AEM 30-6100 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 30-6100

1993-1998 Toyota Supra TT

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! If you are not well versed in

!

This product is legal in California for racing vehicles only and should never

engine dynamics and the tuning of management systems or are
not PC literate, please do not attempt the installation. Refer the
installation to a AEM trained tuning shop or call 800-423-0046
for technical assistance. You should also visit the AEM EMS
Tech Forum at http://www.aempower.com

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

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: 10-6100 (instructions revised Nov 2009)

 2009 Advanced Engine Management, Inc.

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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 standalone system that 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\Toyota” in the AEMTuner
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.

This product is legal in California for racing vehicles only and should never be used on public highways.

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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 well 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 Supra is
behind the passenger 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\Toyota\

This product is legal in California for racing vehicles only and should never be used on public highways.

Page 3 of 12

f)

Set the throttle range: Select Wizards>>Set Throttle Range and follow the on-screen
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 correctly­timed 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.

This product is legal in California for racing vehicles only and should never be used on public highways.

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