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1、VISTEON CONFIDENTIAL1Jianshi Sept 3,2004Visteon EMS Service Training偉世通電噴系統維修偉世通電噴系統維修Visteon EMS Service Training偉世通電噴系統維修偉世通電噴系統維修Yang JingjingYang JingjingGary LepidiGary Lepidi2VISTEON CONFIDENTIALAgendaAgenda Introductions自我介紹 Basic Electronics基本電路知識 Powertrain Control Module發動機控制單元 Engine Mana2、gement System發動機管理系統 Service維修3VISTEON CONFIDENTIALBasic ElectronicsBasic ElectronicsBasic Electronics 基本電路原理 Ohms Law 歐姆定律 INPUTS 輸入Sensors 傳感器Temperature(ECT,IAT)溫度傳感器Pressure(MAP壓力傳感器Variable Reluctance(CMP,CKP)磁電式傳感器Switches 開關 OUTPUTS 輸出Actuators 執行器Stepper Motor步進電機Valves,Injectors,coils電磁閥、噴油3、器、點火線圈 COMBINATION I/O 輸入輸出組合Heated Exhaust Gas Oxygen(HEGO)Sensor 加熱型氧傳感器Heater element 加熱元件Oxygen Sensor 氧傳感器4VISTEON CONFIDENTIALPowertrain Control Module發動機控制單元發動機控制單元Powertrain Control Module發動機控制單元發動機控制單元 Major System Components主要組成 Hardware 硬件 PWB(Printed Wiring Board)電路板 16-Bit Microprocesso4、r 16位微處理器 2K EEPROM Flash 存儲器 Drivers 輸出驅動 Module Case 控制單元外殼 J1 Connector 控制單元81針插頭 Software 軟件 Operating System 操作系統 IVFER(In Vehicle Flash and Erase program)Low level drivers 底層驅動 Strategy 策略 Combination of all engine features working together各種控制功能的組合 Calibration 標定5VISTEON CONFIDENTIALOverview 5、of the EMS system電噴系統概述電噴系統概述Overview of the EMS system電噴系統概述電噴系統概述 Basic Engine operation 發動機基本運行原理 Fuel Subsystem 燃油子系統 Ignition Subsystem 點火子系統 IAC Subsystem 怠速控制子系統 Sensor and Actuators 傳感器和執行器6VISTEON CONFIDENTIAL7VISTEON CONFIDENTIALbcHEGO SensorCamshaft Position SensorCrankshaft PositionSenso6、raBasic Engine Operations 發動機運行原理發動機運行原理Basic Engine Operations 發動機運行原理發動機運行原理凸輪軸位置傳感器曲軸位置傳感器氧傳感器8VISTEON CONFIDENTIALEngine Cycles(1 of 2)發動機工作循環發動機工作循環Engine Cycles(1 of 2)發動機工作循環發動機工作循環IntakeIntake進氣進氣進氣進氣Compression Compression 壓縮壓縮壓縮壓縮9VISTEON CONFIDENTIALEngine Cycles(2 of 2)發動機工作循環發動機工作循環Engi7、ne Cycles(2 of 2)發動機工作循環發動機工作循環Power 做功做功Exhaust 排氣排氣10VISTEON CONFIDENTIALFuel and Spark Events 噴油和點火事件噴油和點火事件Fuel and Spark Events 噴油和點火事件噴油和點火事件11VISTEON CONFIDENTIALEngine Misfire 發動機失火發動機失火Engine Misfire 發動機失火發動機失火Air/Fuel mixture did not ignite during power stroke空氣和燃油混合物在做功沖程未被點燃 Fuel too lea8、n/rich混合物過濃/稀 Spark timing too advance/retard點火時刻過于提前/滯后 Broken spark plug火花塞損壞 Broken fuel injectors噴油器損壞Causes engine stumble and high emission output造成發動機抖動且排放惡化No CombustionNo CombustionVISTEON CONFIDENTIAL12Jianshi Sept 3,2004Review of Engine Management System Components發動機管理系統零部件概述發動機管理系統零部件概述9、Review of Engine Management System Components發動機管理系統零部件概述發動機管理系統零部件概述13VISTEON CONFIDENTIALSensor:CPS 曲軸位置傳感器曲軸位置傳感器Sensor:CPS 曲軸位置傳感器曲軸位置傳感器 Use for determining engine position,spark,and fuel timing.用于確定曲軸角度位置，確定點火正時和噴油正時 CPS sensor failure=Engine disable曲軸位置傳感器失效=發動機不能運行14VISTEON CONFIDENTIALSenso10、r:Heater Exhaust Gas Output 氧傳感器氧傳感器Sensor:Heater Exhaust Gas Output 氧傳感器氧傳感器EOBD EOBD onlyonlyCalc Calc LambdaLambda Upstream HEGO used for closed loop fuel control(determine Lambda)前氧用于閉環燃油控制 Downstream HEGO used for catalyst monitor(EOBD only)后氧用于催化器監測（EOBD）15VISTEON CONFIDENTIALSensor:TMAP 進氣溫度壓11、力傳感器進氣溫度壓力傳感器Sensor:TMAP 進氣溫度壓力傳感器進氣溫度壓力傳感器Two separate sensors in one housing兩個傳感器集成在一個殼體中Temperature sensor provide engine operating conditions溫度傳感器提供發動機運行情況Manifold pressure sensor used for speed-density calculation壓力傳感器用于速度密度法的計算Cylinder Air ChargeCylinder Air Charge氣缸充氣量氣缸充氣量氣缸充氣量氣缸充氣量MAP MAP 進12、氣歧管壓力進氣歧管壓力進氣歧管壓力進氣歧管壓力16VISTEON CONFIDENTIALActuator:Air Bypass Valve 步進電機步進電機Actuator:Air Bypass Valve 步進電機步進電機Provide idle air control during no driver demand用于怠速空氣控制Provide dashpot function during tip-out提供快速松開油門時的緩沖，使發動機運行平順Failure of ABV can cause engine stall,poor idle engine speed,and poor d13、rivability步進電機失效可能造成發動機熄火、怠速不良、駕駛性不良。Factory reset required after replacement.This is achieved by turning the key on and then leave off for 12 seconds.This allows the PCM to learn the ABV position.ABVABVThrottle BodyThrottle BodyTo ManifoldTo Manifold17VISTEON CONFIDENTIALActuator:Canister Purge Val14、ve 碳罐控制閥碳罐控制閥Actuator:Canister Purge Valve 碳罐控制閥碳罐控制閥Controls the fuel vapor flow from carbon canister to the inlet manifold.控制燃油蒸汽從碳罐到進氣歧管的流動Failure may be stuck open/close or non-responding resulting in either lean or rich fuel mixture失效后可能持續打開/關閉或對ECU的控制無響應，可能造成混合氣過濃或過稀18VISTEON CONFIDENTIALEvapo15、rative Subsystem 燃油蒸汽控制系統燃油蒸汽控制系統Evaporative Subsystem 燃油蒸汽控制系統燃油蒸汽控制系統Carbon canister is design to absorb fuel vapour from the fuel tank碳罐吸收來自油箱的燃油蒸汽Canister Purge Valve controls the flow of the fuel vapour flow into or out of the carbon canister.碳罐控制閥控制燃油蒸汽的流動The system needs to model how much fue16、l is absorb by the carbon canister.系統建模估算出碳罐吸收了多少燃油蒸汽The system also needs to compensate fuel mass deliver to the engine when there are fuel vapour being fed back into the manifold.當燃油蒸汽進入進氣歧管時，系統對各缸噴油量進行調整CAPCAPCanister Purge ValveCanister Purge Valve19VISTEON CONFIDENTIALPowertrain Control Module 17、發動機控制單元發動機控制單元Powertrain Control Module 發動機控制單元發動機控制單元 Main“Brain”of Engine Control System發動機管理系統的大腦 81-pins 共81針 Located in drivers side against the firewall位于駕駛室儀表板下方 Last item to replace due to low failure rate最不需要更換的部件，故障率低。20VISTEON CONFIDENTIALFuel Charge Assembly(FCA)油軌總成油軌總成Fuel Charge Assem18、bly(FCA)油軌總成油軌總成FCA delivers fuel to the cylinder for each cylinder event油軌總成將燃油分配到各氣缸Need to maintain fuel rail pressure of 4 bar for proper operation需要維持在4Bar的壓力下才能正確工作Clogged fuel injector will lead to a lean misfire event堵塞的噴油器可能造成過稀失火Stuck open injector will lead to rich misfire or hydrolock不能關19、閉的噴油器會造成過濃失火或液力鎖止21VISTEON CONFIDENTIALEngine Hydrolock發動機液力鎖止發動機液力鎖止Engine Hydrolock發動機液力鎖止發動機液力鎖止Too much Too much liquidliquidx x Occurs when excess fuel gets into cylinder during an intake stroke.當過多液體進入氣缸時發生 Liquid is not compressible.液體不可壓縮 By forcing engine turning with compressed liquid in c20、ylinder head,severe damage may occur on the connecting rod and cylinder發動機強制運轉會損壞連桿和氣缸22VISTEON CONFIDENTIALFuel Delivery Module(FDM)油泵總成油泵總成Fuel Delivery Module(FDM)油泵總成油泵總成Responsible for maintaining pressure to fuel charge assembly維持油軌壓力Pressure is maintained at 4 Bar油壓4BarFailure mode can cause 21、pressure to drop in system thus causing injectors to not deliver enough fuel resulting in lean operation.Overpressure can cause too much fuel to be delivered by injectors resulting in a rich running system.油泵總成失效可能使油路系統壓力下降，噴油器不能噴出足夠燃油，從而導致過稀燃燒。相反，油壓過高會使噴油器噴出過多燃油，從而導致過濃燃燒。23VISTEON CONFIDENTIALEMS A22、rchitecture 發動機管理系統結構發動機管理系統結構EMS Architecture 發動機管理系統結構發動機管理系統結構Throttle Position SensorTPSRRSIGRTNMAPACTTMAPACTMAPHEGOHO2S11HO2S12HTR11CMSHTR12Engine Coolant Temp.ECTCrank Position SensorCKP+CKP-KS+KS-Cam PositionCMPVRSRTNVSSThree Status SWPWRGNDCompressor Thermal SWA/C Demand SWA/C Blower SWRear 23、Seat A/C Blower SWACCS57ACPSWBSW767559FLI3571523213331454Headlight SWHeadlightPWRGNDVPWR77HLSW24174318A/C Temp.Sensor36ACET3773515516Fuel Pump Relay15VREFVREFVPWRIgnition Switch點火開關ECM Power RelayABCDStepper Motor步進電機Canister Purge Valve碳罐控制閥A/C Clutch Relay空調離合器繼電器Fuel Injector 1噴油器 1缸Ignition Coil24、 A點火線圈 AIgnition Coil B點火線圈 BA/C Condenser Fan Relay空調冷凝器風扇繼電器Water Tank Fan Relay水箱風扇繼電器MA/C Condenser Fan空調冷凝器風扇PWRGNDFC1FC241CDACDBCy1Cy2Cy3Cy4INJ 1INJ 2INJ 3INJ 4256463449811102729IAST AIAST BIAST CIAST DCAN+CAN-CAN2-CAN2+To Calibration ToolCANP638193920Battery18916OBD ConnectorOBD診斷接口CAN+KLINE725、27440KLINECASE GNDMFuel PumpFPFPMPWRGNDFDM Fuel GaugeCluster VSSPWRGNDChasis GNDTo Cluster 到儀表盤SIGRTNMWater Tank Fan水箱風扇VPWRVBAT41VBATISPPWRGND26Theft-R2856VEMS MZ 1.0 PCM45CTOTo Cluster Tachometer22KAPWR2/817MIL80PRCVPWRFuse 3AVBATMIL34Rough Road Sensor30ACCRVBATSIGRTNTo A/C Clutch53PWRGNDChassis G26、NDVPWRVPWRVPWRVPWR10AFuse15AFuseFuse 15A20AFuse20AFuseK-line to be connected directlyto the ECU when immobilizeris not present in the systemKnock SensorChassis GNDVBAT15AFuse節氣門位置傳感器路面傳感器進氣壓力溫度傳感器前氧傳感器后氧傳感器熱敏電阻冷卻液溫度傳感器曲軸位置傳感器爆震傳感器凸輪軸傳感器儀表板車速信號大燈開關大燈三態壓力開關油位計壓縮機熱保護開關空調請求開關空調送風機開關空調后座送風機開關油泵繼電器MCUIMMO27、 CONTROLLER防盜控制器蓄電池燃油泵主繼電器發動機故障燈Fuel Injector 2噴油器 2缸Fuel Injector 3噴油器 3缸Fuel Injector 4噴油器 4缸用于標定工具若系統中無防盜器則K線直接與ECU相連VPWRVPWRFC1FC2ACCR24VISTEON CONFIDENTIALUnique Visteon EMS FeaturesUnique Visteon EMS FeaturesKAPWR(Keep Alive Power used for engine soak timer to minimize emissions on next start)28、ECU常電供電線路FPM(Fuel Pump Monitor used for diagnostics)油泵監測電路ISP PRC(Ignition Switch Position,Power Relay Control)點火開關位置信號輸入Vehicle Mileage Accumulation parameter and timer for when VSS is faulted車速信號用于里程累計Fan controlled directly by relay instead of thermistor風扇由繼電器控制VREF 5V,signal return is groundVREF29、表示5V傳感器電源、SIGRTN表示傳感器信號地25VISTEON CONFIDENTIALElectrical Subsystem(Battery)蓄電池蓄電池Electrical Subsystem(Battery)蓄電池蓄電池Battery Operating Range蓄電池正常運行范圍 Normal is 12-14 volts 12-14VLow battery voltage 蓄電池電壓過低 Not charging:Alternator or bad connector未充電：發電機故障或接頭損壞 Old battery needs replacing舊電池需要更換 Cause30、 bad starts and intermittent ECU failure發動機起動困難且可能有ECU間歇失效ECU needs 6 volts to operate發動機控制單元運行需要至少6V26VISTEON CONFIDENTIALElectrical Subsystem(Starter Motor)起動電機起動電機Electrical Subsystem(Starter Motor)起動電機起動電機Ignition Switch closed to crank starter motor點火開關閉合后起動電機開始拖動Problem 問題 Low Battery wont tur31、n engine to high enough RPM蓄電池電壓過低則無法拖動發動機到足夠的轉速Need at least 100 rpm to synchronize and start engine.需要大約100rpm才能使發動機起動27VISTEON CONFIDENTIALIgnition Subsystem(Overview)點火系統點火系統Ignition Subsystem(Overview)點火系統點火系統COIL type 點火線圈類型 Distributor-less Ignition System(DIS)CoilSwitch is closed to charge t32、he coil開關閉合時開始給線圈初級充電Charging coil stores energy in coil.Normal peak current is 5.5 Amp.充電能量儲存在線圈中。通常的充電截止電流5.5APrimary CoilPrimary CoilOffOff-Time(Spark Event)Time(Spark Event)5.5 A5.5 A28VISTEON CONFIDENTIALIgnition Subsystem(Spark Event)點火系統點火系統Ignition Subsystem(Spark Event)點火系統點火系統Spark Ignitio33、n occur at primary off-time 點火發生在初級電流截斷時Failure mode 失效模式Overcharge causes damage to coil or misfire(no spark)or failed emission(spark retard)初級線圈充電過度會造成點火線圈損壞 或 失火 或排放惡化Undercharge causes misfire(no spark)or knock(spark advance)初級線圈充電不足可能造成失火（無點火）或爆震（點火過于提前）29VISTEON CONFIDENTIALService 維修維修Service34、 維修維修 Customer description of problem客戶故障描述 Confirm problem故障確認 Diagnosing problem故障診斷30VISTEON CONFIDENTIALService Tools 維修工具維修工具Service Tools 維修工具維修工具 Multimeter 萬用表 Diagnostic Scanner 電噴系統診斷儀 What are On Board Diagnostics(OBD)?車載診斷系統 Diagnostic Trouble Codes故障診斷代碼 Open circuit 斷路 Short circuit 短路35、 Parameter Identifications(PIDs)發動機運行參數31VISTEON CONFIDENTIALDiagnostic System 診斷系統診斷系統Diagnostic System 診斷系統診斷系統32VISTEON CONFIDENTIALWhat is Self Test?自診斷自診斷What is Self Test?自診斷自診斷This new feature receives commands to perform one of two classes of tests that is commanded by the service technician36、 via an OBD Scan Tool.診斷儀可以向ECU發出請求以執行KOEO或KOER測試。1.Key On Engine Off(KOEO)點火鑰匙ON(發動機不運行)2.Key On Engine Running(KOER)發動機運行33VISTEON CONFIDENTIALKOEO DefinedKOEO DefinedKOEO portion of the OBD system determines if components are operating within their specified tolerance bands when a service technic37、ian commands the test.When a sensor/actuator operates outside of specification or fails,the KOEO test sets a self-test code.This test provides the technician with a method to confirm repairs.它是OBD系統中的一部分,檢測零部件是否工作在正常范圍內.當傳感器或執行器工作不正常或失效,KOEO測試并生成自診斷代碼.為維修人員提供有效的技術支持.34VISTEON CONFIDENTIALSelf Test K38、OEO Entry Conditions診斷條件診斷條件Self Test KOEO Entry Conditions診斷條件診斷條件All the entry conditions below must be met before the above steps are carried out.需滿足以下條件:1.Ignition Switch is ON點火開關ON2.Engine is not running發動機不運行3.Battery voltage greater than 9 volts電瓶電壓大于9伏4.Vehicle stationary停車狀態5.Dont press br39、ake pedal during KOEO test測試過程中不允許踩剎車6.AC must be switched off during test空調關閉7.Engine temperature must be within calibratable range發動機溫度在正常范圍內8.Clutch pedal must be in calibratable position during test 不踩離合器35VISTEON CONFIDENTIALExample KOEO Flow of TestExample KOEO Flow of Test Calibratable Output40、 States are put into“off”mode and the monitors are checked to ensure they agree.If not,the corresponding DTC is logged.檢測驅動/輸出信號在關的狀態下有無故障碼 Calibratable Output States are put into“on”mode and the monitors and again checked to ensure they are on.If they are not on,the corresponding DTC is logged.檢測驅動41、/輸出信號在開的狀態下有無故障碼 Most notable test is the activation of the engine cooling fan.特別注意檢測風扇是否正常工作Test duration is approximately 30 seconds.測試大概需要持續30秒鐘。36VISTEON CONFIDENTIALKOER DefinedKOER DefinedKOER portion of the OBD system checks whether components are operating within their specification toleranc42、e bands during KOER vehicle operation when demanded by a service technician.When a sensor or actuator operates outside of the specification or fails,the KOER test sets a self-test code.OBD系統的一部分,檢查零部件是否工作在正常范圍內.當傳感器或執行器工作不正常或失效,KOER測試并生成自診斷代碼.為維修人員提供有效的技術支持37VISTEON CONFIDENTIALSelf Test KOER Entry 43、Conditions診斷條件診斷條件Self Test KOER Entry Conditions診斷條件診斷條件All the entry conditions below must be met before the above steps are carried out需滿足以下條件:1.Ignition Switch is ON點火鑰匙ON2.Engine is running發動機運行狀態3.Battery voltage greater than 9 volts電瓶電壓大于9伏4.Vehicle stationary停車狀態5.AC must be switched off dur44、ing test空調關閉6.Engine temperature must be within calibratablerange發動機溫度在正常范圍內38VISTEON CONFIDENTIALExample KOER Flow of Test 舉例舉例Example KOER Flow of Test 舉例舉例 A specific RMP is requested of the Idle Speed Control(ISC).This is also known as the Idle Air Control(IAC)Stepper Motor.觀測怠速時發動機轉速 A specific45、 Spark Advance is requested點火角 A specific Air/Fuel Ratio is requested空燃比 Cooling fan is turned on風扇處于工作狀態 Test waits for the idle speed to stabilize and verifies it is what is desired.待發動機怠速轉速穩定時,檢測目標怠速39VISTEON CONFIDENTIALExample KOER Test-continuedExample KOER Test-continued Oxygen sensor heater 46、is commanded to a constant duty cycle and the air/fuel ratio is read to ensure accurate.氧傳感器加熱在穩定工況,空燃比在正常范圍內 Idle speed control duty cycle is unfrozen and the RPM drops and system monitors this is what has occurred.怠速控制負荷不穩定,發動機轉速下降,系統能夠檢測出異常情況 Once all tests are completed,if any failures occur,the47、 corresponding DTCs are logged.所有測試檢測完成后,若發現有失效現象,ECU將會記錄相應的故障代碼40VISTEON CONFIDENTIALQuestions?Questions?41VISTEON CONFIDENTIALContact Information 聯系信息聯系信息Contact Information 聯系信息聯系信息Jason Yang Jason Yang Powertrain Systems EngineerPowertrain Systems EngineerEmail:Email:jyang2visteonjyang2visteon-Phone(Visteon JV Chongqing):86Phone(Visteon JV Chongqing):86-2323-67257188 x850767257188 x8507Gary Lepidi Gary Lepidi Project LeaderProject LeaderEmail:Email:Phone(Visteon US):01Phone(Visteon US):01-1 1-734734-710710-48744874