Project COBRA'33 Project COBRA'33
TEST & TUNE
Project COBRA'33 is a huge project, and one that will test the ability of all who work on it. One area in particular that warrants great concern, is the "State of Tune" the engine will be in. We will be changing many parts on our Ford 4.6L DOHC '04 Cobra engine, and most of them will require a change in the Engine Management Computer. Because of the quantity of changes and the potential for error, we will enlist the aid of Innovate Motor-sports and there wide variety of quality testing equipment. Innovate Motor-sports develops, manufactures, and supports universal digital tuning tools, including wide-band air/fuel ratio meters, gages, and data acquisitions systems. All Innovate products are completely modular, enabling us to build the perfect tuning system for our needs. The MTS is scalable, and all components share a common digital communications protocol.
What we will be using:
LC-1 Wide-band Controller
Key Features
We will be using two (2) of the LC-1's to monitor the O2 readings on both sides of the engine, they will be mounted in the collectors of the headers. These two (2) Wide-Band O2 Sensors will be in addition to the two(2) stock Bosch Narrow Band factory O2 Sensors which will also be mounted in the collector of each header. I will do this to keep the Engine Management System separate from the Tuning System.
The Wide Band O2 Sensors will aid us in achieving the proper tuning of the Air/Fuel system. With so many changes being made to the engine, our stock fuel tables are of no use, and even though we have revised fueling tables provided to us by The Detail Zone, the same people that re-programed our ECM, the Wide-Band O2 Sensor will help us fine tune those settings and hopefully stay out of any Air/Fuel related troubles.
LMA-3 Multi-sensor Device (Aux Box)
Key Features
The Aux Box attach's to the auxiliary input of the LM-1 or it can be integrated into the MTS serial chain. The Aux Box has 5 built-in sensors. The 5 internal sensors are:(1) Manifold Air Pressure (2)(MAP or Boost), (3)Cylinder Head Temperature (CHT) or Exhaust Gas Temperature (EGT), RPM conversion (from a tach signal or inductive clamp), (4) Acceleration, and (5) Injector Duty Cycle (or Dwell). The internal MAP sensor is a 3-bar absolute pressure sensor, providing accurate data up to 44.1 PSIA. The temperature measurement circuit features a K-type thermocouple. The internal accelerometer features 2 axis measurements for a variety of mounting options. The Aux Box also includes 5 external inputs for connecting external sensors in lieu of the internal sensors. This allows users to log data from external sensors like TPS or suspension data.
TC-4
(4 Channel Thermocouple Interface)
The TC-4 device is 4 Channel Thermocouple interface device for the MTS (Modular Tuning System). The TC-4 may be used as a stand-alone 4 channel thermocouple amplifier for logging directly into Log-Works or it can be used in conjunction with any other MTS compliant device to retrieve key temperature metrics.
Each of the four inputs of the TC-4 can be configured by the user for either EGT range (32-1999 deg F, 0-1093 deg C)to measure Exhaust Gas Temperature or for CHT range to measure Cylinder Head Temperatures (32-572 deg F, 0-300 deg C). The TC-4 can also be used to measure other temperature metrics such as turbo inlet and outlet temp, catalytic converter temp, transmission temp, and more.
The TC-4 is also a key component of Innovate Motor-sports' Modular Tuning System (MTS). Using the TC-4's serial ports you can daisy-chain other Innovate devices such as the XD-16, Aux Box (LMA-3), LC-1, DL-32, and SSI-4. We will use the TC-4 to configure our 2-Cylinder Head Temperature probes and our 2-Exhaust Gas Temperature probes.
XD-16: Universal Gauge System
The XD-16 ships as an Air/Fuel Ratio gauge, but can also be configured to display any channel in the MTS chain or it can be connected to the LM-1. The XD-16 features programmable LED colors and a remote control button to start and stop log sessions, initiate calibrations, or view min/max values.
Key Features
DL-32 Data-logger and Sensor Controller - P/N: 3782
The DL-32 is a complete vehicle-mounted data-logging system for advanced engine tuning. The system is anchored by Innovate's award-winning digital wide-band air/fuel ratio technology, but also includes flexible sensors for ROM, MAP, temperature, duty cycle, and analog inputs.
Key Features
32 channels of data recording
17 Minutes of recording per MB of SD card capacity
Horsepower and Torque calculation
1-bar to 3-bar pressure sensor (MAP, Vacuum, Boost, etc.)
Thermocouple amplifier (EGT, CHT)
Duty cycle (dwell) or frequency
2-axis accelerometer (acceleration Gs, braking Gs, and cornering Gs)
Ignition timing sensor
RPM input
5V power supply for external sensors
3 solenoid/relay outputs
Expansion ports for future upgrade ability
MTS compliant
The DL-32 is also a key component of Innovate Motor-sports' Modular Tuning System (MTS). Using the LC-1's serial ports you can daisy-chain other Innovate devices such as the XD-16, Aux Box (LMA-3), LC-1, TC-4, and SSI-4
The DL-32 will be used to anchor the on-board diagnostics of the Innovate Motor-sports systAux Boxem.
A List Of Accessories Needed for Complete Monitoring
0-100, PSI Sensor - #RTD-WB-762
We will use three (3) of these RTD-WB-762 Pressure Sensors to fully monitor the "Terminator" engine. 1. Will be used to monitor Engine Oil Pressure. 2. To monitor the Fuel Pressure. 3. To Monitor the Boost Pressure. These pressure sensors come in many different pressure ratings, for 50psi all the way up to 2500psi. We will be using the 0-100psi sensors.
EGT Probe (Type K) - #RTD-TE-104SH
Project COBRA'33 will use two (2) EGT Probes to monitor the Exhaust Gas Temperature at both the collectors, which are located at the end of each header. These are all Stainless Steel. While the EGT Probes we will be using are the threaded type that require us to weld in EGT Bungs, they do make some that simply clamp-on to the exhaust, as well as the threaded type but not Stainless Steel.
Cylinder Head Temperature Sensors
Two (2) will be used , one on each head. These sensors will simply bolt-on to the cylinder heads, using a valve cover stud or intake manifold stud to secure the sensor. Knowing the cylinder head temperature will give us another look at what is happening inside the engine.
Liquid/Air Temp Sensor (Type K) - #RTD-TE-203H
We will use three (3) of these Liquid/Air Temperature probes for 1. Engine Oil Temperature, 2. Inter-cooler Water Temperature (which will tell us intake air temperature) 3. Transmission Oil Temperature. Yes we do have gages that tell us the same thing, and they are very important by keeping us informed while we are driving along. But we use the sensors to record what is happening so later we can over-lay all the findings and see the whole picture.
Linear Travel Sensor 0-10" String Pot - #RTD-S-201
This linear Travel Sensor will be used to measure and record throttle position. It will allow us to later over lay the throttle position, in relation to RPM, EGT,and everything else we can measure. These Linear sensors are extremely important for race teams that need to monitor suspension travel, be it road racing or off-road racers.
RPM Converter (LMA-2) - P/N: 3726
Innovates
Used to upgrade Aux Box tach signal on vehicles with no distributor or ignition box, simply clamp on to the number one plug wire.
USB to Serial Adapter - P/N: 3733
Allows you to hook-up to your laptop computer when there is no serial connector available. Adapter for computers without Serial ports. This cable will convert Serial to USB.
System Configuration
The following is a representation of what we need to have in order to monitor all the areas mentioned. As you can see the list of parts is not only lengthy, but very, very expensive. But then again, how much would it cost to buy another new 2004 Ford 4.6L DOHC Cobra engine?
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