Chery Fengyun 2 Service Manual (MT80 Engine Management System)
After-Sales Service Deartment! Chery Aut"m"#ile Sales C"$! %t&$
C"ntents Section I Engine Electronic Fuel Injection System..............................................................................................4 Chapter I Introduction to the Engine MT80 Electronic Fuel Injection System for Fengyun Model............4 I. System Introduction............................................................................................................................4 !. Fuel "ump Control Strategy..............................................................................................................4 . "ilot Injection for Starting..................................................................................................................4 #. "rotecti$e Fuel Cut%off Control..........................................................................................................4 4. Function Features of the Engine Management System....................................................................& &. Features of ECM in the Engine Management System......................................................................& '. Coil Magneti(ing Control...................................................................................................................& ). Starting Mode....................................................................................................................................& 8. Idle Speed Control.............................................................................................................................' *. +noc, Control -ogic..........................................................................................................................' !0. Charcoal Canister Solenoid al$e Control -ogic............................................................................) !!. Fan Control -ogic............................................................................................................................) !. /or,ing Conditions of the ir Conditioner.......................................................................................) !#. ir Conditioner Shutdo1n Modes....................................................................................................) Chapter II Introduction to the Input Elements of the Engine MT80 Electronic Fuel Injection System for Fengyun Model..........................................................................................................................................8 !. Cran,shaft "osition Sensor 2C+"3...........................................................................................................8 !.! "osition and Function......................................................................................................................8 !. "rinciple...........................................................................................................................................* !.# Measurement...................................................................................................................................* . Camshaft "osition Sensor 2CM"3...........................................................................................................!0 .! "osition and Function....................................................................................................................!0 . "rinciple.........................................................................................................................................!0 .# Measurement.................................................................................................................................!! #. ccelerator "etal "osition Sensor 2""3................................................................................................ !! #.! Structure and "rinciple..................................................................................................................!! #. Measurement.................................................................................................................................! 4. Throttle "osition Sensor 2Electronic Throttle3.........................................................................................!# 4.! Structure........................................................................................................................................!# 4. /or,ing "rinciple of the Electronic Throttle Motor........................................................................!# 4.# Measurement.................................................................................................................................!4 &. Engine Coolant Te Temperature mperature Sensor 2ECT3........................................................................................... !& &.! "osition and Function....................................................................................................................!& &. "rinciple.........................................................................................................................................!& &.# Measurement.................................................................................................................................!& &.4 System Troule Caused y Element Troule................................................................................!' '. Manifold solute "ressure5Temperature "ressure5Temperature Sensor................................................................................ ..!' '.! "osition and Function....................................................................................................................!'
C"ntents Section I Engine Electronic Fuel Injection System..............................................................................................4 Chapter I Introduction to the Engine MT80 Electronic Fuel Injection System for Fengyun Model............4 I. System Introduction............................................................................................................................4 !. Fuel "ump Control Strategy..............................................................................................................4 . "ilot Injection for Starting..................................................................................................................4 #. "rotecti$e Fuel Cut%off Control..........................................................................................................4 4. Function Features of the Engine Management System....................................................................& &. Features of ECM in the Engine Management System......................................................................& '. Coil Magneti(ing Control...................................................................................................................& ). Starting Mode....................................................................................................................................& 8. Idle Speed Control.............................................................................................................................' *. +noc, Control -ogic..........................................................................................................................' !0. Charcoal Canister Solenoid al$e Control -ogic............................................................................) !!. Fan Control -ogic............................................................................................................................) !. /or,ing Conditions of the ir Conditioner.......................................................................................) !#. ir Conditioner Shutdo1n Modes....................................................................................................) Chapter II Introduction to the Input Elements of the Engine MT80 Electronic Fuel Injection System for Fengyun Model..........................................................................................................................................8 !. Cran,shaft "osition Sensor 2C+"3...........................................................................................................8 !.! "osition and Function......................................................................................................................8 !. "rinciple...........................................................................................................................................* !.# Measurement...................................................................................................................................* . Camshaft "osition Sensor 2CM"3...........................................................................................................!0 .! "osition and Function....................................................................................................................!0 . "rinciple.........................................................................................................................................!0 .# Measurement.................................................................................................................................!! #. ccelerator "etal "osition Sensor 2""3................................................................................................ !! #.! Structure and "rinciple..................................................................................................................!! #. Measurement.................................................................................................................................! 4. Throttle "osition Sensor 2Electronic Throttle3.........................................................................................!# 4.! Structure........................................................................................................................................!# 4. /or,ing "rinciple of the Electronic Throttle Motor........................................................................!# 4.# Measurement.................................................................................................................................!4 &. Engine Coolant Te Temperature mperature Sensor 2ECT3........................................................................................... !& &.! "osition and Function....................................................................................................................!& &. "rinciple.........................................................................................................................................!& &.# Measurement.................................................................................................................................!& &.4 System Troule Caused y Element Troule................................................................................!' '. Manifold solute "ressure5Temperature "ressure5Temperature Sensor................................................................................ ..!' '.! "osition and Function....................................................................................................................!'
/or,ing "rinciple........................................................................................................................ "rinciple................................................................................................................................. .........!' !' '.# Measurement.................................................................................................................................!) '.4 /or,ing "arameters......................................................................................................................!) ). 67ygen Sensor.......................................................................................................................................!8 ).! "osition and Function....................................................................................................................!8 ). "erformance..................................................................................................................................!8 ).# Structure and "rinciple..................................................................................................................!* 8. +noc, Sensor.........................................................................................................................................0 8.! "osition and Function....................................................................................................................0 8. "rinciple.........................................................................................................................................0 8.# Measurement.................................................................................................................................0 *. Electronic Control nit 2EC3.................................................................................................................! *.! "osition and Function....................................................................................................................! *. Structure........................................................................................................................................! *.# EC "arameters...........................................................................................................................! *.4 Measurement................................................................................................................................. !0. Ignition Coil........................................................................................................................................... !0. "erformance................................................................................................................................# !0.# /or,ing "rinciple.........................................................................................................................# !0.4 Measurement...............................................................................................................................# !0.& System Troule Caused y Element Troule..............................................................................4 !!. Electromagnetic Fuel Injector...............................................................................................................& !!.! "osition and Function..................................................................................................................& !!. Structure and /or,ing "rinciple..................................................................................................& !!.# !!.# Measurement............................................................................................................................... ' !!.4 !!.4 System Troule Caused y Element Troule......................................................................... .....' !. Charcoal Canister Control al$e..........................................................................................................) !.! "osition........................................................................................................................................) !. Function.......................................................................................................................................) !.# Structure and /or,ing "rinciple..................................................................................................) !.4 Measurement...............................................................................................................................8 !.& /or,ing Conditions of the Charcoal Canister Solenoid al$e....................................................8 !#. Electric Fuel "ump................................................................................................................................* !#.! Structure......................................................................................................................................* !#. Measurement...............................................................................................................................#0 !#.# System Troule Caused y Element Troule..............................................................................#0 !4. Steel Fuel 9istriution "ipe ssemly..................................................................................................#0 !&. nti%theft Input Signal............................................................................................................................#! !&.! "osition and Function..................................................................................................................#! !&. Structure and /or,ing "rinciple 2nti%theft Controller3...............................................................#! !&.# Structure and /or,ing "rinciple 2Transponder3..........................................................................# !&.4 Structure and /or,ing "rinciple 2:eader Coil3...........................................................................# !&.& Matching of the +ey.....................................................................................................................# !&.' Matching of the nti%theft System................................................................................................## #
4
Secti"n ' Engine Electr"nic Fuel 'necti"n System Chater ' 'ntr"&ucti"n t" the Engine MT80 Electr"nic Fuel 'necti"n System f"r Fengyun 2 M"&el '$
System 'ntr"&ucti"n
The Fengyun series car is e;uipped 1ith CTEC6 series S<:4))F engine= 1hich is de$eloped y Chery utomoile Co.= -td. together 1ith - Company= a 1orld%famous engine design company= and designed 1ith e7cellent performance. The S<:4))F engine is pro$ided 1ith 9elphi MT80 engine management system 1hich is ased on tor;ue control and electronic throttle and featured y computer closed%loop control= se;uential multipoint fuel injection= grouping direct ignition 1ithout current distriutor and post% processing of three%1ay catalytic con$erter. $
Fuel *um C"ntr"l Strategy
!.!.! Fuel "ump Control -ogic Fuel pump start logic> fter the ignition s1itch is turned on= the fuel pump 1ill run for s. If no effecti$e &8? signal is detected= the fuel pump stops and the engine egins to rotate. 6nce the EC detects an effecti$e &8? signal= the fuel pump starts. Fuel pump stop logic> In 0.'s after the rotation speed signal disappears or in case that the anti%theft de$ice re;uires shutdo1n of the fuel pump= the fuel pump 1ill stop. 2$
*il"t 'necti"n f"r Starting
The pilot injection for starting is performed only once in the course of normal start= and the conditions are as follo1s> !. The engine is under operation@ . The fuel pump relay pic,s up@ #. The running time of the fuel pump e7ceeds the pressure accumulation delay time@ 4. The pilot injection for starting has not een performed efore. 6nce the ao$e conditions are met= the pilot injection for starting 1ill e performed in all cylinders at the same time. +$
*r"tective Fuel Cut-"ff C"ntr"l
6nce any of the follo1ing conditions is met= the system 1ill stop fuel injection> The fuel supply is cut off 1hen the engine rotation speed is higher than '400rpm= is reco$ered
1hen the engine rotation speed is lo1er than '000rpm= and is cut off 1hen the system detects any troule in the ignition system. The fuel supply is cut off 1hen the system detects any troule in the ignition system. /hen the system $oltage e7ceeds !8= the system enters electronic throttle function limit mode 2forced idling mode3. ,$
Functi"n Features "f the Engine Management System
Manifold asolute pressure5temperature sensor control> !.
Engine tor;ue output control mode
.
Main po1er supply relay control of the complete $ehicle
#.
Closed loop control se;uential multipoint fuel injection
4.
Fuel supply mode 1ithout fuel return
&.
Fuel pump 1or,ing control
'.
+noc, control
).
Electronic throttle control
8.
ir conditioner control
*.
Cooling 1ater tan, fan control
!0. Charcoal canister solenoid $al$e control !!. System self%diagnosis function !. EC anti%theft control !#. EC uilt%in ignition dri$e module= grouping direction ignition 1ithout current distriutor $
.$
Features "f ECM in the Engine Management System !.
EC de$eloped for the high%end electronic fuel injection system mar,et
.
State%of%the%art electronic hard1are technology
#.
%it microprocessor 2C"3 1ith sufficient memory and high computing speed
4.
Aigh cost performance
&.
Fle7ile I56 ports
'.
In accordance 1ith the current Euro I and E6B9 C"il Magneti/ati"n C"ntr"l
The magneti(ing time of the ignition coil determines the ignition energy of the spar, plug. Too long magneti(ing time 1ill damage the coil or the coil dri$e= 1hile too short magneti(ing time 1ill lead to misfire.
'
$ Starting M"&e nder the starting mode= the system applies a fi7ed ignition angle@ Main ignition ad$ance angle> The main ignition ad$ance angle refers to the minimum timing for the est tor;ue 2MBT3 or the ,noc, orderline 2+B-3 timing. Correction of the ignition ad$ance angle> !.
Correction y 1ater temperature@
.
Correction y air inta,e@
#.
Correction y altitude compensation@
4.
Correction y idling@
&.
Correction y acceleration@
'.
Correction y po1er enrichment@
).
Correction y deceleration and fuel cut%off@
8.
Correction y air conditioner control.
8$
'&le See& C"ntr"l
Basic target idle speed nder different coolant temperatures= the asic target idle speed is set as follo1s> Coolant
Target
Coolant
Target
Coolant
Target
Coolant
Target
temperature
idle
temperature
idle
temperature
idle
temperature
idle
℃
speed
℃
speed
℃
speed
℃
speed
rpm
rpm
rpm
rpm
%0
!!)&
0
!!&0
'0
8&0
!00
)&0
%!0
!00
#0
!!&0
)0
800
!!0
)&0
0
!00
40
!000
80
)&0
D!0
800
!0
!!&0
&0
*00
*0
)&0
1$
n"c3 C"ntr"l %"gic
/or,ing conditions for ,noc, control> !.
Then engine runs for o$er s@
.
The engine 1ater temperature e7ceeds )0℃ @
#.
The engine rotation speed e7ceeds 800rpm. )
fter detecting any ,noc,= the system 1ill= ased on the engine rotation speed= ;uic,ly change the ignition ad$ance angle y #& degrees for ignition delay and return to normal control 1ithin the suse;uent #s.
0$ Charc"al Canister S"len"i& 4alve C"ntr"l %"gic Before the charcoal canister solenoid $al$e opens= the follo1ing conditions must e met> !.
The system $oltage is higher than 8 ut lo1er than !8@
.
The engine 1ater temperature e7ceeds 0℃ @
#.
The engine inta,e temperature e7ceeds 0℃ @
4.
There is no related system troule.
The opening of the charcoal canister solenoid $al$e depends on the duty r atio signal determined y the EC according to the engine state.
$
Fan C"ntr"l %"gic
The 1or,ing modes and conditions of the fan are as follo1s> !.
/hen the 1ater temperature e7ceeds *&℃ = the lo1%speed fan starts@
.
/hen the 1ater temperature e7ceeds **℃ = the high%speed fan starts@
#.
/hen the 1ater temperature is lo1er than *&℃ = the high%speed fan stops@
4.
/hen the 1ater temperature is lo1er than *0℃ = the lo1%speed fan stops@
&.
/hen the air conditioner is s1itched on= the air conditioner fan starts.
2$ 5"r3ing C"n&iti"ns "f the Air C"n&iti"ner The air%conditioning system 1ill start 1hen the follo1ing conditions are met> The engine runs for o$er )s@ The air conditioner s1itch is turned on@ ll air conditioner shutdo1n modes are out of function.
+$ Air C"n&iti"ner Shut&"6n M"&es ir conditioner shutdo1n mode in case of high engine rotation speed> protect the air%conditioning system> /ith the air conditioner shut do1n= the compressor can e started only 1hen the engine rotation speed is lo1er than 4*00rpm. 8
/ith the air conditioner under operation= the compressor 1ill e stopped 1hen the engine rotation speed e7ceeds &!00rpm.
ir conditioner shutdo1n mode in case of high engine coolant temperature> protect the air%conditioning system> /ith the air conditioner shut do1n= the compressor can e started only 1hen the coolant temperature is lo1er than !0'℃ . /ith the air conditioner under operation= the compressor 1ill e stopped 1hen the coolant temperature e7ceeds !08℃ .
ir conditioner shutdo1n mode in case of lo1 air conditioner e$aporator temperature> protect the air%conditioning system> /hen any of the follo1ing conditions is met= the $ehicle 1ill enter the air conditioner shutdo1n mode in case of starting at high amient temperature> The air conditioner e$aporator temperature sensor is defecti$e@ The temperature of the air conditioner e$aporator is lo1er than #℃ @
/hen the follo1ing t1o conditions are met= the $ehicle 1ill e7it from the air conditioner shutdo1n mode in case of lo1 air conditioner e$aporator temperature> The air conditioner e$aporator temperature sensor is in good condition@ The temperature of the air conditioner e$aporator e7ceeds 4℃ .
Chater '' 'ntr"&ucti"n t" the 'nut Elements "f the Engine MT80 Electr"nic Fuel 'necti"n System f"r Fengyun 2 M"&el $ Cran3shaft *"siti"n Sens"r (C*) $ *"siti"n an& Functi"n "osition> The cran,shaft position sensor is installed at the front part of the transmission housing and aligned 1ith the fly1heel outer ring. Function> It is used to detect the rotation position and speed of the engine cran,shaft and output a corresponding signal y 1hich the EC determines the rotation position and speed of the engine cran,shaft. *
Clearance et1een the sensor and the ring gear 0.#!.&mm
Coil resistance
Coil inductance
&'0G!0H
40mAG!&H
$2 *rincile !. "ermanent magnet . Cran,shaft sensor casing #. Transmission housing 4. Soft iron core &. Coil '. Bac,lash 2reference mar,3 ). ir clearance
$+ Measurement The cran,shaft position sensor is a magnetic inducti$e rotation speed sensor. 9ue to lo1 induced $oltage= the sensor is easily influenced y the amient electric 1a$e= so its connecting 1ires are added 1ith a shielding layer. The plug is pro$ided 1ith three terminals as elo1>
A
B
> Signal @ B> Signal %@ C> Shielding 1ire.
Measurement 1ith a ni$ersal Meter>
/a$eform 6utput y the Sensor 2Measured 1ith an 6scillograph3
Measure the resistance to ground of each terminal 1ith a uni$ersal meter set at 6hm range to find out the shielding 1ire connector= and then measure the resistances of the other t1o connectors. fter1ards= preliminary judgement for the sensor state can e made y comparing the measuring results 1ith the technical parameters.
/a$eform 6utput y the Sensor 2Measured 1ith an 6scillograph3 !0
C
2$ Camshaft *"siti"n Sens"r (CM*) 2$ *"siti"n an& Functi"n "osition> It is set at the rear part of the $al$e chamer co$er. The signal gear is installed at the rear part of the camshaft and runs in synchronicity 1ith the camshaft.
Function> It is used to pro$ide the phase information of the camshaft to the EC to judge 1hich stro,e the engine is in during a 1or,ing cycle.
"erformance /or,ing $oltage
/or,ing clearance
4.&!#
0.#mm
2$2 *rincile Aall principle> The integrated circuit is set in front of one pole of the permanent magnet@ 1ith the Aall principle= 1hen the camshaft dri$es the signal gear to rotate= the change of tooth profile leads to change of magnetic force line in terms of intensity= resultng in output of $oltage signal. Characteristic cur$e The characteristic cur$e is coordinated 1ith the cran,shaft signal= namely= the cran,shaft rotates for t1o circles and the camshaft rotates for one circle= y 1hich the top dead center of cylinder ! can e determined.
!!
/a$eform Jraph Measured 1ith an 6scillograph
2$+ Measurement /ire is a signal 1ire= connected to EC E&'K@ /ire B is a signal ground 1ire= connected to EC E!8K@ /ire C is a & po1er 1ire= connected to EC E#K.
+$ Accelerat"r *etal *"siti"n Sens"r (A**) "osition> It is set under the instrument panel at the dri$eLs side and ao$e the accelerator pedal. Function> It is used to feed ac, the position of the accelerator pedal to the EC y means of electronic signal= and then the EC 1ill control the electronic throttle y computation.
+$ Structure an& *rincile It is a non%contacting position sensor 1hich may impro$e the signal reliaility. Besides= it is pro$ided 1ith t1o Aall sensors= 1ithout the need for self%learning.
Troule "henomena> The engine troule indicator lamp is on@ "oor acceleration@ -imited engine rotation speed.
!
!. Signal . Jrounding #. -i$e 1ire 4. Signal &. Jrounding '. -i$e 1ire
+$2 Measurement /hen the ignition s1itch is turned on= the engine is not started= and the accelerator pedal is not stepped= sensors ""! and "" 1ill output the follo1ing $oltage signals.
/a$eform Jraph of the ccelerator "edal
""!> .!8@ ""> 0.!.
/a$eform Jraph of the ccelerator "edal Stepped to the End
. /hen the ignition s1itch is turned on= the engine is not started= and the accelerator pedal is stepped to the end= sensors "! and " 1ill output the follo1ing $oltage signals.
""!> 4.)!@ ""> 0.84.
!#
/a$eform Jraph of the ccelerator "edal under Free State
ll the ao$e $alues are measured 1ith a diagnostic tester 1hen the engine is under normal condition= and are for reference only.
,$ Thr"ttle *"siti"n Sens"r (Electr"nic Thr"ttle)
"osition> The throttle position sensor is set on the electronic throttle. Function> It is used to monitor the positions of the throttle and force motor.
,$ Structure Constitution> !3 Throttle ody@ 3 9ri$e motor@ #3 Throttle position sensor. The sliders of the t1o potentiometers are directly connected 1ith the throttle spindle= of 1hich one potentiometer outputs a positi$e signal and the other outputs a negati$e signal.
,$2 5"r3ing *rincile "f the Electr"nic Thr"ttle M"t"r The throttle dri$e motor is a 9C micromotor. It dri$es a set of particular gear reduction unit and a doule% acting spring. /hen the system is po1er%off= it ,eeps the throttle $al$e plate at a safety opening position leading to a moderate speed higher than the idle speed= so as to ensure the $ehicle can tra$el continuously. If the electronic control system of the engine enters this troule mode= the electronic throttle $al$e plate 1onLt act 1hen the accelerator pedal is stepped.
T*S !4
The sensor signal potential increases 1ith the change of the opening.
T*S2 The sensor signal potential decreases 1ith the increase of the throttle opening.
,$+ Measurement :esistance of the 9C motor> #.*# Measure the $oltage $ariation of 1ires B and C. The $ariation trends of the t1o $oltages are opposite@ /a$eform Jraph of the Throttle "osition Sensor
. & po1er supply B. Signal C. Signal 9. Jrounding
The electronic throttle dri$e motor is a 9C motor 1ith t1o 1ires. E> EC E')K dri$en y the motor A> EC E'!K dri$en y the motor 9> EC E04K B> EC E#*K position sensor signal ! > EC E0#K C> EC E'K position sensor signal nplug the electronic throttle and use a uni$ersal meter set at 6hm range to measure the !&
resistances of 1ires A and E. If oth the 1ires are under conducting state and 1ith small resistances= the throttle dri$e motor is in normal condition. The measured resistances of 1ires A and E are aout 0.'.
$ Engine C""lant Temerature Sens"r (ECT) $ *"siti"n an& Functi"n "osition> It is set at the cylinder head 1ater outlet at the rear part of the engine and under the ignition coil.
"erformance>
/or,ing $oltage
/or,ing temperature
&
%40!#&℃
ECT sensor resistance characteristic
$2 *rincile It is a negati$e thermistor.
temperature coefficient 2TC3
-arge
:esistance
The resistance reduces 1ith the increase of the coolant temperature. Ao1e$er= the resistance is not in linear relationship 1ith the coolant temperature.
Small -o1 Aigh Engine coolant temperature
$+ Measurement
Measurement 1ith a ni$ersal Meter> "ull out the connector= set the uni$ersal meter at 6hm range= and connect the t1o proes 1ith pins !K and K of the sensor respecti$ely for measurement. The rated resistance is .&,G&H at 0℃ .
!' /ater temperature sensor
$, System Tr"u#le Cause& #y Element Tr"u#le In case of any troule= the follo1ing phenomena may appear> 9ifficult cold start@ 9ifficult hot start@ "oor dri$ing performance@ If the sensor is short to po1er supply= the engine 1ill run at the default@ Aigh temperature indicated y the thermometer@ -o1 temperature indicated y the thermometer@ The cooling fan runs under ;uic, mode continuously@ /hen the indicated temperature is lo1= the high temperature 1arning lamp flashes.
.$ Manif"l& A#s"lute *ressure7Temerature Sens"r .$ *"siti"n an& Functi"n "osition> It is set on the manifold resonant ca$ity.
"erformance> The manifold asolute pressure5temperature 2M"5MT3 sensor incorporates the functions of the manifold asolute pressure sensor and the manifold asolute temperature sensor= so as to feed ac, the manifold asolute pressure and temperature simultaneously. The pressure sensor is used to measure the air inhaled y the engine and it is an important element for ma,ing up the speed%density type air flo1 metering system.
5"r3ing *rincile
The manifold asolute pressure 2M"3 sensor is pro$ided 1ith a sealed elastic diaphragm and an iron magnetic core 1hich are precisely set in the coil. /hen the pressure changes= an output signal in direct proportion to the input !)
pressure and in proportion to the reference $oltage 1ill e generated.
.$+ Measurement
"ressure 2,"3
!&
40
*4
!0
6utput $oltage 23
0.!0.#8
!.&!.'8
4.444.'0
4.8'&.04
.$, 5"r3ing *arameters /or,ing $oltage
&
/or,ing current
Ma7. !m
6utput $oltage
6utput impedance
%!00!00m
!0
"ressure
/or,ing
range
temperature
!0,"!!0,"
%40!&℃
5avef"rm rah "f the Manif"l& A#s"lute *ressure Sens"r
9ris3 Accelerati"n (MA*)
Decelerati"n (MA*)
!8
$ :;ygen Sens"r $ *"siti"n an& Functi"n "osition> The !# car is pro$ided 1ith a front o7ygen sensor and a rear o7ygen sensor= of 1hich the former is set on the e7haust manifold and the latter is set ehind the rear three%1ay catalytic con$erter 2T/C3.
Function> It is used to feed ac, the closed%loop control mi7ture signal.
$2 *erf"rmance
Temperature
'0℃
4&0℃
&*&℃
6utput $oltage in case of rich mi7ture
D800
D800
D)&0
00
00
!&0
)&
)&
&0
!&0
!&
*0
2m3 6utput $oltage in case of 1ea, mi7ture 2m3 :esponse time from 1ea, mi7ture to rich mi7ture 2ms3 :esponse time from rich mi7ture to 1ea, mi7ture 2ms3 Internal resistance 23
!00+
!*
$+ Structure an& *rincile The o7ygen sensor is an important typical part in the closed%loop fuel control system. It adjusts and ,eeps the desired air%fuel ratio to ma,e the three%1ay catalytic con$erter achie$e its optimum con$ersion efficiency. /hen the air%fuel ratio in$ol$ed in the engine comustion gets large= the o7ygen content in the e7haust gas increases and the output $oltage of the o7ygen sensor drops@ other1ise= the output $oltage rises. In this 1ay= the sensor feeds ac, the air%fuel ratio to the EC. The sensiti$e element in the o7ygen sensor is made of (irconia and constructed 1ith a hollo1 part and an e7ternal inducti$e part. fter the (irconia element is acti$ated y heating 2D#00℃ 3= the reference air enters its hollo1 part through the 1ire and the e7haust gas passes through its outside electrode so that the o7ygen ions mo$e from its center to outside electrode. In this 1ay= a simple atomic attery is formed and a $oltage is generated et1een the t1o electrodes. The (irconia element can change the output $oltage according to the o7ygen content in the e7haust gas so as to judge the o7ygen content in the e7haust gas. Jenerally= the o7ygen sensor is designed to generate a jump in the $oltage magnitude 1hen the air%fuel ratio determined ased on the e7haust gas is close to the theoretical $alue 2!4.'>!3 so as to help the EC judge the air%fuel ratio precisely.
/a$eform of the 67ygen Sensor
$, Measurement :emo$e the connector= set the digital uni$ersal meter at 6hm range= and connect the t1o proes 1ith pins C and 9 of the sensor respecti$ely to measure the resistance= namely= heaterLs resistance= 1hich is *. under room temperature 2measured $alue3. Connect the connector= set the digital uni$ersal meter at 9C $oltage range after the o7ygen sensor reaches its 1or,ing temperature #&0℃ under idling state= and connect the t1o proes 1ith pins and B of the sensor to measure the $oltage 1hich shall fluctuate ;uic,ly et1een 0.!0.*. 0
/a$eform of the 67ygen Sensor 2Bris, cceleration3
8$ n"c3 Sens"r 8$ *"siti"n an& Functi"n
"osition> It is set under the inta,e manifold. Function> It is used to monitor 1hether the comustion of the gas mi7ture in the engine comustion chamer has a trend of ,noc,. If yes= it sends a ,noc, signal to the EC to help the EC control the ignition ad$ance angle etter.
Fre
=esistance
+>83?/
@M
8$2 *rincile The ,noc, sensor is a $iration acceleration sensor and generates an output $oltage corresponding to the mechanical $iration of the engine. The sensor is pro$ided 1ith a ceramic pie(olectric crystal 1hose $iration generates a $oltage signal. 9uring the ,noc, of the engine= the crystal $irates more seriously so as to change the output signal to the EC.
8$+ Measurement N4 :emo$e the connector= set the digital uni$ersal meter at 6hm range= and connect the t1o proes 1ith pins !K O K and !K O #K of the sensor respecti$ely to measure the resistance 1hich is o$er !M under room temperature. The terminals are independent from each other. . Set the uni$ersal meter at m range= use a ruer hammer to eat the engine cylinder loc, and a $oltage shall e output from the sensor= or gently eat the sensor !
Caacitance ,80>2220f
2donLt damage the sensor3 and a $oltage also shall e output from the sensor.
1$ Electr"nic C"ntr"l Bnit (ECB) 1$ *"siti"n an& Functi"n "osition> It is set on the floor under the instrument panel at the assistant dri$erLs side.
Function> The EC is the core of the engine electronic control system. /ith the signals for electronic control from the sensors= the EC= after internal computation= controls a series of actuators such as the fuel injector and ignition coil to control the 1or,ing of the engine. /or,ing $oltage
6$er$oltage and re$erse $oltage
/or,ing
protection
temperature
45%!4 '0s
%40!0&℃
!!'
1$2 Structure It is composed of a shielded housing and a printed circuit oard 1here lots of electronic control units are integrated for the control of electronic fuel injection.
This electronic control system is pro$ided 1ith an EC anti%theft control system.
"te The ECB h"using an& the fi;ing #"lts must #e insulate& fr"m the chassis$
1$+ ECB *arameters N C" parameters@
N #%digit master chip@ N ''M cloc, fre;uency@ N !M F-SA on%chip memory@ N !+ :M memory@ N 4+ EE":6M memory.
/or,ing "arameters
Normal 1or,ing $oltage range> *.0!'@ N6$er$oltage and re$erse $oltage protection> 45%!4 '0s.
1$, Measurement Simple measurement method> N
Connect the connector and read the engine troule records y using the engine data diagnosis line@
N
:emo$e the connector and chec, 1hether the EC connecting 1ires are in good condition= especially chec, 1hether the EC po1er supply and grounding circuit are normal@
N
Chec, 1hether the e7ternal sensors 1or, normally= 1hether the output signals are reliale and 1hether the circuits are in good condition@
N
Chec, 1hether the actuators 1or, normally and 1hether their circuits are in good condition@
N
t last= replace the EC for test.
0$ 'gniti"n C"il 0$ *"siti"n an& Functi"n N Ignition se;uence> != #= 4 and "osition> The ignition coil is set on the side of the engine upper cylinder head 2ne7t to the transmission3. N N
The ignition coil is used to transform the lo1 $oltage of the primary 1inding into the high $oltage of the secondary 1inding= and then ignite the fuel%air mi7ture in the cylinder y the spar, discharged y the spar, plug. #
0$2 *erf"rmance "rimary resistance
0.&G0.0&
Secondary inductance
!).&G!.A
Secondary resistance
*840G*80
Interruption current pea,
*.&
"rimary inductance
.)&G0.&mA
Secondary output $oltage
#4,
0$+ 5"r3ing *rincile The ignition coil PS%+7 is composed of t1o primary 1indings= t1o secondary 1indings= an iron core and a housing. /hen the grounding circuit of any primar y 1inding is connected= this primary 1inding is charged. 6nce the EC disconnects the primary 1inding circuit= the charging is stopped and a high $oltage is induced in the secondary 1inding to ma,e the spar, plug discharge. nli,e the ignition coil 1ith current distriutor= each end of the secondary 1inding of the ignition coil PS%+7 is connected 1ith a spar, plug= so oth the spar, plugs generate spar, simultaneously. The t1o primary 1indings are energi(ed and deenergi(ed alternati$ely= and correspondingly= the t1o secondary 1indings discharge alternati$ely. Coil resistance
Min. 1or,ing $oltage
/or,ing temperature
!G0.4
4.&
%40!#0℃
0$, Measurement se a uni$ersal meter set at 6hm range to measure the resistances of the primary coils of 1ires B and C as 1ell as 1ires 9 and C respecti$ely 1hich are 0.4&0.&&. :emo$e the high%tension 1ires of cylinders ! and 4= and use a uni$ersal meter to measure the resistance et1een the high% tension 1ire connectors of the t1o cylinders= namely= the resistance of the secondary coil= 1hich is 8.8!0.8,. > Shielded ground 1ire B> ! po1er 1ire C> EC E!)K 4
SAIE-9 2dual%core shielding3
9> EC E0!K 'gniti"n 5avef"rm '' 'gniti"n Timing
0$ System Tr"u#le Cause& #y Element Tr"u#le N nstale idling 'gniti"n 5avef"rm 'gniti"n in E;haust St"3e
N Insufficient engine po1er N Increased fuel consumption N Increased emission
&
$ Electr"magnetic Fuel 'nect"r $ *"siti"n an& Functi"n "osition> It is set et1een the fuel rail and inta,e manifold and ao$e the fuel rail. Function> It is used to supply the atomi(ed fuel to the engine y injecting fuel in a set time according to the command from the ECM. Besides= it is also used to store the high%pressure fuel to eliminate the resonance resulted y the operation of the fuel pump= so as to ,eep the pressure steady.
$2 Structure an& 5"r3ing *rincile 6%ring "lastic particle
The electromagnetic controlled fuel no((le is e;uipped 1ith a return spring in the shell to press the $al$e needle on the $al$e seat and the opening is sealed up.
djusting slee$e Coil Spring Juard strip eedle $al$e component
N
al$e seat component
For injection= the electronic controller sends a control signal to get the electromagnetic coil energi(ed to produce an electromagnetic field 1hich is helpful in o$ercoming the pressure of the return spring= the gra$ity of the needle $al$e and the friction to lift up the needle $al$e. In this 1ay= the fuel may e injected under the fuel pressure. There are only t1o states for the needle $al$e= namely= the $al$e is lifted up or lo1ered do1n= and its lift can not e adjusted. "ro$ided that the pressure difference et1een the inlet and outlet of the fuel no((le is constant= the fuel injection ;uantity 1ill depend on the needle $al$e opening time= i.e.= the opening electric pulse 1idth. The lift of the needle $al$e shall not e7ceed 0.!mm.
'
6rifice plate
$+ Measurement Measurement 6ith a Bniversal Meter
There are t1o 1ires for the fuel no((le connector= one of 1hich is connected to the EC and the other is connected to a ! po1er supply. > ! po1er supply@ B> EC E'#K. For measurement= remo$e the connector= set the uni$ersal meter to 6hm range and then connect the t1o proes 1ith the t1o pins of the fuel injector respecti$ely. The rated resistance at 0℃ is !!!'.
Measurement 6ith a Diagn"stic Tester
5avef"rm rah "f the Fuel 'nect"r
$, System Tr"u#le Cause& #y Element Tr"u#le 'n case "f any tr"u#le! the f"ll"6ing hen"mena may aear N
"oor idling= poor acceleration= failure in starting 2difficulty in starting3= etc.
N
Failure due to the gum accumulated in the fuel injector as a result of lac, of maintenance. )
2$ Charc"al Canister C"ntr"l 4alve 2$ *"siti"n N
It is set at the right corner of the engine compartment and near the e7pansion $al$e.
NN Specification :ated 1or,ing $oltage
!
/or,ing temperature
!40!0℃
/or,ing $oltage range
8!'
Coil resistance
!*
-imited $oltage
&
Coil inductance
!!&mA
2$2 Functi"n !. Connecting to the fuel tan, . Charcoal canister #. ir 4. Charcoal canister control $al$e &. Connecting to the inta,e manifold '. Throttle
2$+ Structure an& 5"r3ing *rincile
The charcoal canister control $al$e consists of electromagnetic coil= armature= $al$e= etc. filter screen is set on the inlet. The air flo1 of the charcoal canister control $al$e depends on t1o factors= namely= the duty ratio outputted y the EC to the charcoal canister control $al$e in the form of electric pulse= and the pressure difference et1een the inlet and outlet of the charcoal canister control $al$e. In case the electric pulse is not a$ailale= the charcoal canister control $al$e 1ill e closed. The EC is used to control the po1er%on time of the charcoal canister solenoid $al$e according to the signals pro$ided y the sensors of the engine= so 8
al$e component Seal ring
Electromagnetic coil
Casing Core
ir flo1 direction
as to control the cleaning air flo1 indirectly.
2$, Measurement N
Failure Chec,
!3 Conduct failure detection y measuring the resistance of the charcoal canister solenoid $al$e. It has t1o 1ires> > ! po1er supply@ B> EC E&)K.
The EC controls the on5off of the cleaning duct y the grounding of the charcoal canister solenoid $al$e. /hen measuring the resistance of the charcoal canister solenoid $al$e= remo$e the charcoal canister control $al$e harness connector to measure the coil resistance. It shall e !*= other1ise= replace the coil.
3 Chec, the charcoal canister solenoid $al$e for failure 1hen it is under operation.
2$ 5"r3ing C"n&iti"ns "f the Charc"al Canister S"len"i& 4alve 5avef"rm rah f"r the Charc"al Canister S"len"i& 4alve C"ntr"l
To minimi(e the affect of the fuel $apor to1ards the acting of the engine under normal comustion condition= the follo1ing re;uirements shall e met efore the charcoal canister solenoid $al$e opens>
N The system $oltage is higher than 8 ut lo1er than !8@ N The engine 1ater temperature is higher than 0℃ @ N The engine inta,e temperature is higher than 0℃ @ N There is no related system troule.
*
+$ Electric Fuel *um "osition> It is set in the fuel tan,.
Function> It is used to send the fuel from the fuel tan, to the engine at certain pressure and flo1 rate.
6utput pressure
D#&0,"a
/or,ing $oltage
8!'
+eep%up pressure
Q4,"a
6$er$oltage protection
%!#.&'
6utput flo1
D!0g5s
:unning 1ithout fuel
'0s
+$ Structure !. Fuel pump end co$er 2integrated 1ith chec, $al$e= relief $al$e and anti%electromagnetic interference elements3 . Motor #. Fuel duct 4. Blade pump ormal 1or,ing $oltage> 8!4 ormal 1or,ing temperature> %#0)0℃ System pressure> 400,"a
#0
+$2 Measurement The fuel pump is a 9C motor. It is controlled y the EC 1ith the fuel pump relay.
4erificati"n "f Fuel *um 5"r3ing Status Turn on the ignition s1itch and the fuel pump 1ill 1or, for a short time. In this case= a sound arising from the running fuel pump 1ill e heard. 8'> Jrounding 8)> ! po1er supply
+$+ System Tr"u#le Cause& #y Element Tr"u#le Troule "henomena> Jreat noise= poor acceleration= failure in starting 2difficult starting3= etc. Common troule cause> the application of dis;ualified fuel resulting in> !. Insulating layer formed y the accumulated gum@ . -oc,ing of the fuel pump shaft ushing and armature@ #. Corrosion of fuel le$el sensor components= etc.
,$ Steel Fuel Distri#uti"n *ie Assem#ly "osition> It is set ao$e the inta,e manifold. Function> It is used to store the high%pressure fuel to eliminate the resonance resulted y the operation of the fuel pump= so as to ,eep the pressure steady.
#!
$ Anti-theft 'nut Signal Anti-theft C"ntr"ller It is integrated 1ith a microprocessor to reali(e such functions as ,ey identification and system matching. It can produce an induction field to transmit the communication signals et1een the controller and the transponder.
Mechanical 3ey
Trans"n&er c"il
$ *"siti"n an& Functi"n "osition> The engine anti%theft EC is fi7ed in the instrument panel at the dri$erLs side y olts. Function> This de$ice functions directly against the engine= so it significantly impro$es the o$erall safety in terms of anti%theft performance.
$2 Structure an& 5"r3ing *rincile (Anti-theft C"ntr"ller) Anti-theft C"ntr"ller The anti%theft controller mainly consists of microprocessor and peripheral elements. It is used for the communication et1een the transponder and the engine management system. If the $erification for the transponder is done in a set time= the engine management system may allo1 the startup of the engine.
Ignition loc, cylinder
+ey head Coil
+ey casing
System status> /hen the engine is under anti% theft status 2unauthori(ed startup3= the engine Electromagnetic field troule indicator lamp 2or E"C lamp3 1ill flash ;uic,ly. In this case= the engine can rotate ut can not 1or,.
#
Transponder
$+ Structure an& 5"r3ing *rincile (Trans"n&er)
Transponder 2,ey chip and remote control ,ey3> It is set in the ,ey handle. This transponder= 1ithout po1er supply= is of small si(e and long ser$ice life. /ith the e7citation in the electromagnetic field= it recei$es the po1er supply signal and cloc, signal= and carries out communication 1ith the anti%theft controller. For each $ehicle= at most fi$e transponders can e pro$ided= i.e.= fi$e ,eys= and the ,ey chip is only a$ailale for 1riting%in once. E$ery ,ey is pro$ided 1ith a uni;ue code. "lease get the ne1 ,ey from the dealers of Chery utomoile Co.= -td.
$, Structure an& 5"r3ing *rincile (=ea&er C"il) "osition> It is set on the loc, cylinder of the ignition s1itch. Function> It is used to read the ,ey information from the ,ey chip and send the signal to the anti% theft controller. Structure> It is set in a lac, plastic co$er around the ignition s1itch. T1o coil harnesses are connected to the anti%theft controller.
=ea&er C"il /or,ing principle> The coil is fed y the regulated current from the anti%theft controller. /hen the ,ey is 1ithin cm 20.)8in3 a1ay from the ignition coil= and the ignition s1itch is at RCC position= an electricity energy of a fre;uency of !&,A( 1ill e sent from the coil to the anti%theft controller under the principle similar to that of an emitter. The anti%theft controller 1ill modulate the recei$ed data and encode them again= and then compare them 1ith the sa$ed identification codes. If the data are correct= the engine can e started.
$ Matching "f the ey !. "lug the diagnostic connector@ . Insert the ,ey to e matched into the ignition loc, and turn it to 6 position@ #. Select Rnti%theft de$ice Rnti%theft de$ice matching RInput code RInput safety code on the option menu of the diagnostic tester= and then input the safety code5"I code@ ##