Emtron GT86 User manual

Z
GT86/BRZ/FR-S
USER
MANUAL
Rev 1.0
GT86/BRZ/FR-S
Plug-in

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
1
Table of Contents
1.0 Introduction .........................................................................................................................2
1.1 Guide ...........................................................................................................................2
2.0 Plugin Features.....................................................................................................................3
3.0 Kit Contents..........................................................................................................................4
3.1 Expansion Loom...............................................................................................................4
4.0 ECU Channel Assignment.....................................................................................................6
5.0 Plug-in Specific Information.................................................................................................9
5.2 Fuel Model .......................................................................................................................9
5.3 Inlet Air Temperature ....................................................................................................10
5.4 Check Engine Light .........................................................................................................10
5.5 AirCon Switch.................................................................................................................11
6.0 Diagnostic Trouble Codes (DTCs).......................................................................................12
7.0 User CAN Bus 1 ..................................................................................................................13
7.1 Emtron Lambda to CAN .................................................................................................13
8.0 OEM CAN Bus 2..................................................................................................................13
9.0 Emtron Torque Management ............................................................................................14
9.1 Torque Reduction Ign Retard Clamp..............................................................................14
9.2 Torque Nitrous Gain.......................................................................................................14
9.3 BSFC................................................................................................................................14
9.4 Engine Torque Correction Table ....................................................................................14
9.5 Torque Demand Correction Table .................................................................................15
9.6 Frictional Loss Table.......................................................................................................15
9.7 Frictional Loss Offset 1 Table.........................................................................................16
9.8 Torque Reduction Ignition Retard Gain Table ...............................................................16
9.9 Torque Reduction Gain Table ........................................................................................16
10.0 Ordering Information.......................................................................................................17
Appendix A - ECU Pinout..........................................................................................................18

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
2
1.0 Introduction
The Toyota/Subaru GT86/BRZ/FR-S features a flat four configuration engine that employs an
interesting combination of four (4) direct injectors and four (4) port injectors for fuel. The
ECU must be able to control both types of injector along with accurately control the GDI
pump pressure to a target. GDI pressures operate significantly higher than a conventional
port injection system.
To correctly calculate the fuelling requirements the ECU is able to accept sensor inputs from
the MAF Meter and/or MAP sensor depending on the fuel model mode selected.
1.1 Guide
This manual does not cover ECU installation.

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
3
2.0 Plugin Features
General
▪KV12 ECU based platform.
oDual 100MHz Processors
o32MB ECU logging Memory
▪Over 1000 channels available
▪1Hz to 500Hz logging rate
oEmtune Software for tuning and data analysis
oKnock Control using digital filtering with Bosch technology
▪6061 Grade Aluminium CNC Billet Enclosure
▪Fully compatible with all OEM systems and user programmable. This includes:
oVehicle Stability Control (VSC ) using throttle torque reduction
▪Compatible with all Emtron Proven Motorsport features
▪Upgradeable to run the Emtron Fuel model through installation of a Flex Meter, Fuel
Temperature and Fuel Pressure Sensor
▪Input Expansion Capabilities through DTM connector
o4x User Analog Volt Inputs (Fuel Temperature, Inlet Temp and Pressure)
o1x User Digital Input (Flex Meter Input)
•Output Expansion Capabilities through the DTM connector
o1x Auxiliary Output (Boost Control Solenoid)
Communications
▪CAN 2.0B Node 1: User CAN Bus for I/O expansion(Lambda, EGT)
▪CAN 2.0B Node 2: 500k Baud Full CAN Bus OEM Integration
▪High Speed Ethernet 100Mbps
Operating Temperature
▪Operating Temperature Range: -30 to 125°C (-22 to 257°F)
Physical
▪Enclosure Size 160 mm x 162 mm x 38 mm
▪890g

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
4
3.0 Kit Contents
When purchasing a Toyota/Subaru GT86/BRZ/FR-S plug-in the following items are included:
▪GT86/BRZ/FR-s Plug-in ECU
▪DTM 12 way Female Connector and pin kit
3.1 Expansion Loom
The ECU's Input capabilities can be expanded using the expansion connection which is a
male DTM 12 Way (DT06-12SA) See Table 3.0 and Figure 3.1
These additional inputs can be connected to any sensor, but the recommended sensors are
indicated in brackets.
Pin Number
Function
1
Analog Sensor 0V Reference
2
5.0V Aux Supply
3
AN 8 (e.g. Fuel Temp or Inlet Temp)
4
AN 9 (e.g. Fuel Temp or Inlet Temp)
5
AN 10 (e.g. Fuel Pressure)
6
DI 6 (e.g. Ethanol Content Sensor)
7
14V Out Protected (ELC1 Power Supply)
8
Ground (ELC1 Ground)
9
Auxiliary Output 5 (e.g. Boost Control solenoid)
10
NC
11
CAN 1 Hi
12
CAN 1 Lo
Table 3.0 - Expansion Port Pin out
To minimise signal contamination and maximise noise immunity, it is recommended to
twist the CAN wire pairs at a minimum one twist per 40mm of cable:
Pair 1
Pair 2
CAN High
<------->
CAN Low

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
5
Figure 3.0 - DT06-12SA (ECU Side)
The Mating connector, Part number: DT04-12PA
Figure 3.1 DT04-12PA (Car side)
T

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
6
4.0 ECU Channel Assignment
ECU Channel - Injection
Function
Injection Channel 1
Port Fuel Injector Cylinder 1
Injection Channel 2
Port Fuel Injector Cylinder 2
Injection Channel 3
Port Fuel Injector Cylinder 3
Injection Channel 4
Port Fuel Injector Cylinder 4
Injection Channel 5
Rear Lambda Heater
Injection Channel 6
Purge
Injection Channel 7
DBW Power Supply Relay
Injection Channel 8
Direct Injection Power Supply Relay
Injection Channel 9
DI Fuel Injector Cylinder 1
Injection Channel 10
DI Fuel Injector Cylinder 2
Injection Channel 11
DI Fuel Injector Cylinder 3
Injection Channel 12
DI Fuel Injector Cylinder 4
ECU Channel - Ignition
Function
Ignition Channel 1
Ignition Cylinder 1
Ignition Channel 2
Ignition Cylinder 2
Ignition Channel 3
Ignition Cylinder 3
Ignition Channel 4
Ignition Cylinder 4
Ignition Channel 5
Alternator Control
Ignition Channel 6
Engine Fan Relay
Ignition Channel 7
AC Clutch Relay
Ignition Channel 8
Starter Relay (Push Start)
Start Inhibit (Key Start)
Ignition Channel 9
Not Used
Ignition Channel 10
Not Used
Ignition Channel 11
DI Fuel Pump Control
Injection Channel 12
Not Used

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
7
ECU Channel - Analog Inputs
Function
Analog Voltage 1
MAP
Analog Voltage 2
DBW 1 Servo Position Main
Analog Voltage 3
DBW 1 Servo Position Sub
Analog Voltage 4
MAF
Analog Voltage 5
Rear O2 Sensor
Analog Voltage 6
IO Expansion Loom (e.g. Fuel Pressure)
Analog Voltage 7 (Pull-up Channel)
Engine Temperature
Analog Voltage 8 (Pull-up Channel)
IO Expansion Loom (IAT/FTemp/FPressure
Analog Voltage 9 (Pull-up Channel)
IO Expansion Loom (IAT/FTemp/FPressure
Analog Voltage 10 (Pull-up Channel)
IO Expansion Loom (IAT/FTemp/FPressure)
Analog Voltage 11 (Pull-up Channel)
Intake Temperature MAF
Analog Voltage 12 (Pull-up Channel)
Engine Oil Temperature
Analog Voltage 13
Pedal Position Sensor (PPS) Main
Analog Voltage 14
Pedal Position Sensor (PPS) Sub
NOTE: Analog Voltage Channels 7-12 have switchable pull-ups which are suitable for
temperature measurement.
ECU Channel - Digital Inputs
Function
Digital Input 1
Cam Position - Inlet RH
Digital Input 2
Cam Position - Exhaust LH
Digital Input 3
Cam Position –Exhaust RH
Digital Input 4
Neutral Position Switch
Digital Input 5
Direct Injection 1 Feedback
Digital Input 6
IO Expansion Loom (e.g. Ethanol Sensor)
Digital Input 7
Direct Injection 2 Feedback
Digital Input 8
DI Fuel Pump Feedback
Digital Input 9
Clutch Switch
Digital Input 10
Start Signal from Starter Relay (Button Start)
NC (Key Start)
Digital Input 11
AC Pressure (some models only)
Digital Input 12
Start/Stop Switch (Button Start)
Start Signal from Starter Relay (Key Start)
Digital Input 13
Brake Switch
Digital Input 14
Cruise Control Switch

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
8
ECU Channel - Auxiliary Outputs
Function
Auxiliary 1
VVT Solenoid Inlet RH
Auxiliary 2
VVT Solenoid Inlet LH
Auxiliary 3
VVT Solenoid Exhaust RH
Auxiliary 4
VVT Solenoid Exhaust LH
Auxiliary 5
IO Expansion Loom (e.g. Boost Control
Solenoid)
Auxiliary 6
Engine Speed Output
Auxiliary 7
Fuel Pump Speed Control
Auxiliary 8
AC Fan Relay
Auxiliary 9
DBW +
Auxiliary 10
DBW –
Auxiliary 11
Start Inhibit (Button Start)
NC (Key Start
Auxiliary 12
Not Used
Auxiliary 13
Canister Pump Module Relay (PPMP)
Auxiliary 14
Canister Pump Module Relay (VPMP)
Auxiliary 15
Canister Pump Module Relay (MPMP)
Auxiliary 16
Not Used
NOTE: Auxiliary Channels 13-15 have drivers suitable ONLY for relay control with switching
currents that must be less than 0.5A.
ECU Channel - Crank/Cam
Function
Crank Index
Crank Sensor
Sync Sensor
Cam Position - Inlet Bank 1 (LH)

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
9
5.0 Plug-in Specific Information
5.2 Fuel Model
The ECU can use many combinations of methods to generate the fuel mass output . The
ECU base calibration is supplied using simple but common Speed Density (MAP). There are
many other fuel modelling methods possible to achieve an excellent result. Commonly
modified camshafts, aftermarket air bypass valves, larger turbochargers and modified intake
piping will tend to create unstable Mass Flow Sensor readings so MAP based fuel models
tend to make the process much simpler.
Figure 5.1. Fuel Model Setup
Press F1 when you have this setting selected for more detailed help on each Fuel Model.
When MAF is selected the Secondary Load table can be used to scale the MAF if required.
The factory calibration should provide good initial air mass calculations but it will be
common to modify the intake and therefore this will require re calibration of the MAF
meters. This table will need to be switched ON. To do this select Fuel Menu-> Fuel Table
Control -> Secondary Load Table. Set to a value of 12 as shown in Figure 5.2.

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
10
Figure 5.2. Secondary Load Table - MAF Scaling
There is also a runtime in the F3 Menu -> Fuel Tab showing the current Fuel Model the ECU
is running in.
Figure 5.3. Fuel Model Runtime
5.3 Inlet Air Temperature
A factory fitted Inlet Temperature Sensor is fitted. This is available on Analog Input 11 and
should already be configured in the base calibration shipped with the ECU.
5.4 Check Engine Light
The control of this light is done through the CAN bus. The base calibration file has the
output already configured and selected to “CAN Bus OEM”.

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
11
5.5 AirCon Switch
The AirCon Switch status is read through the CAN bus. The base calibration file has the Input
Source selected to “CAN Bus OEM”.

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
12
6.0 Diagnostic Trouble Codes (DTCs)
On initial installation it is advised to clear all the DTC's if error(s) are reported. To check,
connect to Emtune and look at the DTC status in the bottom toolbar. If there are Errors the
status box will be Red as shown in Figure 5.0.
Figure 7.0. DTC example showing 8 errors.
To open the DTC window, click on the DTC Status box in the bottom toolbar OR use the File
menu -> Open DTC. Next select "Clear ALL DTCs" and confirm all the Error Codes have been
removed; the DTC Status box should go Green indicating this as shown in Figure 7.1. Close
the DTC window.
Figure 7.1. DTC example showing no errors.
If the Error Codes have not all been removed, select "Update DTC" then use the DTC
window to locate the sensor that is on fault.

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
13
7.0 User CAN Bus 1
The ECU CAN Bus 1 is available for Input/Output expansion allowing a wide range of Emtron
CAN devices to be connected into the CAN Bus. This includes the following CAN Modules:
•ELC1/2 (Emtron Lambda to CAN 1/2 channel)
•ETC4/ETC8M (Emtron Thermocouple to CAN 4/8 channels)
•EIC10/EIC16M (Emtron Input to CAN 10/16 Channel)
7.1 Emtron Lambda to CAN
The ELC uses Bosch proven integrated circuit technology to precisely control an LSU4.9
Lambda sensor. The Lambda value is transmitted over the CAN Bus and can be used by the
ECU for Tuning and Closed Loop control. More information is available by looking at the
Emtron ELC User Manual.
The ELC Power, Ground and CAN wires can be directly connected into the IO Expansion
Loom as outlined in Table 7.0.
Name
ELC 4-Way DTM
ECU IO Expansion 12-Way DTM
Ground
Pin 1
Pin 8
CAN Lo
Pin 2
Pin 12
CAN Hi
Pin 3
Pin 11
Power
Pin 4
Pin 7
Table 7.0 –ELC1 to IO Expansion Port wiring
8.0 OEM CAN Bus 2
The ECU Communicates on CAN Bus 2 which is reserved for the GT86/BRZ/FR-S. The ECU
maintains full compatibility with all other CAN devices within the vehicle.
The ECU transmits a wide range a raw and calibrated data over the Bus, communicating with
other devices but it is also receiving data.

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
14
9.0 Emtron Torque Management
The ECU performs extremely accurate torque calculations provided the engine model
configuration is accurate. This section allows the user to calibrate any errors in the torque
model whilst also influencing the engine torque delivery characteristics.
9.1 Torque Reduction Ign Retard Clamp
This limits the maximum torque reduction the ECU can perform based on ignition timing
retard
9.2 Torque Nitrous Gain
In applications where Nitrous is used to increase torque. The ECU calculates this torque
increase however if required the gain of this torque increase can be used to trim the output.
9.3 BSFC
Brake Specific Fuel Consumption torque calculation is not used by the ECU however it can
be useful when calibrated correctly to cross check the ECU calculated torque levels.
Figure 8.0 Engine Torque Setup
9.4 Engine Torque Correction Table
The ECU accurately calculates the Engine Torque however if any calibration errors lead to
incorrect readings this table allows the user to adjust the gain based on any parameter
listed in the axis setup form.
Figure 8.1 Engine Torque Correction Table

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
15
9.5 Torque Demand Correction Table
Torque Demand is calculated based on various parameters in the ECU along with driver
controlled pedal inputs. The GT86/BRZ/FR-S requests accurate information on the torque
demanded by the driver so decisions can be made in the many systems in the vehicle. The
ECU needs to be reporting this correctly. If there is correlation issues between the torque
reported and the Torque Demanded the vehicle will not function as intended and can also
lead to drivetrain operation issues. This table allows for gain control of this channel
however it should not require modification unless there are engine model or calibration
problems.
Figure 8.2 Torque Demand Correction Table
9.6 Frictional Loss Table
The engine torque produced by combustion is calculated by the ECU and commonly referred
to as “Torque Ideal”. The moving parts inside the engine assembly create drag and
therefore limit the torque available. This table allows for entry of the frictional loss and is
represented in Nm. Figure 8.3 shows the default setting provided with the base calibration.
Figure 8.3 Frictional Loss Table

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
16
9.7 Frictional Loss Offset 1 Table
There are two (2) tables that allow offsetting of the frictional loss. Figure 8.4 shows a
common offset table setting spanned against Engine Oil Temperature.
Figure 8.4 Frictional Loss Offset 1 Table
9.8 Torque Reduction Ignition Retard Gain Table
This table calibrates the torque reduction % per degree. When a torque request is applied
the ECU will calculate how much retard is required to achieve this torque request. Figure
8.5 shows the default table settings.
Figure 8.5 Torque Reduction Ignition Retard Gain Table
9.9 Torque Reduction Gain Table
This table calibrates the torque reduction % per %cut. When a torque request is applied the
ECU will calculate how much cut is required to achieve this torque request. Figure 8.5
shows the default table settings.
Figure 8.6 Torque Reduction Cut Gain Table

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
17
10.0 Ordering Information
Product
Part Number
Emtron GT86/BRZ/FR-S Plugin
1609-72086

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
18
Appendix A - ECU Pinout
OEM Pin Number
Function
A1
Throttle Servo Motor -
AUX1012 Supply (option 2)
A2
Throttle Servo Motor +
AUX9
A3
Power Ground
GND
A4
Power Ground
GND
A5
Cam Solenoid Exhaust RH
Aux 4
A6
O2 NarrowBand Heater
GROUND
A7
Cam Solenoid Exhaust LH
Aux 3
A8
Ignition 4
Ign 4
A9
A10
Ignition 2
Ign 2
A11
Purge
Inj 6
A12
Injector 1 (Port)
Inj 1
A13
Injector 4 (Port)
Inj 2
A14
Injector 1 (Direct)
Inj 1 Direct
A15
A16
Cam Solenoid Inlet RH
Aux 2
A17
Cam Solenoid Inlet LH
Aux 1
A18
TPS (Main)
An 2
A19
5V Engine (TP and VSV)
Eng 5V
A20
Oil Temperature
An 10
A21
Ignition 1
Ign 1
A22
Injector 2 (Port)
Inj 2
A23
Injector 4 (Direct)
Inj 4 Direct
A24
Injector 3 (Direct)
Inj 3 Direct
A25
Injector 2 (Direct)
Inj 2 Direct
A26
A27
A28
TPS (Sub)
An 3
A29
Sensor Ground (Knk,MAF,Oil Temp,Eng Temp)
Sensor 0v Ref
A30
ECT
An 7
A31
Ignition 3
Ign 3
A32
Injector 3 (Port)
Inj 3
A33
A34
B1
Canister Pump Module (VPMP)
B2
B3

EMTRON TOYOTA/SUBARU GT86/BRZ/FR-S PLUGIN USER MANUAL
WWW.EMTRON.WORLD
© EMTRON AUSTRALIA PTY LTD
19
B4
B5
Direct Injector Power Supply Relay
Inj 8
B6
B7
DBW (ETCS) Power
Inj 7
B8
Canister Pump Module (MPMP)
B9
B10
Fuel Pump Feedback
DI 5
B11
Cooling Fan Relay 3
Ign 5
B12
Cooling Fan Relay 1 2
Ign 6
B13
EFI Relay (Gnd)
B14
B15
Tacho
Aux 6
B16
B17
DBW Relay (Gnd)
Inj 7
B18
Alternator Control
Aux 8
B19
FPC
Aux 7
B20
Canister Pump Module
GROUND
B21
5V Eng (FPS Main)
5V Eng
B22
5V Eng (FPS Sub)
5V Eng
B23
FPS Main Signal
An 13
B24
B25
B26
Starter Relay
Ign 8
B27
B28
B29
Sensor Ground (PP)
Sensor 0V Ref
B30
Sensor Ground (PP)
Sensor 0V Ref
B31
FPS Sub Signal
An 14
B32
B33
B34
Start Cut Relay
Aux 11
B35
AC Clutch
Ign 7
C1
Power Ground
GROUND
C2
Power Ground
C3
Power Ground
C4
C5
02 Wideband Heater
C6
14V ECU Power
C7
C8
C9
Fuel Pressure Signal
An 6
C10