HKS EVC-S User manual
Instruction Manual
E05121-K00121-00
2009.10.01
Ver. 3-1.01
HKS ELECTRONICS TECHNOLOGY
NOTICE
This manual assumes that you have and know how to use the tools and equip-
ment necessary to safely perform service operations on your vehicle.
This manual assumes that you are familiar with typical automotive systems and
basic service and repair procedures.Do not attempt to carry out the operations
shown in this manual unless these assumptions are correct. Always have
access to a factory repair manual. To avoid injury, follow the safety precautions
contained in the factory repair manual.
㧙㧙
INTRODUCTION
PRODUCT
USE
APPLICATION
PART No.
REMARKS
EVC-S
Boost Pressure Controller for Turbocharged Automobile Engines
DC12V Negative Ground Vehicles
45003-AK009
A fuel controller (e.g. F-CON V Pro, F-CON iS, etc) may be required when using this
product.
When installing this product on a twin turbocharged vehicle or a vehicle using a
4mm hose line, a separate Hose Set is required.
When the boost pressure is increased, the factory ECU may activate a fuel cut. To
deactivate the fuel cut function, a unit such as the HKS FCD is required. When using
an HKS FCD, a fuel controller must be used as additional fuel tuning.
˴
Read this instruction manual prior to installation to ensure safe and correct usage for optimal
product performance.
˴The HKS EVC enables the adjustment of boost settings from inside the vehicles cabin area.
˴This product was developed to improve engine output and was designed to be used for racing
on a closed circuit, where this unit is highly effective. When the engine output is improved,
water and/or oil temperature may rise, and insufficient oil pressure may occur. Always monitor these
vital readings to obtain optimal engine performance.
If using this product on a public road, follow all necessary laws, procedures and regulations for
a tuned/modified vehicle.
٨Compact Size / 4 Separate Units
EVC-S includes 4 separate units: Display Unit, Control Unit, Boost Sensor, and Solenoid Valve.
Each unit is compact and easy to install in the engine bay and the interior. Since the Boost Sensor
is independent, hose routing does not need to run into the vehicles interior.
٨Capable of Controlling High Boost
˴EVC-S can control up to 250kPa (36PSI)
٨Simple Boost Setting
Directly input the desired boost value to modes A and B, and let the HKS EVC control the boost.
٨Return Function
The boost setting returns to the factory setting when the power is turned off. On some vehicles,
the boost value may be lower than the boost before installing the EVC-S.
٨2 Mode Boost Setting Function
˴A Mode and B Mode allow for 2 different boost settings. ˴
㧙㧙
٨Warning Function
˴˴If the boost level exceeds the warning value, the unit will warn the user will an audible buzzer and
visually on the display. The boost value will be lowered to the set value. This function protects the
engine and turbocharger from excessive boost.
٨After Image Display Function
˴˴When the boost changes from positive pressure to negative pressure, the maximum boost under
positive pressure can be displayed for 3 seconds. This function can be turned off.
٨Data Memory Function
˴˴Each setting value is saved in the internal memory; the saved values are retrievable even after the
ignition is shut-off or the battery is disconnected.
٨Exhaust Bypass Select Function
˴˴Can be used as swing valve type (internal wastegate/actuator) or poppet valve type (external
wastegate) for a large capacity turbocharger.
٨Boost Unit of Measure Select Function
˴˴The boost unit of measure is selectable between kPa and PSI.
٨Data Lock Function
˴˴The setting data can be protected by a password to prevent unwanted or accidental changes.
٨This manual indicates items you need to pay attention to in order to install this product safely
and lists precautions to avoid any possible damage and/or accidents.
٨For any missing, defective and/or damaged parts, contact your Authorized HKS Dealer.
٨This product was developed for racing use. To use this product on public roads, follow the
necessary laws, procedures and regulations for a tuned/modified vehicle.
٨HKS will not be responsible for any damage caused by incorrect installation and/or use or use
after modification and/or dismantling of this product.
٨This product was designed based on installing it onto a factory vehicle or a vehicle using other
HKS products. The performance and/or safety cannot be guaranteed if this product was
installed onto other inapplicable vehicles.
٨This product works only on vehicles with a DC12V negative ground.
٨The specifications of this product are subject to be changed without notice.
٨This manual is subject to be revised without notice.
٨This manual must be given to the end user after installation is complete.
㧙㧙
INTRODUCTION
INDEX
SAFETY PRECAUTION
PARTS LIST
NAMES & FUNCTIONS
INSTALLATION
CONFIRMATION AFTER INSTALLATION
OPERATION
OPTIONAL PARTS LIST
MAINTENANCE
TROUBLESHOOTING
REPAIR SERVICE
FOR SUBSEQUENT OWNERS
PRODUCT SPECIFICATIONS
INSTRUCTION MANUAL REVISION RECORD
INDEX
㧙㧙
SAFETY PRECAUTION
WARNING
٨
Make sure to work on the vehicle in a well-ventilated area to prevent possible
explosion or fires.
٨To avoid possible accidents, do not mount the unit in areas where the driver may
become distracted during driving or the product cannot be mounted securely.
٨Do not install this product on a 24V vehicle. It may cause a fire.
٨Make sure to disconnect the negative cable from the battery to avoid possible
damage to other electronic parts and/or a fire caused by a short circuit.
٨Make sure to hold and remove wire connectors properly to avoid possible
damage to other electronic parts and/or a fire caused by disconnection or a
short circuit.
٨Stop using this product if any unusual problems should occur. Consult your
Authorized HKS Dealer immediately.
٨Do not operate this product while driving to avoid possible accidents.
٨Do not install this product by yourself unless you have and know how to use the
t
ools and equipment necessary to safely perform service operations on your vehicle.
٨
Do not modify, disassemble, and/or repair this product and supplied parts to avoid
any damage to the unit and/or wiring harness. This will also void the warranty.
٨Handle parts with extra care at all times.
٨Avoid allowing oil and/or water from entering the unit. It may damage the unit
and cause damage to the engine.
٨
Prior to installation, make sure the engine bay temperature has cooled down.
Failure to let the engine cool can lead to severe burns.
٨
Select the appropriate exhaust bypass type. Selecting the wrong type may cause
damage to the engine.
٨To avoid possible malfunction and damage to the engine, install the unit away
from areas of excessive heat or water/moisture.
٨
Do not tie or bundle any hoses or harnesses to any vehicle fuel lines. It may cause
a fire or severe damage to the vehicle.
٨Make sure all connections and wiring are correct and do not become shorted
or disconnected. If so, it may cause an electric shock or damage the vehicle.
٨Use the provided crimp connectors and install them in the correct positions. If
not, it may cause serious damage to the vehicle.
CAUTION
㧙㧙
٨
Connect the ground wire to a good chassis ground. If not, it may cause damage
to the vehicle.
٨Insert the vacuum filter and replace it at regular intervals. If not, it may cause
damage to the vehicle.
٨When installing the vacuum filter, make sure no oil or lubricants exist causing
the hose to come off. If a hose comes off, it may cause damage to the vehicle.
٨
Replace the vacuum filter more frequently if there is excessive dirt build-up.
Dirt build up may cause an inability to control boost, which may cause damage
to the engine.
٨Do not raise the boost pressure excessively.
It may cause damage to the engine
and turbocharger.
٨Activate the Warning Function of this product to prevent damage to the engine
caused by excessive boost pressure.
٨Do not test this product on public roads.
٨If this product or the vehicle with this product installed does not operate properly,
consult your retailer/dealer immediately.
٨Do not try to repair this product by yourself.
٨If any unusual noises, scents, and/or vibration are noticed, consult your
Authorized HKS Dealer immediately.
٨If this product is removed, make sure all wires from the vehicle are insulated
to prevent damage to other electrical parts.
CAUTION
Daily vehicle maintenance is the responsibility of the owner.
This manual shows a typical installation. Actual installation may vary depending
on the vehicle application.
When removing the factory parts, refer to the factory manual.
Make sure all connections and wiring are correct.
Make sure to keep all removed factory parts.
Make sure to use the appropriate tools when tightening nuts and bolts. Do not over-
˴tighten.
Make sure not to disconnect any of the vehicle's wiring when installing this product.
For vehicles equipped with a boost pressure control solenoid valve, disconnect
the hoses and/or connector to deactivate this function.
㧙㧙
˴
PARTS LIST
Instruction Manual
Valve Bracket Set
Bracket x 1
M4 Bolt x 2
Double-sided Tape
Crimp Connector
Tie Wrap
Hose Clamp
Vacuum Filter
T-fitting
4mm Hose
Control Unit Solenoid ValveDisplay unit
㧝㧝㧝
㧝
㧝Set
㧝Set
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6mm
㨙㨙
㧝㨙
Ǿ 4mm & 6mm
٨Keep unused parts.
٨The following tools are required for installation: voltage meter, 10mm socket with ratchet,
10mm wrench 12mm wrench, phillips screwdriver, wire cutters, crimping tool and pliers.
Power Supply Harness
㧝
6mm Hose
1801-SA033
1801-SA004
6mm: 4599-RA016
4mm: 4599-RA017
Boost Sensor
Valve Extension Harness
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M6 BoltNut x 1
M6 Flat Washer x 1
M6 Rubber Washer x 2
Valve Install Hardware
㧝Set
Boost Sensor Install Hardware
㧝Set
M6 Bolt Nut x 1
M6 Flat Washer x 1
M6 Lock Washer x 1
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HKSELECTRONICSTECHNOLOGY
126
Fitting
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NAMES & FUNCTIONS
٨5YKVEJ
˴Use this switch to select functions and settings. This switch can be pressed in 5 directions: up,
down, left, right, and center. Each direction has 2 selectable options based on the duration of switch
depression. In total, there are 10 ways of selecting functions and/or settings.
٨Display
˴˴˴˴˴˴Boost pressure or setting value is displayed.
˴˴˴˴˴˴This sign appears when editing the setting value under the Boost Setting Mode or Function
Setting Mode.
˴˴˴˴˴˴This sign appears when the Boost Control Mode is activated with the A Mode setting value,
or when editing the A Mode setting under the Boost Setting Mode. This sign does not
appear under the Control Off Mode.
This sign appears when the Boost Control Mode is activated with the B Mode setting value,
or when editing the B Mode setting under the Boost Setting Mode. This sign does not
appear under the Control Off Mode.
This sign appears when setting the Off Set Value under the Boost Setting Mode.
This sign appears when setting the Response Value under the Boost Setting Mode.
This sign appears when setting the Drop Value under the Boost Setting Mode.
This sign appears when setting the Over Boost Value under the Boost Setting Mode.
This sign appears when displaying the Peak Hold Value of the Boost value under the
Boost Control Mode.
This sign appears when the Warning function is being activated.
This sign appears when "kPa" is selected as the unit of boost value.
This sign appears when "PSI" is selected as the unit of boost value.
This sign appears when setting the Off Set Value, Response Value or Drop Value under
the Boost Setting Mode.
This sign appears when setting the Data Lock, or trying to edit locked data.˴˴˴˴˴˴˴˴˴˴˴
For more details, refer to "Operation."
Display Switch
Display Unit
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INSTALLATION
(1) Disconnect the negative cable from the battery.
٨This manual shows a typical installation. Actual installation may vary depending on the vehicle
application.
1. Removal of the Battery Cable
2. Hose Connection Layout
˴
٨Do not install this product on a 24V vehicle. It may cause a fire.
WARNING
1. Removal of the Battery Cable
2. Hose Connection Layout
˴
˴
3. Wiring
4. Mounting the Components
5. After Installation
2-1. Connecting the Boost Sensor
2-2. Connecting the Solenoid Valve
2-3. Connection of a Swing Valve Type
2-4. Connection of a Poppet Valve Type
(1) Considering the hose and harness lengths, determine the appropriate mounting layout
of the Display Unit, Control Unit, Boost Sensor, and Solenoid Valve.
ADVICE
Leave some slack for the harnesses and hoses to avoid tension during engine movement.
Do not install any components in high temperature areas.
㧙㧙
2-1. Connecting the Boost Sensor
˴˴Remove any oil and/or lubricants on or in the
hose and Vacuum filter.
4mm Hose (5cm)
4mm Vacuum Filter
Surge
Tank
Surge
Tank
Disconnect
Fuel
Regulator
4mm Hose (5cm)
4mm Hose
Fuel Regulator
4mm Hose
4-4-4mm
T-fitting
Surge
Tank
4mm Vacuum Filter
Boost Sensor
Fuel
Regulator
4mm Hose
4-4-4mm
T-fitting
Boost Sensor
(1) Cut the 4mm Hose to 5cm in length and connect
the cut hose to the 4mm Vacuum Filter as
illustrated in the diagram.
NOTE
(2) Disconnect the 4mm Hose between the fuel
regulator and surge tank from the surge tank side.
(3) Cut the 4mm Hose to 5cm in length and insert the
T-fitting as illustrated in the diagram.
(4) Connect the T-fitting and 4mm Vacuum Filter using the
remaining 4mm Hose as illustrated in the diagram.
NOTE
Keep the 4mm Hose to a minimum length.
Remove any oil and/or lubricants on or in the hose
and vacuum filter.
Face the Boost Sensor's fitting downward to prevent
any oil and/or water from entering the sensor.
㧙㧙
2-2. Connecting the Solenoid Valve
Swing Valve Type
(2) Install the Fittings to the COM terminal and NO
terminal.
(3) Cut the 6mm Hose to 5cm in length, and connect
the cut hose to the Fitting on the NO terminal
and the 6mm Vacuum Filter.
Swing Valve Type
(1) Remove the caps on the COM terminal,
NO terminal, and NC terminal.
Poppet Valve Type
(2) Install the Fittings to the COM terminal and NC
terminal.
(3) Cut the 6mm Hose to 5cm in length, and connect
the cut hose to the 6mm Vacuum Filter.
Poppet Valve Type
6mm Hose (5cm)
6mm Vacuum Filter
6mm Hose (5cm)
6mm Vacuum Filter
㧯㧻㧹
㧺㧻
㧺㧯
Hose Clamp
Hose Clamp
Cap
NOTE
Use a hose clamp to connect the hose to the
fitting.
Remove any oil and/or lubricants on or in the
hose and vacuum filter.
NOTE
Use a hose clamp to connect the hose to the
fitting.
Remove any oil and/or lubricants on or in the
hose and vacuum filter.
(4) Refer to 2-4 to connect to the vehicle.
㧙㧙
2-3. Installing the Boost Sensor and Solenoid Valve to Swing Valve Type
Before Installation (Factory Connection Layout)
After Installation
Turbine
Actuator
Airflow Meter
Air Cleaner
Fitting Ԙ
6mm Hose
Throttle Valve
Surge
Tank
Fuel Regulator
2-3.1 For Applications without a Boost Pressure Control Solenoid Valve
Turbine
Actuator
Compressor
Airflow Meter
Air Cleaner
Fitting Ԙ
6mm Hose
Throttle Valve
Surge
Tank
Fuel Regulator
4mm Hose
4-4-4mm T-fitting
6mm Hose
Vacuum Filter
Valve
01
%1/
Remove the c a p on
the NC terminal. (Ref.2-2)
Compressor
㧙㧙
Hose Clamp
Hose Clamp
Hose Clamp
Hose Clamp
Fitting Ԙ
Fitting Ԙ
Actuator
Solenoid Valve
6mm Vacuum Filter
6mm Hose
Factory Hose
NOTE
Remove any oil and/or lubricants on or in the hose and vacuum filter.
Use hose clamps when connecting the 6mm Hose to the 6mm fittings.
Depending on the vehicle, the factory hose may not be long enough to connect from the actuator
to the Solenoid Valve. If so, additional 6mm Hose can be purchased as an optional part.
(3) Connect the factory hose from the actuator to the
fitting on the COM terminal of the Solenoid Valve.
(2) Connect the provided 6mm Hose to fitting Ԙand
the 6mm Vacuum Filter on the NO terminal of the
Solenoid Valve.
(1) Disconnect the hose connected to the actuator from
fitting Ԙon the compressor side.
NOTE
The position on the compressor side fitting Ԙmay
vary depending on the vehicle.
Keep the removed factory hose clamp for later use.
2-3.2 For Applications with a Boost Pressure Control Solenoid Valve 1
Before Installation (Factory Connection Layout)
After Installation
6mm Hose
Turbine
Actuator
Boost Control
Solenoid Valve
Compressor
Airflow Meter
Throttle Valve
Air Cleaner
Surge
Tank
Fuel Regulator
6mm Hose
4mm Hose
4-4-4mm T-fitting
6mm Hose
Turbine
Actuator
Boost Control
Solenoid Valve Compressor
Airflow Meter
Throttle Valve
Air Cleaner
Surge
Tank
Fuel Regulator
Rubber Cap
Rubber Cap
٨
For vehicles equipped with a boost pressure control solenoid valve, disconnect the connector
and hose to deactivate this function.
Vacuum Filter
%1/
Valve
㧙㧙
Remove the cap on the NC
terminal. (Ref.2-2)
01
㧙㧙
Before Installation (Factory Connection Layout)
After Installation
2-3.3 For Applications with a Boost Pressure Control Solenoid Valve 2
6mm Hose
Turbine
Actuator
Boost Control
Solenoid Valve
Compressor
Airflow Meter
Throttle Valve
Air Cleaner
Surge
Tank
Fuel Regulator
6mm Hose
4mm Hose
4-4-4mm T-fitting
6mm Hose
Turbine
Actuator
Compressor
Airflow Meter
Throttle Valve
Air Cleaner
Surge
Tank
Fuel Regulator
Rubber Cap
Rubber Cap
Valve
٨For vehicles equipped with a boost pressure control solenoid valve, disconnect the connector
and hose to deactivate the function.
Vacuum
Filter
%1/
01
Remove the cap on the
NC terminal. (Ref.2-2)
Boost Control
Solenoid Valve
㧙㧙
2-4. Installing the Boost Sensor and Solenoid Valve to Poppet Valve Type
Before Installation
After Installation
8mm Hose
Turbine
Compressor
Airflow Meter
Throttle Valve
Air Cleaner
Surge
Tank
Fuel Regulator
6mm Hose
6mm Hose
4mm Hose
4-4-4mm T-fitting
6mm Hose
Turbine
Compressor
Airflow Meter
Throttle Valve
Air Cleaner
Surge
Tank
Fuel Regulator
6-8-6mm T-fitting
Upper Port
Wastegate
Wastegate
Install the fitting
to upper port
㧔Straight or L-shaped㧕
A Poppet Valve Hose Set is required for this installation and is available seperately.
Vacuum Filter
Valve
%1/
0%
Remove the cap on the
NC terminal. (Ref.2-2)
㧙㧙
˴˴˴Remove any oil and/or lubricants on or in the
hose and vacuum filter.
˴˴NOTE
˴˴The position of the fittingԘon the compressor
may vary depending on the vehicle.
FittingԘ
Fitting Ԙ
Cut
5cm
Wastegate
6-8-6mm T-fitting
Use hose clamps when connecting hoses to fittings.
˴˴Use the 6-8-6mm T-fitting and 8mm Hose
Clamp included in the Poppet Valve Hose
Set.
6mm
Vacuum Filter
6mm Hose
Hose
Clamp
0%
6mm Hose
Hose Clamp
6mm Fitting
8mm Fitting
8mm Hose
(1)
Cut the 8mm hose 5cm from the compressor’s
fitting
Ԙ. Remove the remaining 8mm hose
and 8mm fitting from the wastegate.
(2)
Install the 6-8-6mm T-fitting using the 8mm Hose
Clamp.
NOTE
(3)
Connect the T-fitting with the 6mm vacuum filter
to the NC terminal fitting using the 6mm hose
from the Poppet Valve Hose Set
.
ADVICE
(4)
Remove the 8mm fitting from the wastegate, and
install
the 6mm fitting (straight or L-shaped)
included in the Poppet Valve Hose Set.
(5)
Connect the T-fitting to the wastegate using the
provided 6mm hose
.
NOTE
Hose
Clamp
(1) Connect the Solenoid Valve to the Valve Extension Harness. Pull the Valve Extension Harness and
the harness connected to the Boost Sensor from the engine compartment into the vehicle's interior.
(2) Connect the Valve Extension Harness and the Boost Sensor to the Control Unit.
(3) Connect the Display Unit to the Control Unit.
(4) Connect the Power Supply Harness.
Connect the red wire of the Power Supply Harness to a 12V IG (Ignition) using a crimp connector.
a) Reconnect the negative cable to the battery.
b) Turn the ignition on to find the 12V IG wire using a voltage meter.
c) Disconnect the negative cable from the battery. Connect the ground wire to a good chassis
ground.
Remove any paint and/or rust from the surface where the ground wire is connected.
(5) Connect the Power Supply Harness to the Control Unit.
3. Wiring
3-1. Installing the Crimp Connectors
ԘStrip about 5mm of wire insulation.
ԙConnect another wire to the uncovered portion
by twisting the wires together.
ԚCrimp the twisted wires using a crimp connector.
ԛCover the crimp connector and wires with electrical tape
to insulate.
Strip 5mm of insulation.
Twist wires together.
Crimp the wires using
a crimp connector.
Insulate with electrical tape.
3-2. Wiring
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Interior Engine Room Solenoid Valve
Boost Sensor
Display Unit
Control Unit
㧙㧙
NOTE
Power Supply
Harness
Valve Extension
Harness
4. Mounting Components
Display Unit (Back)
4-1. Mounting the Display Unit
4-2. Mounting the Solenoid Valve
(1) Install the Valve Bracket to the Solenoid Valve
using the M4 bolts from the Valve Bracket Set.
(2) Secure the Valve Bracket and the Solenoid Valve
to the vehicle using the Valve Installation Hardware.
˴˴
Double-sided Tape
Valve Bracket
Valve Bracket
Bolt (M4)
Solenoid Valve
Valve Installation
Hardware
4-3. Mounting the Boost Sensor
Boost Sensor
Installation Hardware
Fitting (face downward)
㧙㧙
CAUTION
(1) Remove any dirt, dust and/or oil from the mounting
surface for the Display Unit.
(2) Mount the Display Unit using the double-sided
tape.
Mount the Display Unit in a position lower than eye
level,
or tilted downward for best visibility.
NOTE
Install the Solenoid Valve away from excessive heat
or water/moisture to avoid damage to the valve.
(1) Secure the Boost Sensor to the vehicle using the
Boost Sensor Installation Hardware.
(2) When securing the Boost Sensor, make sure the
fitting faces downward as shown in the diagram.
㧙㧙
4-4. Securing Hoses and Harnesses
5. After Installation
(1) Reinstall all removed factory parts.
(2) Reconnect the negative cable to the battery.
(1) Secure hoses and harnesses using the provided Tie Wraps.
NOTE
Leave some slack for the harnesses and hoses to avoid tension during engine movement.
CONFIRMATION AFTER INSTALLATION
NOTE
Do not raise the engine RPM right after the engine is started. (Let it idle.)
CHECK
CHECK˴˴˴˴˴˴˴˴˴˴˴˴˴˴˴ITEMS TO CHECK
Make sure hoses are routed and connected correctly.
Make sure hoses are not loosened.
Make sure hoses are not damaged.
Make sure hose clamps are tightened.
Make sure all bolts and nuts are tightened securely.
Make sure all installed components do not come in contact with any other parts.
Make sure all installed parts are properly secured.
Make sure wiring is done correctly.
Make sure crimp connectors are connected securely.
Make sure proper crimp connectors are used and crimped securely.
Make sure the installed parts are mounted securely and do not interfere with driving.
Make sure the negative cable terminal is securely attached to the battery.
Make sure the boost pressure control solenoid valve is deactivated.
Check the following after the installation process is complete:
1. Check the following after the installation process is complete:
2. Start the engine and check the following:
˴˴˴˴˴˴˴˴˴˴˴˴˴˴ITEMS TO CHECK
Make sure air is not leaking.
Make sure the RPM rises smoothly after revving the engine 2-3 times while in neutral.
Make sure the installed parts do not come in contact with any other parts.
Make sure there is no excessive stress on hoses and/or harnesses.
Make sure all installed parts have not loosened after stopping the engine.
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