Archived Knowledge Base articles from T.I. Performance.

J3 Chip Installation Instructions

This guide describes how to install a T.I. Performance J3 Chip into your ECU.

Please take the time to read this guide completely. Follow all the steps to ensure trouble free operation of your chip. Most problems can be traced to not following the instructions!

Required Tools: Philips Head Screwdriver, Flat Blade Screwdriver, 10mm socket, 7mm socket, 600 grit sandpaper, Methylated Spirits.

J3 Chip Installation Steps

  1. Remove the passenger side kick panel and unscrew the ECU retaining bracket. In AU vehicles, this bracket is riveted in. You will need to drill/punch out the rivet, which can be replaced with a screw.
  2. Unbolt the ECU connector using a 10mm socket and remove the ECU from the car. Pry off the cap which covers the J3 port on the bottom of the ECU. Note on EB-ED V8 ECUs there is a screw and sticker which must be removed.
  3. Remove the 6 bolts around the edges of the ECU to remove the ECU covers and allow proper access to the port on both sides. The back cover may require a tap to remove.
  1. Wipe off the white paste (where present) with a rag and methylated spirits or isopropyl alcohol.
  2. Using a 3-4mm flat bladed screwdriver, gently scrape off the clear conformal coating from the J3 port terminals by running the screwdriver in the direction of the terminals. Keep scraping up and down until all the clear coating is removed from and in between the terminals. You should be left with a smooth, silver terminal. Repeat this process on the other side of the board.
    • Note: You must do this on both sides of the J3 port. This is the most important step of the process! Failure to follow this step correctly will lead to issues with operation of the chip!
  1. Once you have removed all clear lacquer, use some 600 grit sandpaper and lightly scuff the terminals, no more than 3 or 4 scuffs. Do not over sand, or you will remove the protective silver coloured solder. Finally, give the terminals a clean with some methylated sprits or isopropyl alcohol to remove any oils or residue and ensure the best possible contact.
  1. AU Series 1 only. If your ECU is missing two small black resistors between the pads circled in the picture on the top side of the board, you will need to join the J3 Enable links on the back side of the board as shown in the Figure 4 for the J3 port to detect the Chip.
    • This process will need to be done by someone familiar with soldering components on circuit boards, using a temperature-controlled iron, single strand wire, and flux core solder.
    • Carefully clean the solder pads with 600 grit sandpaper, then use single strand wire to join each horizontal pair as in the bottom half of the image. Do not join the vertical pairs or scratch between the terminals or you could permanently damage the ECU.
    • Tip: Use the Zoom function to see the photos more clearly.
  1. Screw the covers back on the ECU. Hold the ECU with the label and screws facing up and insert the J3 Chip as shown in the picture.
    • Note: Early V8 ECUs will require the tin cover to be cut and a capacitor to be bent over slightly to make room for the J3 Chip.
  1. Use a strip of gaffer or duct tape to secure the chip in place and insulate the open terminals on the bottom of the unit, as shown in the photo on the right. If you don’t have any duct tape, we offer a Clip In J3 Chip Cover that you can 3D print or purchase.
    • Note: This step is essential for reliability. Vibration or movement of J3 Chip while the car is running will cause failure of the chip and/or ECU. Do not leave the Chip unsecured.
  1. Install the ECU back in the car and replace the retaining bracket and kick panel.

Before starting the vehicle

  1. Turn the ignition to on, leaving the engine off. Listen for the fuel pump. You should hear the regular 1 second priming of the fuel pump. If the pump stays on constantly, the car is in LoS mode. Read the Troubleshooting section for how to resolve before attempting to start the car, or it will not run properly.
  2. If you are installing the chip in an AU Falcon, read the Troubleshooting section for AU vehicles before you attempt to start the car.
  3. Start the car and get it to operating temperature. If you have issues with starting, idle, including rev hang, high idle or hunting, see the Troubleshooting section.
  4. Reset your base ignition timing (distributor models) to the factory setting for your ECU in timing/diagnostic mode. This is critical if you have previously dialled in any advance on the distributor, as the tune on your chip assumes factory base timing. Click the link above for more information on how to reset your base timing.

Troubleshooting

  • If the car runs rough or blows black smoke with the chip installed, check whether the fuel pump runs constantly with the Key On Engine Off. This indicates the ECU is in LoS mode. In most cases this is caused by the J3 port not being properly cleaned. Please ensure that you have followed all installation steps correctly, particularly step 5, and then repeat the test.
  • If you have issues with idle (including high idle, low idle, rev hang, hunting or stalling), your base idle will need to be adjusted. With the car at operating temperature, your chip installed and the ISC unplugged, the car should idle between 500-550rpm (or as close as possible when a large camshaft is installed). Adjust the throttle stop screw on the throttle body with a screwdriver to achieve this. You may need to turn this in a couple of screws to get a steady idle with the ISC unplugged. Also check the intake and all hoses thoroughly for vacuum leaks. Modified throttle bodies and leaking intake gaskets are a culprit for leaking air into the manifold, a main cause of high idle, rev hang and hunting.
  • AU Falcon Only: If you fit the chip and your car does not crank, do not attempt to start the vehicle more than 3 times consecutively with the chip installed. Doing so will immobilise the car, which will require an OBD2 Scan tool with Forscan to do a PATS Reset. If the Smartshield hand on the dash is flashing fast, and the car won’t crank with the chip removed, this means the car has been immobilised. The chip can still disable Smartshield once installed properly. Remove the chip and start the car to reset the failure count, then revisit steps 5 and 6 to make sure the J3 port is enabled and clean before trying again.
  • If you still have trouble getting your vehicle running correctly, reply to your order email with:
  • clear photos of your ECU, showing the J3 port itself and the whole ECU, from both sides, with the covers off, and J3 port removed,
    • a clear acknowledgement that you followed these instructions and have read this step,
    • a detailed description of the problem you’re experiencing,
    • what the fuel pump does with the key on engine off, and
    • confirmation that any mods on the car match the tune notes.
EF Fairmont Fuel Gauge

Ford Falcon Fuel Economy Guide

Fuel economy is increasingly an important aspect of motor vehicle ownership. From the sky-rocketing cost of fuel to environmental concerns, its never been more important to maximise your fuel economy.

In this article we’ll lay out some key tips to improve your fuel economy, and make your car go further on a tank of fuel.

General Vehicle Maintenance

Before we get to the engine itself, there are a number of general vehicle maintenance factors that can have an impact on fuel economy and fuel consumption.

Top tips:

  • Your Oxygen Sensor plays a critical role in allowing the ECU to monitor unburnt fuel in the exhaust and trim the fuel map to get the most efficient Air:Fuel Ratio. If your O2 sensor is old, its response can be slow or non-existent and this will result in the car using the default safe and rich fuel map. Replacing your O2 sensor can have a huge improvement on economy.
  • Check that the engine warms up to the correct operating temperature. A stock or cold thermostat will leave the engine running cold, which puts the ECU into cold start enrichment and poor fuel economy. Replace your thermostat with the correct one for your model.
  • Ensure your vehicles sensors are in good condition. Faulty readings from air flow sensors in the intake, temperature sensors for air or coolant can all trigger your car’s ECU to demand more fuel. We have a range of replacement sensors in stock for many models.
  • Check your brakes after a highway drive. If the wheels are excessively hot, your brakes may be dragging and need an adjustment or rebuild.
  • A vehicles weight plays a huge factor in fuel economy. The heavier the vehicle, the more effort required to get it up to speed and keep it there. Remove any unnecessary weight from the vehicle (eg. anything stored in the boot or backseat) and carefully consider any modifications that add excess weight. Common culprits are aftermarket bullbars or heavy car stereo sound systems.
  • Efficient aerodynamics are important to achieving good highway fuel consumption figures. Open windows can create a large amount of drag, as can roof racks, bull bars, trailers etc. If you’re not using them, remove them from your vehicle.
  • Tyres have a huge impact on fuel economy. Ensure they are inflated to the manufacturers specifications and are in good condition. Rolling resistance of tyres also plays a big part. Many 4WD enthusiasts replace their wheels and tyres with a package that is more effective for off-roading, but these changes can result in a much higher rolling resistance and a heavier wheel and tyre combo, both of which contribute to fuel use. Consider where you drive the most and what your needs really are (rather than looking cool at the local Woolies), and optimise your wheel and tyre combo.
Bosch Oxygen / O2 Sensor suit EA EB ED EF EL Falcon XR6 XR8
Bosch Oxygen / O2 Sensor suit EA EB ED EF EL Falcon XR6 XR8

Engine Management and Tuning

A vehicles tune is also an integral aspect to achieving good fuel economy. 

If your car is standard and in good condition, small fuel economy gains can still be made through modifying the tune, especially when running high octane fuels such as 98, E85 or LPG.

If you’ve modified your engine in any way, a good quality tune is critical not only to the safety and performance of your engine but also your fuel economy. A tune whether via a J3 Chip or more advanced engine management like our range of Haltech Aftermarket ECUs products is essential for getting the best results from your engine.

 

J3 Chip & Tuning Products
J3 Chips & Tuning Products

Our J3 Chip opens up access to stock EEC parameters such as:

  • Fuel Stabilised Table which sets the AFR target by load/RPM
  • MFA / Lean Cruise Mode Fuel Multiplier Table which controls what AFR the EEC targets when in cruise mode
  • MPG / Lean Cruise Mode and Normal Mode Spark Table which controls what ignition timing the EEC will use in cruise and normal mode
  • MINPW scaler which controls the lowest allowable pulse width the EEC will command. Use 0 to enable decel injector shut off
  • And many more!

While its impressive to see high peak kilowatt dyno numbers, getting your tuner to focus on driveability will pay off in the long run. This means spending more time on the low load areas of the map optimising fuel and spark where your engine will spend the most time while driving. Efficient air/fuel ratios and optimal ignition advance under low load, cruise, and all the way through the rev range can the achieved with a good tune, and this will maximise fuel economy as well as power.

For more information about achieving a good fuel economy tune, contact us.

Driving style and conditions

Frequently, the biggest variable in a vehicles fuel economy is driving style. Having a heavy right foot can be fun at times, and many of us enjoy listening to our engines hit redline, this will burn fuel more quickly than smooth driving. The smoother you drive, the better your fuel consumption results will be.

Gearing is also important – typically automatic transmissions will select an appropriate ratio , but if you are driving a manual, make sure you’re in the right gear for the speed and conditions and don’t rev your car too high unnecessarily.  

Traffic conditions also play a large part in achieving fuel economy. Short trips and start-stop driving in heavy traffic are both bad for achieving fuel economy and minimising litres per kilometre. 

Top tips:

  • Monitor your fuel economy. Lots of modern vehicles have live fuel economy readouts and if your’s doesn’t, you can measure fuel economy with the odometer and how many litres of fuel you’ve added when filling up. Having awareness of how your driving style effects fuel economy is the first step to changing your driving behaviour to be more frugal.
  • Try to drive as smoothly as possible. Accelerate slowly, anticipate traffic movements & coast to a stop and generally try to minimise jerky throttle applications.
  • Try to minimise short trips – modern vehicles will often have a ‘cold start enrichment’ function which burns more fuel to quickly heat up the catalytic converter to reduce emissions.
  • Try to avoid driving in heavy or stop-start traffic. Your vehicle will use a lot more fuel moving off from a stop as compared to maintaining a consistent speed.
  • Don’t let your car idle for excessive amounts of time.

Summary

This article demonstrates that good fuel economy does not just come from the Engine or ECU. Having a vehicle in good working condition overall will get the best possible economy. Happy driving!

LS Engine Hose Fitting and Bolt Thread Size Guide

We’ve started this guide to capture common thread and fitting sizes on the GM LS1, LS2 and LS3 engine series. If you can help fill it in please contact us.

FittingThread Size
LS Oil FeedM16 x 1.5
LS Thread and Fitting Guide

Electrical Connectors

Part Connector
LS Connectors

If you have any others to add, please contact us!

AU Hybrid Intech vs EL Falcon SOHC Differences and Camshaft Fitment

How do you tell if you have an EL Falcon with a Hybrid AU engine? Know what that means? In this knowledge base article, we explain how to identify a Hybrid head and also which parts work with which engines. Read more

TunerPro Ford Falcon Tuning Screenshot

J3 Chip Transmission Shift Edit & Shift Kit

Using a J3 Chip you can unlock many transmission shift parameters on your 6 cylinder EB-AU Falcon, or V8 AU Falcon.  Through the chip you can edit shift firmness (line pressure), gear change RPM, and even torque convertor lock up.  Read more

Haltech Elite vs Nexus ECU Model Comparison Guide

Choosing the right ECU for your application can be a complex task. They come with a varying range of features, inputs and outputs which you’ll need to map to your combo to pick the right product.

Below is a table comparing the main features of all Haltech Elite and Nexus ECUs. It lists features, inputs & outputs on the Elite 750 through Elite 2500 ECU.

For any more info or to choose the right ECU for your next build, please contact us.

Read more

Tuning an XF Falcon Crossflow 250 with a J3 Chip by converting to EA EB ED EL Falcon EEC-V EFI

A lot of people contact us with Xflow Falcons from the XD, XE and XF range, asking us how to run modern, tunable EFI on these engines cheaply. The good new is it can be done very simply, and our J3 Chip gives full control of the ECU! Read more below.

Read more

GU / GQ Patrol Barra Conversion Tips

This short guide is a collection of tips for people doing Barra conversions to GQ /GU Patrols. We will update the guide as more info comes to light. If you have any tips please contact us!

Read more

Falcon Hose Fitting and Bolt Thread Size Guide

We’ve started this guide to capture common thread and fitting sizes on the Ford Falcon 4L 6 Cylinder SOHC, Barra and V8 models. If you can help fill it in please contact us.

FittingThread Size
EA-AU Falcon 4L Power Steering Pump5/8″-18 Inverted Flare
EA-EL & XG XH Falcon Power Steering Rack Feed Line ThreadM16x1.5 Bump Tube
EA-EL & XG XH Falcon Power Steering Rack Return Line ThreadM18x1.5
EA-AU Falcon Power Steering Pressure Switch3/8″-24 UNF
EA-BF Falcon 4 Speed BTR Auto Transmission Cooler FittingsM16 x 1.5
EA-BF Falcon 4 Speed BTR Torque Convertor Bolts10×1.25 .75″ UHL 171-2801
Fuel Line Quick Release5/16″ Quick Connect
EA-AU Falcon 4L & 5L V8 Engine Coolant Temperature (ECT) Sensor3/8 x 18 NPTF
EA-AU Falcon Oil Feed / Oil Pressure Sensor Thread1/4″ NPT
Use this adapter to add an oil feed and retain the oil pressure sender
EA-AU Flywheel Bolt Thread10mm x 1.25 27mm 73Nm
EA-AU Clutch Pressure Plate Bolts8mm x 1.25 17.3mm 32Nm
XE Falcon Steering Box11/16″-18 Inverted Flare
BA BF FG GT35 Turbo Oil Drain50.8mm / 2″ Flange
BA BF FG GT35 Turbo Oil Supply7/16″-24
BA BF FG GT35 Turbo Water Supply/DrainM14x1.5
EA-FG Live Axle Hard Line Brake Fitting ThreadM10 x 1.0mm
E-Series and AU Falcon Thread and Fitting Guide

Electrical Connectors

Part Connector
AU Falcon InjectorsUSCAR Plug
EA-EL Falcon InjectorsBosch Minitimer Plug
E-Series and AU Falcon Connectors

If you have any others to add, please contact us!

Programming the FG Falcon ABS module for a Turbo conversion

When converting an FG Falcon to run on a Turbo PCM, you will see DTCs from the PCM as the calibration on the ABS unit differs between models.

This guide covers how to reprogram the ABS module to suit the Turbo PCM using Forscan. You must have an Extended Licence, which can be registered for free from Forscan.org.

You’ll also need an OBD2 scan tool — Click here for a low cost VGate Scan Tool that will work with Forscan or for a Tactrix cable that will work with Forscan and PCMTec click here.

Credit to Nigel from CAN Solutions for this guide.

Read more
EB Falcon Diagnostic Connector

How To Read EA-EL Ford Falcon Diagnostic Codes

EA-EL Ford Falcon EEC-V and EEC-IV ECUs have advanced diagnostic modes that can be useful to identify sensor and wiring problems. This guide outlines how to read stored codes to help with tracing problems.

TunerPro Keyboard Shortcut

TunerPro Keyboard Shortcuts

Did you know that TunerPro allows custom keyboard shortcuts?  In this short article we cover how to create and change existing keyboard mappings to make common tasks quicker.

Read more

T5 Trans Switches

Wiring up the neutral switch in a Ford Falcon manual conversion

Wiring up the neutral switch in a Ford Falcon manual conversion is a commonly overlooked item. In this quick guide we show how to wire it up. Read more

T.I. Performance Wideband Gear

How to fit and use a Wideband O2 Sensor

When modifying cars, Wideband O2 sensors are a very useful diagnostic and monitoring tool.  In this second article of the series, we explain how to fit and use a Wideband O2 sensor. Read more

T.I. Performance Wideband Gear

Why you need a Wideband O2 sensor

In the world of modified cars, a Wideband O2 sensor is a very useful diagnostic tool.  In this article we explain the purpose of Wideband O2 sensors, and give some reasons as to why every modified car should have a one. Read more

BA XR6 Turbo MAP Sensor T.I. Performance

Fitting a XR6T MAP sensor to an AU BA or BF Falcon – Quick Reference Guide

This quick reference guide contains the pinout details for fitting one of our XR6T 2-Bar MAP sensors to an AU, BA, BF or FG Falcon NA vehicle.

Read more

5.0L Windor V8 Hilux EFI Conversion

EB-ED V8 Thermofan Control

This guide outlines the steps involved in controlling an electric thermofan via the Factory ECU in an EB-ED V8 Falcon, XR8, Fairlane or Fairmont. This guide does not apply to the I6 as the parameters to enable fan control are currently not known.

Read more

EL Falcon ECU pins

Fitting an EL ECU to an EA-ED Falcon

This guide outlines the steps involved in fitting an EL ECU into an EA, EB, ED, NA, NC, or XG Falcon/Fairmont/Fairlane 6 cylinder. This provides several benefits, including:

  • Faster ECU with larger memory capacity and more advanced strategy programming
  • Better idle control
  • Better spark control
  • Better automatic transmission control including more advanced shifting
  • EF/EL Broadband Manifold (BBM) control
  • Thermofan control
  • More current definitions

Read more

Idle video screenshot

Idle control – fixing rev hang

Does your Falcon have a high idle?  Do you have rev hang for a few seconds after a quick stab at the throttle?  Does your car stall when you come to a quick stop?  Read this article for some fixes to resolve this fairly common problem. Read more

Smartlock PCB

Smartlock Guide – How To Fix Common Problems And Bypass Smartlock

This post explains how to fix common problems with Smartlock in EB, ED, EF, EL and AU (Series 1) Falcons, NC-NL Fairlane, and XG-XH Utes.