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Home arrow Project Red GT arrow Project Blog entry for Jeff & Cal's red Mustang GT arrow Red GT - AEM Series 2 Install
Red GT - AEM Series 2 Install PDF Print E-mail
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Written by Trever   
Jan 17, 2011 at 06:16 AM
AEM Series 2 30-6050 and Universal Harness
AEM Series 2 Box converted over to run a Ford Small Block
 
Last year we had some electrical gremlins we could never figure out.  We had gone through the harness, checked grounds, pulled our hair out...  After confiding in me that he was thinking of joining Hair Club for Men, Cal sold the AEM 30-1400 box that had been running the car and evaluated every aftermarket EMS under the sun, only to return back to AEM and their Series 2 EMS.  Problem with that is that they don't yet have a Mustang specific Plug & Play EMS...  So what do you do then?  Click through to read on and find out what we're up to.

First, how about a little background on this project:
We gave careful consideration to about 4 or 5 different engine management systems available out there.  There are some really cool sounding systems from Holley, FAST's XFI 2.0, Pro-Tuner EFI, etc...  We looked at all of them, compared features, pricing, capabilities, downfalls, etc.  When it came down to it, the AEM Series 2 was a bargain compared to the others.  It's lacking some things the others have like low-impedence drivers and integrated UEGO drivers, but we already had 2 UEGO drivers and high flow high impedence injectors are becoming pretty common and affordable.  The AEM excelled with its boost and traction control, and things like Boost Compensation tuning should make tuning easier with a turbo motor.

 But...  AEM didn't make a Plug & Play Mustang EMS -or- a Universal race EMS like the 30-1900U box I have on my Fairmont.  We could have taken the Mustang engine harness for a small block Ford and hacked the ECU connector off and mated the connectors for an application specific EMS, but then we'd be connecting a state of the art EMS to a 20 year old engine harness.  Ideal?  No...  AEM sells a Universal race harness that retails for around $600.  Only problem there is that the Universal race harness won't mate to any of the Series 2 boxes.  However, they sell a "Plug and Pin" kit for each flavor of EMS they sell.

So, we settled on the AEM Series 2 Honda EMS (30-6050), the corresponding Plug & Pin kit for a Honda EMS (35-2610), and the Universal race harness with 72" leads and integral relay & fuse box (30-2900-72).  Throw them into a box, shake them up, and you almost get a AEM Series 2 Universal race EMS!

Now that that's out of the way, onto the pictures and descriptions of how we're making this work.

AEM Series 2 parts in a box
We received our AEM Series 2 30-6050, 72 inch harness, 2x 100 psi pressure sensors for fuel & oil pressure and a 3.5 bar MAP sensor.

30-6050 and race harness
Here is the EMS and race harness laid out next to each other. The race harness is a good place to start. All the wiring is new, so we'll be starting out fresh and not with 20 year old wiring. It also has the correct fuses and relays for things like fans, fuel pumps and the main EMS relay. All of the leads are gauged accordingly to their load capacity, so no weight is lost through oversized wires.

AEM Race Harness Wire Bundle label
A nice thing about the race harness is that the wires come bundled together according to its use. Both ground and power wires will be bundled together if they're needed as well as signal wires in the case of sensors.

AEM Race Harness silk screen
In the photo above you can see the silk screening on the injector wires. Each wire is labeled according to its purpose. In this case it's "INJ 1".

Series 2 EMS and fuse & relay panel
Here is a close-up of the Series 2 and fuse box and relays.

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The connector end of the Honda 30-6050 is recessed into the box. This saves space over the Mustang Plug and Play EMS and makes the box a little more robust. The Series 2 box is also about 1/2 inch thinner than the original Mustang plug & play EMS which would make it easier to fit into the Mustang's kickpanel.

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The connector end of the box has both serial and USB data ports. USB is a welcome addition since serial ports are a little flaky under modern operating systems.

AEM 30-6050 EMS disassembled
Since this box will not be used in a Honda application, some jumper settings needed to be made. The Series 2 box has 8 onboard coil drivers, but only 4 are enabled from the factory (to clarify that, you can drive 8 coils with ignitors or 4 dumb coils). Jumpers are changed to enable them. I also had to change jumper settings around for the cam and crank pickup.

Dissecting the AEM Universal Race Harness
There are SEVERAL wires in the Universal harness that were unnecessary for our application. I re-pinned the Universal harness using the Honda connectors from the Plug & Pin kit and only brought over leads that I knew would be used. This resulted in about a 40% reduction in the number of leads we'll actually use. This was probably the most time consuming part so far.

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The number of wires not used is fairly substantial!

 That's where this part of the project stands so far.  The harness looks like the first picture at the top of this post and interfaces with the Honda EMS.  Next we'll be terminating each lead to the sensors.  We've purchased new connectors/sensors for just about everything.  Reliability is the goal here.  We'll post up some more pics as the rest of the harness shapes up in coming weeks.

Last Updated ( Jan 18, 2011 at 06:26 PM )
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