70 2.5 TDI 140 hp
Localise the air flow meter plug (A) at the air filter box.
Connect the black wire from the TDI‐System at the highest
connected pin at the plug (A) from the air flow meter
(stripping / solder). Here it is pin 4. You can see the pin
assignment under the rubber / plastic grommet. Connect it
always at the highest pin number. If there is a cable on pin 5
you must connect the black wire on pin 5.
Sometimes the air flow meter is an oval plug. Connect here
the black wire at the same highest, connected pin.
A
Backside: TDI module
‐
+
P1
Settings:
Keep ignition off and connect the setting (extension) cable to
vehicle interface. Take the other end of the cable into the
vehicle interior. Connect the TDI‐System to the cable.
The TDI plug has a standard setting for approx. + 25 % power
performance and torque. You can change the settings with a
potentiometer (P1). To get the standard settings (ex works)
turn the potentiometer to the right until it clicks, then back
approximately three to four rotations.
If enhancement of power performance is too low, the
potentiometer should be turned clockwise ((+)) by one or two
units. If enhancement of power performance is too high, the
engine switches to emergency operation. If so, the
potentiometer must be turned anti‐clockwise (‐) by one or
two units.
Should the filament in the speedometer lighten up as a
warning signal, then the power performance is also set too
high and should be reduced. The signal turns off
automatically. In no case at all should soot exhaust be higher
than in the standard condition
10
Version1.2 ‐14.11.2008‐ENG