To effectively troubleshoot complex engine control systems, you need to have the right test equipment. Our customers often ask us to recommend equipment and suppliers. We have compiled a list of what we believe are the most cost effective choices. Warning: the Snap-on and Mac Tools guys will hate you if you read on.

Laptop PC 

A reliable laptop PC will be your most important tool for EFI remapping and tuning. New models lack the 9-pin serial port required to interface to some devices, including the WEGO units sold by Daytona Sensors and the Screamin' Eagle^® Race Tuner. If you have a device that uses the 9-pin serial port, you will require a USB adapter such as our P/N USBG-232 (see our PC Link Tech FAQ for details). We have used numerous Dell laptops and desktops for many years with an excellent track record of reliability (zero failures excluding battery packs). The new Dell Inspiron 1501 is a good choice. A typical system (including basic options such as a DVD drive and nylon carrying case) costs under $1000. Order Dell systems on-line at www.dell.com.

Dell Inspiron 1501

Scope Meter 

The days of the troubleshooting with a basic DVM (digital voltmeter) have come to an end. In many cases, you can’t identify and fix problems without being able to observe signal waveforms. To do this, you need a scope meter. You can buy high priced scope meters from Tektronix and Fluke starting at about $1200.00. A new low cost scope meter with all the features you will ever need for troubleshooting is now available from Seintek. 

Seintek S2405 Two Channel Scope Meter

Seintek S2405 Two Channel Scope Meter Data Sheet

We use the Seintek S2405 for some of our own work and highly recommend it. The two channel capability is very useful for comparing signals. It comes with a carrying case, rechargeable batteries, and a PC link that allows you to download waveforms to your laptop. If you have a strange looking sensor signal, you can email the waveform to us. Circuit Specialists sells this unit for $299.00. Circuit Specialists can be reached at 800-528-1417 or www.circuitspecialists.com

Insulation Piercing Test Clips 

Now that you have a scope meter, you need some means of probing signals. You can go out and buy some breakout boxes (for example the Kent-Moore units available for H-D^® ECMs). An alternate technique is to use insulation piercing test clips. Once you use these, you will wonder how you ever got along without them. The best type is the Pomona 6405. These lock onto the wire.   

Pomona 6405 Test Clip Set

Pomona Test Clip Data Sheet

A set of the Pomona test clips is available from Newark as their P/N 23C2020. They also sell extended reach versions (refer to the data sheet). You will also need a set of test leads with banana plugs to connect the insulation piercing test clips to the scope meter. These are also available from Newark as P/N 34F850 (36” red) and 34F851 (36” black). The test clips and leads together will cost about $50.00. Newark can be reached at 800-463-9275 or www.newark.com.

Current Probe 

While we are on the subject of probing signals, you may also come across a need to measure current, i.e. to diagnose charging system and starter problems or observe ignition coil or injector driver waveforms. In many situations, looking at a current signal provides more information than looking at the voltage. You can readily identify a defective coil or injector winding by looking at the current. The easiest way to do this is a clamp-on adapter that connects to the scope meter. You don't have to break or tap into any connections, just clamp the adapter around the wire. We use the Extech 380945 and 380946. The 380945 has a 0-200A range and is ideal for charging and starting system diagnostics. The 380946 has a 0-30 amp range (and better resolution for small currents) and is ideal for looking at actuator drive signals. You could also use it to diagnose lighting and accessory circuits.

 

Extech Clamp-on Current Probes

Extech Clamp-on Current Probe Data Sheet

The Extech 380945 ($149.00) and 380946 ($229.00) are available from the Test Equipment Depot at 800-517-8431 or www.testequipmentdepot.com.

IR Thermometer 

IR thermometers are not new, but prices have been dropping rapidly. The newer units include a laser pointer that shows the measurement area. Every shop needs one of these. You can use it to measure just about any temperature. We use an IR thermometer to measure cylinder head and exhaust temperatures during dyno tests.

Extech 42529 IR Thermometer with Laser Pointer

Extech 42529 Data Sheet

The best value we have been able to find is the Extech 42529 that sells for $89.00 and is available from Extech Direct at 800-899-2241 or www.extech-direct.com. Extech manufactures a wide range of cost effective test equipment, including a variety of other IR thermometers. We suggest you visit their website at www.extech.com.

3-In-1 Humidity, Temperature, and Airflow Meter 

No dyno lab should be without this new instrument that is also available from Extech. 

Extech 45160 3-In-1 Humidity, Temperature, and Airflow Meter

Extech 45160 Data Sheet

The Extech 45160 sells for $149.00 and is available from Extech Direct at 800-899-2241 or www.extech-direct.com. Extech manufactures a wide range of cost effective test equipment, including a variety of other anemometers and flow meters. We suggest you visit their website at www.extech.com.

 

Mixed Signal Oscilloscope 

Some of our more sophisticated customers have expressed an interest in high-end test equipment for R&D and diagnostics. The Agilent (formerly Hewlett-Packard) 54600 series mixed signal oscilloscopes represent the current state-of-the-art. We use the 54622D in our own lab and have found it to be an invaluable piece of equipment. This unit can monitor 2 analog and 16 digital signals and has extensive triggering capabilities, including the capability to trigger on glitches and signal patterns. Triggering on a signal pattern allows you to quickly capture data that would otherwise be almost impossible. With 4 MB memory, it can capture a long waveform and then allow you to zoom in to view details. For example, you can capture 10-15 seconds of data after an engine is started and then look at two analog signals, like MAP and a coil drive, and several digital signals, such as injector drive, on an individual cylinder firing basis. The built-in floppy disk drive allows you to transfer data to your PC for printing hardcopy or further analysis.   

Agilent 54622D Mixed Signal Oscilloscope

Agilent 54622D Data Sheet

 

The 54622D retails for about $5,350 and is available from most major electronics equipment suppliers, including Newark at www.newark.com and Test Equity www.testequity.com.

Books and Reference Materials 

Every day we encounter people that claim to be experienced engine builders and tuners, yet from their questions, they clearly lack a basic understanding of engine theory and operation. You can't tune an engine if you have no understanding of the underlying mechanical and thermodynamic principles. A basic reference library of technical books is just as important as a well equipped tool box. If you are not spending as much on books and seminars as you are on tools, you will have trouble keeping up within rapid pace of technological advances. We have listed a few suggested volumes that you are will find on the bookshelf of any professional automotive engineer.

Internal Combustion Engine Fundamentals by J. B. Heywood

The Internal Combustion Engine in Theory and Practice (two volume set) by C.F. Taylor

Advanced Engine Technology by H. Heisler

Vehicle and Engine Technology by H. Heisler

Engines - An Introduction by J.L. Lumley

Design Techniques for Engine Manifolds by D.E. Winterbone

Engine Testing Theory and Practice by Plint & Martyr

Design and Simulation of Four-Stroke Engines by G.P. Blair

Automotive Electronics Handbook (2nd Edition) by R.K. Jurgen

Introduction to Modeling and Control of Internal Combustion Engine Systems by L. Guzzella and C.H. Onder

Automotive Control Systems by U. Kiencke and L. Nielsen

Introduction to Internal Combustion Engines by Richard Sone

Critical Topics in Exhaust Gas Aftertreatment by Peter Eastwood

The High Speed Internal Combustion Engine by Sir Harry Ricardo (historical reference)

 

Most of these books are available at Amazon (www.amazon.com)  or from the SAE (Society of Automotive Engineers) book store (store.sae.org). The SAE offers a wide range of books and reprints of technical papers on automotive topics. They also offer excellent seminars on automotive technology.  We suggest that you visit their website at www.sae.org. 

  

Suppliers 

Our customers often ask us where they can source electronic components, connectors, mechanical parts, and tools. We have listed some of the major industry suppliers. 

Electronic Components

Supplier	Phone	Website
Digi-Key	1-800-344-4539	www.digi-key.com
Mouser	1-800-346-6873	www.mouser.com
Newark	1-800-463-9275	www.newarkinone.com

 

Connectors (minimum quantity orders required - no online ordering)

Supplier	Phone	Website
Ladd Industries (Deutsch)	1-800-223-1236	www.laddinc.com
Power & Signal Group (Packard/Delphi)	1-216-378-6116	www.powerandsignal.com

 

Hardware, Materials, and MRO

Supplier	Phone	Website
McMaster-Carr	1-630-833-0300	www.mcmaster.com
MSC Industrial Supply	1-800-645-7270	www1.mscdirect.com

 

Precision and Electronic Tools

Supplier	Phone	Website
Contact East	1-800-225-5370	www.contacteast.com
Jensen	1-800-426-1194	www.jensentools.com
Techni-Tool	1-800-832-4866	www.techni-tool.com
ENCO (also MRO parts and machine tools)	1-800-873-3626	www.use-enco.com