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MegaSquirt MS3 User Manual

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MS3(base)/V3.0 Hardware Guide
Megasquirt-3 Product Range
MS3 1.4.x
Dated: 2016-11-13
Hardware manual covering specific wiring and configuration of your Megaquirt MS3/V30 ECU.
This version of the documentation applies to:
MS3 on a V3.0 mainboard without MS3X as shown above running firmware MS3 1.4.x
See the Setting Up manual for more detail on version numbers.
Does not apply to other Megasquirt products or other firmware versions.
(c) 2014-6 James Murray

Table of Contents

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MegaSquirt MS3 Specifications

General IconGeneral
Clock Speed40 MHz
Real Time ClockYes
Knock Control Channels2
Lambda/Wideband InputYes
EEPROM4 KB
Fuel ControlSequential, semi-sequential, batch
Ignition ControlDistributor, wasted spark, coil-on-plug
CommunicationCAN, USB, RS232
Tuning SoftwareTunerStudio MS
Number of Injector Outputs8
Number of Ignition Outputs8
Number of Digital Inputs16
Number of Analog Inputs8
Data LoggingInternal SD card
Operating Temperature-40°C to 85°C

Summary

Megasquirt V3.0 Hardware Introduction

Emissions Compliance and Disclaimer

Legal and emissions compliance information for the hardware.

Tools Required for Setup

Essential tools needed for Megasquirt installation and configuration.

Manual Usage Guide

Guidance on navigating the manual to understand concepts and wiring for EFI components.

Scope of Advice Excluding MS3X

Clarification on the manual's focus on the MS3/V3.0 mainboard, excluding MS3X functionalities.

Megasquirt System Hardware Overview

System Hardware Overview

General description of the Megasquirt ECU, its function, and component interactions.

Megasquirt Installation Guidelines

Recommendations for installing the Megasquirt unit, considering temperature and environmental protection.

Wiring Harness and I/O Connections

Details on wiring harnesses, crank/cam inputs, sensor inputs, outputs, and tuning interfaces.

Wiring the Megasquirt System

Wiring Best Practices

Guidelines for wiring: wire choice, soldering/crimping, fusing, relay standards, and power routing.

Grounding (Earthing) Schemes

Critical guidance on establishing proper grounding points for reliable sensor readings and system operation.

Core Wiring Diagram and Connections

Diagrams detailing main connections, optional circuits, internal I/O, and the relay board for system integration.

System Inputs

Details on various sensor inputs including Crank/Cam, MAP, IAT/MAT, CLT, TPS, O2, MAF, Flex, and spare ADC inputs.

System Outputs

Information on outputs for Fuel Injectors, Ignition, Fuel Pump, Idle Valve, Tacho, Boost Control, and Alternator.

Ignition System Fundamentals

Ignition System Safety Notes

Important safety precautions regarding the high voltages produced by ignition systems.

Crank and Cam Tach Inputs

Crucial setup for tach inputs; correct installation and configuration are vital for RPM reading and system operation.

Coil Negative Input (Fuel Only)

Obtaining a tach trigger from a single coil's negative terminal for fuel-only installs.

VR (Magnetic) Sensor Input

Wiring and setup for VR sensors, including the conditioner circuit and connecting to Megasquirt's tach-in.

Hall Sensor Input

Guide to Hall effect sensors, typically three-wire, acting as switches to ground with magnetic fields.

Hall / Geartooth / Logic / Optical Sensor

Wiring and configuration for various sensor types including Hall, geartooth, logic, and optical sensors.

5.2.4 Hall Sensor Input (Built-in Pull-up)

Hall sensors with internal pull-up resistors providing 0V or 5V signals, simplifying connection.

5.2.5 Gear-tooth Sensor Input

Using gear-tooth sensors, a variant of Hall sensors, for crank and cam triggering with magnetic built-in capability.

5.2.6 GM LS 24X Crank/Cam Sensors

Specific wiring for GM LS 24X crank and cam sensors, detailing supply voltage and sensor logic.

5.2.7 GM LS 58X Crank/Cam Sensors

Specific wiring for GM LS 58X crank and cam sensors, detailing supply voltage and sensor logic.

5.2.8 Optical Sensor

Guide to optical sensors, acting as switches to ground with light, often requiring a pull-up resistor.

5.2.9 Distributor Points Input

Converting distributor points to a tach input, requiring locking advance and phasing for Megasquirt timing control.

5.2.10 Combined Ignition Module (TFI, EDIS, HEI, GMDIS)

Using ignition modules that combine tach input and coil driving, presenting a digital signal to the Megasquirt.

5.2.11 Nissan CAS / GM Optispark

Connecting Mitsubishi CAS and GM Optispark systems, supporting high-resolution signals for improved ignition accuracy.

5.2.12 4G63 / 6G72

Support for specific CAS types like 4G63 and 6G72 using special decoders for their trigger patterns.

5.2.13 Mitsubishi CAS with Aftermarket Disc

Using aftermarket trigger discs with Mitsubishi CAS for standard patterns, requiring 'Toothed Wheel' mode.

5.2.14 Adding a Cam Sensor Input

Internal modifications to add a cam sensor input for engines requiring dual tach inputs like coil-on-plug ignition.

Building Ignition Outputs

5.3.1 Building Ignition Outputs

Steps for building internal circuits to drive ignition coils, requiring interface circuits for all outputs.

5.3.1.1 High Current Output (One)

Building a single high-current ignition output for directly driving an inductive coil using BIP373.

5.3.1.3 Logic Spark Outputs: FET Driver Method

Circuit for driving logic coils using FET drivers, requiring 'Going High' spark output setting.

5.3.1.4 Logic Spark Outputs: Resistor Method

Simple method for wiring logic outputs using resistors, requiring 'Going Low' spark output setting.

5.3.1.5 Optional DB15 Connector for Spark Outputs

Adding an optional DB15 connector for additional spark outputs when main connector pins are insufficient.

5.3.2 Logic Coils

Directly connecting logic coils that accept 0-5V signals from Megasquirt, containing internal ignition drivers.

LS1 Coil

Wiring and configuration for LS1 coils, advising a 3.5ms dwell and 'Going High' spark output setting.

LS2 Coil

Wiring and configuration for LS2 coils, advising a 3.5ms dwell and 'Going High' spark output setting.

D585 Truck Coil

Pin-out and wiring details for D585 truck coils, requiring a 3.5ms dwell and 'Going High' spark output setting.

General Layout for 4-cyl Coil-on-Plug using LS Coils

Diagram showing the general layout for connecting 4-cylinder coil-on-plug systems using LS coils.

IGN1A Logic Coil

Wiring and pin-out for the IGN1A logic coil, a high-energy aftermarket coil requiring 'Going High' spark output.

0 004- 402 001 - Single Logic Coil

Pin-out and wiring for a single logic coil used with distributors, requiring 'Going High' spark output.

032 905 106B - 4 Tower Wasted Spark Logic Coil

Wiring for a 4-tower wasted spark logic coil, common in VAG vehicles, requiring 'Going High' spark output.

06A905097 - 4 Way Logic Coil

Pin-out and wiring for a 4-way logic coil from VW/Jetta/Skoda, requiring 'Going High' spark output.

06B 905 115 - 4 Wire Logic COP

Wiring for 4-wire logic COPs, specifying dwell times and requiring 'Going High' spark output.

5.3.3 Ignition Amplifiers and Modules

Using ignition amplifier modules to drive high-current coils, keeping ignition noise outside the Megasquirt.

5.3.4 High Current Coils

Information on high-current coils requiring ignitors or custom drivers.

5.3.5 CDI Modules

Connecting CDI modules using a 'white wire' trigger input for ignition control.

5.3.6 Mazda Rotary Ignition Wiring

Ignition support modes for Mazda rotary engines (FC, FD, RX8).

5.3.7 Toyota DLI Ignition Wiring

Wiring Toyota DLI systems using multiplexed signaling, requiring specific software settings.

Ignition System Specific Operating Modes

6.1 Coil Negative Input (Fuel Only)

Using a coil negative trigger for fuel-only installs, not suitable for wasted spark or CDI coils.

6.2 Distributor Pickup Types

Traditional distributor methods for spark timing, including mechanical/vacuum advance and breakerless systems.

6.2.2 Distributor Input Phasing

Configuring distributor input phasing, locking advance mechanisms, and the recommendation for crank trigger wheels.

6.2.3 Rotor / Output Phasing - All Distributor Installs

Critical step of rotor phasing to prevent cross-firing and ensure proper engine operation.

6.2.4 Distributor with Hall/Optical Trigger Return

Using trigger return mode for accurate timing with both edges of a vane/slot.

6.2.5 Distributor with Basic Crank Trigger

Using a flying magnet crank trigger for improved ignition control, eliminating distributor slop.

6.2.6 Distributor with Crank Trigger Wheel

Preferred method using a trigger wheel on the crank for accurate ignition control.

6.3 Ford TFI Module

Details on Ford TFI modules, focusing on PIP and SPOUT connections for ignition control.

6.4 GM HEI7 Ignition System

Wiring and configuration for GM HEI7 distributors designed for computer timing control.

6.5 GM HEI8 Ignition System

Similar to HEI7 but with different packaging; requires same internal modifications for ignition control.

6.6 Dual Sync Distributor

Using aftermarket dual-sync distributors for clean trigger signals.

6.7 Ford EDIS System

Overview of the Ford EDIS system, its components, and ECU wiring.

6.7.4 36-1 Trigger Wheel and VR Sensor

Critical phasing relationship between VR sensor and missing tooth for EDIS module operation.

6.7.5 Checking Timing with EDIS

Procedure for confirming ignition timing with EDIS, including limp home mode and fixed timing checks.

6.8 GM DIS (Reference Only)

Comparison of GM DIS ignition to HEI7, noting ECU does not receive cylinder ID or phase info.

6.9 Toothed Wheel Triggering

Support for various trigger wheel combinations and their compatibility with Megasquirt spark modes.

6.9.1 Wheel Combinations and Naming

Common trigger wheel configurations and their naming conventions.

6.9.6 Missing Tooth Crank Wheel

Common configurations for wasted spark using 36-1 or 60-2 crank wheels.

6.9.7 Missing Tooth Cam Wheel

Using missing tooth cam wheels for sequential triggering, noting accuracy limitations.

6.9.8 Missing Tooth Crank/Single Tooth Cam Wheel

Common arrangement supporting full sequential and COP, using missing tooth crank and single tooth cam.

6.9.9 Missing Tooth Crank Wheel and Polled Cam Wheel

Arrangement using missing tooth crank and polled cam wheels for full sequential triggering.

6.9.10 Nippondenso CAS

Connecting Nippondenso CAS for sequential and COP/wasted spark.

6.9.12 Mitsubishi CAS with Aftermarket Disc - Single Coil / Wasted Spark

Using aftermarket discs with Mitsubishi CAS for single coil/wasted spark.

6.9.13 Mitsubishi CAS with Aftermarket Disc - Coil-on-Plug

Wiring Mitsubishi CAS with aftermarket discs for coil-on-plug, requiring cam input.

6.9.14 Other Wheel Arrangements

General principles for applying trigger wheel configurations not explicitly covered.

6.9.15 Ford Zetec Example

Wiring and configuration for Ford Zetec engines using 36-1 crank wheel.

6.10 Neon/420A Ignition Mode

Crank and cam signal patterns for Chrysler Neon/420A engines.

6.11 36-2+2 (NGC) Ignition Mode

Chrysler's 'next gen crank' pattern for consolidating crank/cam patterns.

6.12 36-2-2-2 Ignition Mode

Mode for Subaru and Mazda RX8 engines with stock trigger wheels.

6.13 Miata 99-05 Ignition Mode

Miata 99-05 ignition setup using low-resolution crank and camshaft teeth.

6.14 Subaru 6/7 Ignition Mode

Mode for Subaru EJ series engines with unique 6/7 trigger.

6.15 6G72 Ignition Mode

Applications for Mitsubishi 6G72 engines, using optical CAS.

6.16 IAW Weber Ignition Mode

Application for Ford Sierra Cosworth and Fiat/Lancia engines.

6.17 Mitsubishi CAS 4/1

Connecting Mitsubishi CAS 4/1 with optical distributors.

6.18 Mitsubishi 4G63 (and Miata)

Wiring for Mitsubishi 4G63 engines with distributorless ignition.

Mazda MX5 Miata CAS (1990-1997)

Using Mitsubishi optical CAS on 2G 4G63 and pre-1999 Miata.

Twin Trigger Ignition Mode

Mode for 4-cylinder bike engines with single tooth and two pickup coils.

Chrysler 2.2/2.5 Ignition Mode

Unique setup for Chrysler 2.2/2.5 engines using 4-tooth cam trigger.

Renix 44-2-2 (66-2-2-2) Ignition Mode

Trigger mode for Renault/Jeep engines requiring cam sensor.

Suzuki Swift Ignition Mode

Suzuki Swift engines with distributors, VR sensors, and irregularly spaced teeth.

Suzuki Vitara 2.0 Ignition Mode

Vitara 2.0 variant using an uneven crank wheel with eleven teeth.

Daihatsu 3cyl Ignition Mode

Experimental mode for Daihatsu 3-cylinder engines with distributor trigger.

Daihatsu 4cyl Ignition Mode

Experimental mode for Daihatsu 4-cylinder engines with distributor trigger.

VTR1000 Ignition Mode

Honda V-twin motorcycles using 12-3 crank trigger with VR sensor.

Rover#1 Ignition Mode

Rover K-series engines with 36-tooth crank trigger and two 1-tooth gaps.

Rover#2 Ignition Mode

Rover K-series engines with 36-tooth crank trigger and four 1-tooth gaps.

Rover#3 Ignition Mode

Rover K-series engines with differently positioned gaps.

GM7X Ignition Mode

GM 7X trigger wheel system with six equally spaced teeth and a seventh for cylinder ID.

QR25DE Ignition Mode

Nissan QR25DE engines requiring crank and cam sensors.

Honda RC51 Ignition Mode

Honda RC51/RC46/FSC600/CBR variants using 12-tooth crank and 3-tooth cam triggers.

GM LS1 (24X) Ignition Mode

Chevrolet LS1 V8s using a 24X crank pattern.

GM LS2 (58X) Ignition Mode

Chevrolet LS2 V8s using a 58X crank pattern.

YZF1000 Ignition Mode

Yamaha YZF1000/FZR models using 60-tooth crank and 2-missing teeth.

HD 32-2 Ignition Mode

Harley Davidson with 32-2 crank trigger, using VR sensor and MAP.

Miata 36-2 Ignition Mode

Miata 99-05 with aftermarket 36-2 crank trigger, requiring VR sensors.

Fiat 1.8 16V Ignition Mode

Fiat 1.8 16V engines using irregular 6-tooth crank and 3-tooth cam triggers.

GM Optispark Ignition Mode

GM Optispark system using optical triggers, supporting sequential fuel and single coil.

Throttles and Airflow Control

Optional Hardware and Example Wiring

Optional Expansion Boards

Add-on boards for increased inputs/outputs and CAN communications.

Nitrous System Example Wiring

Typical wiring for a wet nitrous system using specific Megasquirt pins.

Junkyard Guide to Finding EDIS Components

North America: EDIS4 Components

Guide to locating EDIS4 modules and VR sensors in Ford Escort/Mercury Tracer.

Europe: EDIS4 Components

Identifying EDIS4 modules in European Ford vehicles.

Europe: EDIS6 Components

Locating EDIS6 modules in European Ford Mondeo V6 and Scorpio.

Europe: 36-1 Trigger Disc

Sourcing 36-1 trigger discs from Ford Sierra or aftermarket suppliers.

V3.0 Board Assembly Guide

Board Assembly Introduction

Introduction to DIY soldering, required tools, and component handling for the V3.0 mainboard.

Build Choices Affecting Functionality

Key build choices like spark drivers, PWM idle support, and cam input circuits.

Mainboard Assembly Steps

Step-by-step guide to assembling the Megasquirt V3.0 board, assuming basic soldering skills.

Bill of Materials (Parts List)

List of parts used to assemble the V3.0 main board, with quantities, references, and descriptions.

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