Implementation Notes for installing the Adaptronic onto the 4G15 Engine (CE Mirage, CE Lancer)

Test system
The test vehicle was a Mitsubishi Mirage, CE shape. The modifications to the engine were: 1. Aftermarket turbocharger (GT28), intercooler, exhaust, pod filter and blow-off valve fitted 2. 400cc/min injectors fitted 3. Oxygen sensor swapped for heated type (4-wire, a generic replacement for a Toyota vehicle) 4. MAP sensor changed to a 2-bar type Documentation on the vehicle was provided, which described some extra features which were not implemented on this vehicle. These were: 1. Air conditioning compressor and air conditioner input request 2. Automatic transmission

Installation
The following summarises the main details of the installation: 1. Wires were spliced into the factory loom at the factory ECU connector, in the passenger footwell. The ECU was mounted on a custom bracket beneath the glovebox by running screws into the glovebox crossmember and using an existing firewall stud. 2. The original distributor, ignition system, injector wiring and all other engine wiring was retained. 3. The original distributor cam angle sensor was not modified. 4. A standard Delco 2-bar MAP sensor was added, mounted in the original location. The vacuum/boost hose was run to the original MAP sensor port on the plenum. The wiring of the installation is given on the last page of this document.

Installation Details
Below are the wires and functions of the ECU, along with the pin allocations on the factory ECU.

Mitsubishi ECU Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 - 24 25 26 Colour Yellow / Blue Blue / Green NC Blue / Yellow White NC Black Green / White Yellow / Green White NC Red / Yellow Black Yellow / Black Lt Green / White NC Yellow Green NC Blue Blue Red NC Red / Yellow Black

Function

Adaptronic connector 8-pin 8-pin 16-pin 16-pin

Adaptronic ECU Colour Purple White Red / Black Red / Brown Pin 5 6 16 8

Notes

Injector 1 Injector 3 Idle motor 1 Idle motor 4 AT unit (NC) AC unit (NC) Purge valve Ignition Drive Main power Power GND Injector 2 Injector 4 Idle motor 3 Idle motor 6 AC unit (NC) Thermofan Fuel pump relay Main power Power GND

Aux output 5 Aux output 6 Test vehicle was manual Test vehicle had no AC Aux output 2

6-pin 16-pin

Red Yellow

2 2

No need to connect (see pin 82) 8-pin Black 8-pin Grey 8-pin Pink 16-pin 16-pin Red / Green Red / Blue

2 8 7 15 7 Aux output 7 Aux output 8

6-pin 6-pin

Green Brown

3 1

Aux output 3 Aux output 1

No need to connect (see pin 82) 8-pin Black

31 - 35 36 37 38 39 - 44 45 46 51 52 53 - 58 59 60 - 62 71 72 73 - 75 76 77 - 80 81 82 83 84 85 86 87 88 89 90 91 92

NC Lt Green / Black Yellow / Black Red NC Green / Black NC NC Black / Blue NC White NC NC Red / White NC White NC Green / Blue Black / White Yellow / Green Green / White Yellow / Red Yellow Yellow / Red NC Brown / Green NC Black or B/Y Black

Check lamp Pwr steering Engine on/off A/C / A/T (NC_

20-pin 6-pin

White Blue

14 4

Dig Inp 1 Aux output 4 Test vehicle was manual with no AC

Timing check AT unit (NC)

No connection Test vehicle was manual

Air temp O2 sensor Sensor 5V Ignition power WT TPS sig MAP sens sig VSS Throttle switch CAS AT / MT Sensor GND

20-pin 20-pin 20-pin 8-pin 20-pin 20-pin 20-pin 16-pin

Blue Inner of Black Red & Yellow Red Green (thin) Green (thick) Orange Brown

7 6 8, 19 1 17 10 18 14

Power to ECU

16-pin No connection 20-pin

Red&Black, shielded

5, 13

Brown & Black

9, 20

In addition, the 1-bar MAP sensor was replaced with a 2-bar type, as described earlier. This is only a requirement for boosted engines. The oxygen sensor was also replaced with a heated (3 or 4-wire) type, as the oxygen sensor was relocated to downstream of the turbine.

Triggering and real-time outputs

The original cam angle sensor is retained. On the test vehicle, this sensor gave a rising edge at 65 BTDC and a falling edge at TDC. One in four cycles, the rising edge was approximately 3 degrees earlier. The injector firing sequence is set to "Fully Sequential", and "Batch on crank". The current is set to 1.5A, and the peak-hold drive type is selected. The current isn't too relevant as the injectors on this engine are high impedance. Dwell time is set to 4000s. Ignition timing during cranking is triggered from the falling edge of the Hall effect sensor.

Auxiliary Outputs
Aux outputs 5 - 8 are set up to be idle stepper motor control, hold type, 1-4, respectively. The number of steps of the idle motor is 120, and this should be set as the crank duty cycle in the special function, idle speed control (see ECU configuration file). Aux output 1 is set to be the fuel pump. Aux output 2 is set to be the purge valve, 3 is the thermofan and 4 is set to unconditional "on" (main relay control).

Special functions and control

The ECU runs in closed loop using the standard oxygen sensor below 80kPa of MAP. Above this, the ECU switches to open loop mode. The target air-fuel ratios below this value are set within the hysteretic region of the oxygen sensor so that the ECU can regulate the mixture, except for at idle where a richer mixture is required. The idle speed control has feed-forward based on coolant temperature and electrical load. A throttle cracker is provided for when the vehicle is in motion, as there is no neutral switch on the gearbox. The idle motor is a 120-step device. The idle motor position is reset at power-up when the idle motor is fully opened to aid cranking. Both acceleration enrichment and asynchronous throttle pump have been implemented on this engine to allow acceptable transient throttle response.

Evaluation
This evaluation follows the installation and road tuning of the Adaptronic on the test vehicle. This was performed on the 8th of January, 2005. Cold starting, warm starting, hot restarting after heat soak - all operate OK on the test vehicle. Idle speed control - the cold idle-up and extra idle air during power steering inputs is functioning correctly. Idle speed regulation appears to be limited by the vacuum leak of the turbocharger bleed valve (boost controller). Engine responds well to tuning, and triggering is very reliable. Vehicle speed sensing verified. For some reason, this engine seems to need quite a rich mixture at idle to prevent backfiring in the exhaust. Acccording to tuning specialists, this is a common occurrence with large injectors. After an evaluation period, the car was dyno tuned at MRT (http://www.mrtrally.com.au) on a Dynapack chassis/hub dynamometer. This occurred on the 22nd of January 2005.

Andy Wyatt, Adaptronic http://www.adaptronic.com.au andyw@adaptronic.com.au

Diagram to wire Adaptronic 420 V0.2 ECU to standard 4G15 engine

D

Tested on turbocharged Mirage, manual, no A/C Andy Wyatt 2005-01-01

Aux Out 5 - Red/Black Aux Out 7 - Red/Green MVSS - Brown DigIn1 - Black Internal (option 1) C

J4 - Adaptronic B16 B15 B14 B13 B12 B11 B10 B8 B7 B6 B5 B4 B3 B2 B1

Aux Out 6 - Red/Brown Aux Out 8 - Red/Blue SVSS - Orange DigIn2 - Red Internal (option 1) C CAS GND - White Internal and sheild

DigIn3 - Yellow Internal (option 1)

IGN1 - Yellow IGN3/Tacho - Blue

IGN2 - Green

B9

16-way connector J3 - Adaptronic TPS GND - Black A20 A10 10 11 12 13 31 32 33 34 35 36 37 38 51 52 53 54 55 56 71 72 73 74 75 76 77 78 79 80 81 TPS +5V - Red A19 A9 A8 A7 A6 A5 A4 A3 A2 A1

TPS Sig - Green MAP GND - Brown MAP +5V - Yellow MAT - Blue EGO - core of black shlielded Spare input - Grey Dig2 - Pink Dig4 - Red / Brown Dig6 - Red / Green Dig8 - Orange / Red B

MAP Sig - Orange A18 WT - Green (skinny) A17 TT - Violet A16

14

15

16

17

18

19

20

21

22

23

24

25

26

39

40

41

42

43

44

45

46

57

58

59

60

61

62

82

83

84

85

86

87

88

89

90

91

92

Knock - core of grey shielded Dig1 - White Note: all connectors viewed from wiring side (not pin side) To confirm: check wire colours (see spreadsheet) J1 - Adaptronic Red 1 Black 2 Black 3 Black 4 Purple 5 White 6 Pink 7 Grey 8 8-way connector J2 - Adaptronic Brown 1 Red 2 Green 3 Blue 4 Black 5 Black 6 6-way connector Dig3 - Red/Black Dig5 - Red / Blue Dig7 - Orange / Black

A15 A14 A13 A12 A11

20-way connector

Title Size A4 Date: File: 26-Jan-2005 Sheet of B:\ECUConfigs\010_4G15_Turbo_Mirage\ImplementationNotes\WiringDiagram.ddb Drawn By: 4 Number Revision