AEM 30-6040 Series 2 Plug Play EMS Installation Instructions

WARNING:

This installation is not for the tuning novice nor the PC illiterate!

Installation Instructions for:

EMS P/N 30-6040

1992-1995 Civic / Del Sol / Integra

90-95 Accord / Prelude (2.1L Only)

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!

!

This product is legal in California for racing vehicles only and should

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 an AEM-trained
tuning shop. A list of tuners can be found in the “AEM EMS
Tuning” subsection of the AEM Electronics Forums at

http://www.aempower.com or by calling 800-423-0046.

NOTE: AEM holds no responsibility for any engine damage that
results from the misuse of this product!

never be used on public highways.

ADVANCED ENGINE MANAGEMENT INC.

2205 126th Street Unit A Hawthorne, CA. 90250

Phone: [phone] Fax: [phone]

Http://www.aempower.com

Instruction Part Number: 10-6040, rev A (Oct 2009)

 2009 Advanced Engine Management, Inc.

Page 1 of 11

Thank you for purchasing an AEM Engine Management System.

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 a 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
without any jumper harnesses. 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.

For stock and slightly modified vehicles, the supplied startup calibrations are configured to
work with OEM sensors, providing a solid starting point for beginner tuning. For more
heavily modified cars, the EMS can be reconfigured to utilize aftermarket sensors and has
many spare inputs and outputs allowing the elimination of add-on rev-limiters, boost
controllers, nitrous controllers, fuel computers, etc. It also includes a configurable onboard
1MB data logger that can record any 16 EMS parameters at up to 250 samples per
second. Every EMS comes with all functions installed and activated; there is no need to
purchase options or upgrades to unlock the full potential of your unit.

The installation of the AEM EMS on the supported vehicles uses the stock sensors and
actuators. After installing the AEMTuner software, the startup calibration will be saved to
the following folder on your PC:
C:\Program Files\AEM\AEMTuner\Calibrations\Honda-Acura\
Multiple calibrations may be supplied for each EMS; additional details of the test vehicle
used to generate each calibration can be found in the Calibration Notes section for that
file.

Please visit the AEM Performance Electronics Forum at http://www.aempower.com and
register. We always post the most current strategy release, PC Software and startup
calibrations online. On the forum, you can find and share many helpful hints/tips to make
your EMS perform its best.

TUNING NOTES AND WARNING:
While the supplied startup calibration may be a good starting point and can save
considerable time and money, it will not replace the need to tune the EMS for your specific
application. AEM startup calibrations are not intended to be driven aggressively before
tuning. We strongly recommend that every EMS be tuned by someone who is already
familiar with the AEM software and has successfully tuned vehicles using an AEM EMS.
Most people make mistakes as part of the learning process; be warned that using your
vehicle as a learning platform can damage your engine, your vehicle, and your EMS.

Page 2 of 11

Read and understand these instructions BEFORE attempting to install this product.

1) Install AEMTuner software onto your PC

The latest version of the AEMTuner software can be downloaded from the AEMTuner
section of the AEM Performance Electronics forums. Series 2 units are not supported
by the older AEMPro tuning software.

2) Remove the Stock Engine Control Unit

a)

Access the stock Engine Control Unit (ECU). The location of the ECU on the OBD1
Hondas is behind the driver side kick panel.

b)

Carefully disconnect the wiring harness from the ECU. Avoid excessive stress or
pulling on the wires, as this may damage the wiring harness. Some factory ECUs
use a bolt to retain the factory connectors, and it must be removed before the
harness can be disconnected. There may be more than one connector, and they
must all be removed without damage to work properly with the AEM ECU. Do not
cut any of the wires in the factory wiring harness to remove them.

c)

Remove the fasteners securing the ECU to the car body, and set them aside. Do
not destroy or discard the factory ECU, as it can be reinstalled easily for street use
and troubleshooting.

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
Velcro fasteners.

b)

Plug the comms cable into the EMS and into your PC.

c)

Turn the ignition on but do not attempt to start the engine.

d)

The USB drivers must be installed the first time you connect to a Series 2 EMS with
an onboard USB port. When the Series 2 EMS is connected to the PC’s USB port
and receiving power from the vehicle, the “Found New Hardware” window will
appear. Select “Install from a list of specific location (Advanced)” and browse to the
following folder: C:\Program Files\AEM\AEMTuner\USB Drivers (Series 2)\

e)

With the AEMTuner software open, select ECU>>Upload Calibration to upload the
startup calibration file (.cal) that most closely matches the vehicle’s configuration to
be tuned. Check the Notes section of the calibration for more info about the vehicle
it was configured for. These files can be found in the following folder:

C:\Program Files\AEM\AEMTuner\Calibrations\Honda-Acura\

Page 3 of 11

f)

Set the throttle range: Select Wizards>>Set Throttle Range and follow the on­screen instructions. When finished, check that the ‘Throttle’ channel never indicates
less than 0.2% or greater than 99.8%, this is considered a sensor error and may
cause some functions including idle feedback and acceleration fuel to operate
incorrectly.

4) Ready to begin tuning the vehicle.

a)

Before starting the engine, verify that the fuel pump runs for a couple of seconds
when the key is turned on and there is sufficient pressure at the fuel rail.
If a MAP sensor is installed, check that the Engine Load indicates something near
atmospheric pressure (approximately 101kPa or 0 PSI at sea level) with the key on
and engine off. Press the throttle and verify that the ‘Throttle’ channel responds but
the Engine Load channel continues to measure atmospheric pressure correctly.

b)

Start the engine and make whatever adjustments may be needed to sustain a safe
and reasonably smooth idle. Verify the ignition timing: Select Wizards>>Ignition
Timing Sync from the pull-down menu. Click the ‘Lock Ignition Timing’ checkbox
and set the timing to a safe and convenient value (for instance, 10 degrees BTDC).
Use a timing light and compare the physical timing numbers to the timing value you
selected. Use the Sync Adjustment Increase/Decrease buttons to make the
physical reading match the timing number you selected.

c)

Note: This calibration needs to be properly tuned before driving the vehicle. It is
intended for racing vehicles and may not operate smoothly at idle or part-throttle.

NEVER TUNE THE VEHICLE WHILE DRIVING

5) Troubleshooting an engine that will not start

a)

Double-check all the basics first… engines need air, fuel, compression, and a
correctly-timed spark event. If any of these are lacking, we suggest checking simple
things first. Depending on the symptoms, it may be best to inspect fuses, sufficient
battery voltage, properly mated wiring connectors, spark using a timing light or by
removing the spark plug, wiring continuity tests, measure ECU pinout voltages,
replace recently-added or untested components with known-good spares. Check
that all EMS sensor inputs measure realistic temperature and/or pressure values.

b)

If the EMS is not firing the coils or injectors at all, open the Start tab and look for the
‘Stat Sync’d’ channel to turn ON when cranking. This indicates that the EMS has
detected the expected cam and crank signals; if Stat Sync’d does not turn on,
monitor the Crank Tooth Period and T2PER channels which indicate the time
between pulses on the Crank and T2 (Cam) signals. Both of these channels should
respond when the engine is cranking, if either signal is not being detected or
measuring an incorrect number of pulses per engine cycle the EMS will not fire the
coils or injectors.

c)

If the Engine Load changes when the throttle is pressed this usually indicates that
there is a problem with the MAP sensor wiring or software calibration; when the
EMS detects that the MAP Volts are above or below the min/max limits it will run in
a failsafe mode using the TPS-to-Load table to generate an artificial Engine Load
signal using the Throttle input. This may allow the engine to sputter or start but not
continue running properly.

Page 4 of 11

Application Notes for EMS P/N 30-6040

Make: Honda Spare Injector Drivers: Inj 5, Pin A8
Model: Integra/Civic/Prelude/Accord Spare Injector Drivers: Inj 6, Pin A6
Years Covered: 1990-1995 Spare Injector Drivers: Inj 7, Pin A16
Engine Displacement: 1.5L - 2.2L Spare Injector Drivers: Inj 8, Pin A14
Engine Configuration: Inline 4 Spare Injector Drivers: Inj 9, Pin D4
Firing Order: 1-3-4-2 Spare Injector Drivers: Inj 10, Pin A11
N/A, S/C or T/C: N/A
Load Sensor Type: MAP
Map Min: 0.32V @ -13.9 PSI Spare Coil Drivers: Coil 2, Pin B6
Map Max: 4.84V @ 10.94 PSI Spare Coil Drivers: Coil 3, Pin B3
# Coils: 1 Spare Coil Drivers: Coil 4, Pin B4*
EMS Ignition driver type: 5-0V, Rising Edge trigger
Boost Solenoid: PW 2, Pin C10
# Injectors: 4
Factory Injectors: 190-240cc/min Saturated EGT #1 Location: Pin D5
Factory Inj Resistors: No EGT #2 Location: Pin D2
Injection Mode: Sequential EGT #3 Location: Pin D9
Knock Sensors used: 1 EGT #4 Location: Pin D10
Lambda Sensors used: 1 (aftermarket wideband:
factory O2 not supported) Spare 0-5V Channels: MAF, Pin D8
Idle Motor Type: Duty-controlled solenoid Spare 0-5V Channels: ADCR11, Pin D12
Main Relay Control: No Spare 0-5V Channels: ADCR13, Pin B7
Crank Pickup Type: Magnetic (2-wire) Spare 0-5V Channels: ADCR14, Pin C9
Crank Teeth/Cycle: 24
Cam Pickup Type: Magnetic (2-wire) Spare Low Side Driver: Low Side 1, Pin C6
Cam Teeth/Cycle: 1 Spare Low Side Driver: Low Side 2, Pin A10
Transmissions Offered: M/T, A/T Spare Low Side Driver: Low Side 8, Pin A18
Trans Supported: M/T Only Spare Low Side Driver: Low Side 9, Pin C4
Drive Options: FWD
Supplied Connectors: Plug C with spare pins Fuel Pump Relay control Low Side 11, Pin A7
Check Engine Light: Low Side 10, Pin A13
Plug-N-Pin kit: AEM part# 35-2611 Spare High Side Driver: High Side 2, Pin C11
(includes plugs A-D, pins)
Spare Switch Input: Switch 1, Pin C7**
Spare Switch Input: Switch 2, Pin C12**
Spare Switch Input: Switch 5, Pin B8**
Spare Switch Input: Switch 6, Pin C5**

WARNING: * If converting a calibration that was originally developed for a 30-1040
(Series 1) EMS, please note that the 30-6040 uses Coil 4 rather than Coil 5 on pin B4. All
settings used for Coil 5 on the 30-1040 calibration will need to be adjusted for use with
Coil 4 on the 30-6040. This will be especially important when used with coil-on-plug
ignition conversions.

**All switch input pins must connect to ground, the switch should not provide 12V power to
the EMS because that will not be detected as on or off. Connecting 12V power to the
switch input pins may damage your EMS and void your warranty.

The function of the following pins have been changed from the original 30-1040 EMS,
please see pinout chart for more info:
A22, B4, C2, D4

Page 5 of 11

Solution for distributed ignition ‘kick back’ when cranking:

With the Series 1 EMS, some vehicles would experience erratic ignition timing at low
RPM. The most noticeable symptom would be an engine that ‘kicks back’ when cranking,
and in some cases the EMS would count timing errors or lose ‘Stat Sync’ at low engine
speeds.
These problems have been eliminated by adjusting calibration settings in Series 2 Honda
EMS startup calibrations, but could be re-introduced by converting Series 1 calibrations or
copying values from Series 1 calibrations. If users wish to convert old Series 1 calibrations
for use with the new Series 2 EMS, please ensure that the following options and tables
match the Series 2 startup calibration:

Crank H Sens Below, Crank L Sens Above, Cam(T2) H Sens Below,
Cam(T2) L Sens Above, Coil Dwell Factor, Dwell Max, Dwell Min,
Dwell vs RPM (table), Dwell vs Batt Volts (table)

Wiring accessories to the EMS:

Please follow this suggested wiring diagram when adding accessories such as UEGO
gauges, Boost Control solenoids, or switches for use with the EMS. Note that wire polarity
is not important for the Boost Control Solenoid.

Page 6 of 11

Pin #

A1
A2
A3
A4
A5
A6
A7
A8

A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20

A21
A22
A23
A24
A25
A26

Connection Diagram for EMS P/N 30-6040

OBD1 Honda / Acura

Injector 1 Injector 1 Output
Injector 4 Injector 4 Output
Injector 2 Injector 2 Output

VTEC Solenoid Valve High Side Driver 1 Output

Injector 3 Injector 3 Output

Primary 02 Heater Control Injector 6 Output

Fuel Pump Relay Low Side Driver 11 Output

Fuel Pump Relay (Accord/Prelude Only) Injector 5 Output

Idle Air Control Valve PW 1 Output

--- Low Side Driver 2 Output Avail, Switched Gnd, 1.5A max

EGR Solenoid (Accord/Prelude Only) Injector 10 Output

Radiator Fan Control (Except Prelude) Low Side Driver 12 Output

Malfunction Indicator Light Low Side Driver 10 Output Avail, Switched Gnd, 1.5A max

--- Injector 8 Output

A/C Clutch Relay Low Side Driver 6 Output
Alternator Control (Except Accord/Prelude)
IAB Control Solenoid (Accord/Integra Only)

--- Low Side Driver 8 Output Avail, Switched Gnd, 1.5A max

--- Idle #4 Output Avail, Ground / +12V, 1.5A max

EVAP Purge Control Solenoid Low Side Driver 4 Output Avail, Switched Gnd, 1.5A max

Ignition Control Module Coil 1 Output
Ignition Control Module CAN1L --- Dedicated

Power Ground 1 Power Ground Both Dedicated
Power Ground 2 Power Ground Both Dedicated

Power Source 1 +12V Switched Both Dedicated

Logic Ground 1 Power Ground Both Dedicated

AEM EMS 30-6040 I/O

Injector 7 Output

Idle #2 Output Avail, Ground / +12V, 1.5A max

Availability

PnP for Injector 1
PnP for Injector 4
PnP for Injector 2

PnP for VTEC Solenoid

PnP for Injector 3

Avail, Injector Gnd, 1.5A max

PnP for Fuel Pump Relay
Avail, Injector Gnd, 1.5A max
PnP for Idle Air Control Valve

Avail, Injector Gnd, 1.5A max

PnP for Radiator Fan

Avail, Injector Gnd, 1.5A max

PnP for A/C Clutch Relay
Avail, Injector Gnd, 1.5A max

PnP for Ignition Control Module

(12/0V Rising edge)

Page 7 of 11

Pin #

B1
B2
B3
B4
B5
B6
B7
B8

B9
B10
B11
B12
B13
B14
B15
B16

OBD1 Honda / Acura

Power Source 2 +12V Switched Both Dedicated

Logic Ground 2 Power Ground Both Dedicated

--- Coil 3 Output Avail, Rising Edge Trigger Coil Out

--- Coil 4 Output Avail, Rising Edge Trigger Coil Out

A/C Switch Signal Switch 3 Input PnP for A/C Switch Signal

--- Coil 2 Output Avail, Rising Edge Trigger Coil Out

--- ADCR13 Input Avail, 0-5 Volt Input, 100k pull up

Power Steering Pressure Switch Switch 5 Output

Starter Switch Signal +12V When Cranking Input Dedicated

Vehicle Speed Sensor T3 (Vehicle Speed) Input PnP for Vehicle Speed Sensor

CYP + Cam Sensor Input Dedicated, PnP 1 pulse per cycle

CYP - Timing Ground Output

TDC + T4 (Spare Speed) Input Avail, Magnetic Speed Sensor

TDC - Timing Ground Output

CKP + Crank Sensor Input Dedicated, PnP 24 pulses per cycle

CKP- Timing Ground Output

Pin # OBD1 Honda / Acura

C1
C2
C3
C4
C5
C6
C7
C8

C9
C10
C11
C12

--- +12V Switched Input Dedicated

--- CAN1H --- Dedicated

--- Tach Output (LS7) Output Avail, Switched Gnd, 1.5A max

--- Low Side Driver 9 Output Avail, Switched Gnd, 1.5A max

--- Switch 6 Input Avail, Switched Input

--- Low Side Driver 1 Output Avail, Switched Gnd, 1.5A max

--- Switch 1 Input Avail, Switched Input

--- IDLE #3 Output Avail, Ground / +12V, 1.5A max

--- ADCR14 Input Avail, 0-5 Volt Input, 100k pull up

--- PW 2 Output

--- High Side Driver 2 Output

--- Switch 2 Input Avail, Switched Input

AEM EMS 30-6040 I/O

AEM EMS 30-6040 I/O

Availability

Avail, Switched Input

Dedicated

Dedicated

Dedicated

Availability

Avail, Boost Control Solenoid

Avail, +12V, 1.5A max

Page 8 of 11

Pin #

D1
D2
D3
D4
D5
D6
D7
D8

D9
D10
D11
D12

EGR Valve Lift Sensor (Accord/Prelude Only)

D13
D14
D15
D16
D17
D18
D19
D20
D21
D22

OBD1 Honda / Acura

Voltage Back Up Permanent +12V Input Dedicated

Brake Switch (Except Prelude) EGT 2 Input Avail, jumper set for 0-5V Input

Knock 1 Knock 1 Input Dedicated

Service Check Connector Injector 9 Input Avail, Injector Gnd, 1.5A max

--- EGT 1 Input Avail, jumper set for 0-5V Input

VTEC Pressure Switch Switch 4 Input Avail, Switched Input

Data Link Connector High Side Driver 1 Output

--- MAF Input Avail, 0-5 Volt Input, 100k pull up

Alternator FR Signal EGT 3 Input Avail, jumper set for 0-5V Input

Electronic Load Detector EGT 4 Input Avail, jumper set for 0-5V Input

Throttle Position Sensor TPS Input Dedicated

Engine Coolant Sensor Coolant Input Dedicated, 2.2k pull up

Primary 02 Sensor Lambda 1 Input Available, 0-5V Lambda 1 input
Inlet Air Temp Sensor AIT Input Dedicated, 2.2k pull up
Secondary 02 Sensor Lambda 2 Input Available, 0-5V Lambda 2 input

Map Sensor MAP Input Dedicated

Shift Up Indicator Light (D15 only) IDLE #1 Output Avail, Ground / +12V, 1.5A max

Sensor Voltage 1 +5V Sensor Output
Sensor Voltage 2 +5V Sensor Output
Sensor Ground 1 Sensor Ground Output
Sensor Ground 2 Sensor Ground Output

AEM EMS 30-6040 I/O

ADCR11 Input Avail, 0-5 Volt Input, 100k pull up

Availability

Avail, same as pin A4

Dedicated

Dedicated
Dedicated, sensors only
Dedicated, sensors only

Page 9 of 11

30-1040 (Series 1) vs 30-6040 (Series 2) OBD1 Honda EMS pin differences:

Pin OBD1 Honda / Acura

30-1040 function

30-

6040 function

Notes

The EMS functions assigned to certain pins have been changed and no longer match the

30-1040 EMS. Unless otherwise noted, the following pins and functions will need to be

manually reconfigured after using AEMTuner to convert a V1.19 (30-1100, Series 1 EMS)

calibration for use with the 30-6100 Series 2 hardware.

A22 Ignition Control Module --- CAN1L

Copy settings for Ign Phasing,
B4 --- Coil #5 Coil 4
C2 --- --- CAN1H
D4 Service Check Connector Knock #2 Injector 9 Knock 2 not available

knock feedback, cylinder ign trim

Page 10 of 11

AEM Electronics Warranty

Advanced Engine Management Inc. warrants to the consumer that all AEM Electronics
products will be free from defects in material and workmanship for a period of twelve
months from date of the original purchase. Products that fail within this 12-month warranty
period will be repaired or replaced when determined by AEM that the product failed due to
defects in material or workmanship. This warranty is limited to the repair or replacement of
the AEM part. In no event shall this warranty exceed the original purchase price of the
AEM part nor shall AEM be responsible for special, incidental or consequential damages
or cost incurred due to the failure of this product. Warranty claims to AEM must be
transportation prepaid and accompanied with dated proof of purchase. This warranty
applies only to the original purchaser of product and is non-transferable. All implied
warranties shall be limited in duration to the said 12-month warranty period. Improper use
or installation, accident, abuse, unauthorized repairs or alterations voids this warranty.
AEM disclaims any liability for consequential damages due to breach of any written or
implied warranty on all products manufactured by AEM. Warranty returns will only be
accepted by AEM when accompanied by a valid Return Merchandise Authorization (RMA)
number. Product must be received by AEM within 30 days of the date the RMA is issued.

Please note that before AEM can issue an RMA for any electronic product, it is first
necessary for the installer or end user to contact the tech line at 1-800-423-0046 to
discuss the problem. Most issues can be resolved over the phone. Under no
circumstances should a system be returned or a RMA requested before the above
process transpires.

AEM will not be responsible for electronic products that are installed incorrectly, installed
in a non approved application, misused, or tampered with.

Any AEM electronics product can be returned for repair if it is out of the warranty period.
There is a minimum charge of $50.00 for inspection and diagnosis of AEM electronic
parts. Parts used in the repair of AEM electronic components will be extra. AEM will
provide an estimate of repairs and receive written or electronic authorization before
repairs are made to the product.

Page 11 of 11