Purple Garage: Deep Orange 3 ECU Reset and Setup on Mazda Concept Car
Project Background
Deep Orange is vehicle prototype program offered through the Department of Automotive Engineering at Clemson for masters students. It is an 18 month project that works with industry partner and produced prototype vehicles to make the student more prepared to work at OEMs.
Deep Orange 3 was designed as a blank sheet fully functional hybrid mainstream sports car targeted towards Generation Y. This project was in partnership with Mazda and had the Art Center College of Design as styling partner who also made the body. DO3 was completed in 2013 then was used to showcase what the program was able to do before it moved between storage and display until it was inherited for by The Purple Garage to bring it back to life for showcases and events.
While DO3 would start and run, the ECU was password locked so we were unable to further tune it. Unable to find, guess, or reach out to anyone who knew the password, it was decided to wipe the ECU and start from scratch.
Deep Orange 3 Details
Created: 2013
Body Layout: 4 Door Hatchback
Powertrain: Mazda Turbo 4 -Cylinder with a through-the-road Parallel Hybrid powering rear axle
Transmission: 6 Speed Manual
Features Removed for Complexity and Maintenance Upkeep:
Hybrid Powertrain and Batteries
Project Details / Methods
Project Objectives:
Reset AEM ECU and build engine maps using AEM manual and engine knowledge
Figure out engine timing method
Set engine start map
Get car to idle
Set base tune to be able to be able to drive around the block
Take on Dynamometer and tune MAP and Ignition Timing Map
Methods:
Use similar 1.6L Turbo Honda Civic engine map as base on AEM software
Read through Mazda engine maintenance manual to figure out key attributes
Number of teeth and Timing Teeth on Flywheel
Firing Order and Cylinder Numbers
Extract Spark Plugs and take slow motion video of engine trying to crank
Allows us to define where top dead center is, should be sparking near top dead center
Will be able to figure out which cycle the engine is by the way it run when trying to start
Adjust Ignition Timing once car is off its start map to allow car to idle nicely
Rev car and take data logs to see discrepancies between ECU Lambda values and O2 sensor Lambda values
Project Progress (On Going)
Project Successes
Set engine parameters in AEM ECU allowing DO3 to start and idle
Adjust ignition timing during idle for smoother idle and start up
Make base tune for car to be able drive around the block (private road)
Project Setbacks and Still Need to Complete
Alternator needs to be replaced
Internal regulator of alternator was damaged while troubleshooting battery charging issues
Brakes need to be inspected and likely replace fluid and bleed system
Brake pedal is very squishy and the system hasn’t been serviced since it was completed (2013)
Take car on Chassis Dynamometer and sweep through engine map to tune MAP values
Make engine run better and increase power
Decrease emissions by running having a stoichiometric combustion (allows for 3 way catalyst to work properly)
Adjust suspension set up
Wheels rub at full steering lock
