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Engine Management Requirements  Must Comply With Any Anti Pollutant Legislation  Must Meet Customers Requirements for Easy Operation  Must Be Extremely Reliable With Minimal Maintenance  Must Give Smooth Driving Capability  Must Be As Economical As Possible  Must Be As Powerful As Possible  Must Be As Quiet As Possible

Previous Engine Management Systems MEMS 1.3 MEMS 1.6 MEMS 1.9 MEMS 2J PGMFI

Engine Management System Types MEMS K SERIES 1.6 K SERIES 1.8 K SERIES 1.8 K SERIES VVC SIEMENS KV6 2.5 KV6

Fuel Delivery System K Series Fuel Tank & Swirl Pot

Fuel Delivery System K Series Fuel Pump

Fuel Delivery System K Series Filter

Fuel Delivery System K Series Injector

Fuel Delivery System K Series Pressure Regulator

System Inputs MEMS 3 Siemens 2000

Crankshaft Position Sensor

Crankshaft Signal

MEMS 1.6MEMS 1.6 Robust MEMS1.9

MEMS 3 Siemens 2000

Camshaft Position Sensor

Camshaft Signal in Relation to Crankshaft Signal MEMS 3

Camshaft Signal in Relation to Crankshaft Signal Siemens 2000

Throttle Position Sensor VOLTAGE DEGREE OF THROTTLE BUTTERFLY SIEMENS 2000 MEMS3

Coolant & Oil Temperature Sensor Cº 

Coolant & Oil Temperature Sensor Cº V

Temperature Manifold Absolute Pressure Sensor

Heated Oxygen Sensors

Oxygen Sensor Operation

Oxygen Sensor Signal

Catalytic Converter Processes Carbon dioxide CO2 13% Water H2O 14% Nitrogen N 72.9% CO + HC + Nox 0.1%

Downstream Oxygen Sensor Signal

Fuel Correction

Knock Sensors

Immobilisation Signal

Inputs Inertia Switch PAS Load Switch

Inputs Fuel Level Alternator Load

Inputs Ignition Switch Air Con Request

Inputs Trinary Switch Evaporator Temperature Sensor

Inputs Automatic Gearbox Variable Induction Sensors

Traction Control

Inputs Rough Road/Speedo

Outputs MEMS 3 Siemens 2000

Stepper Motor

Bipolar Stepper Motor

Ignition Coils

MEMS 3 Ignition Coils

Siemens 2000 Ignition Coils

Ignition Coil Care Points Never Disconnect an HT Lead & Crank the Engine Never Remove a Coil From Its Mountings & Crank the Engine Never Hold an HT Lead With the Engine Running Never Fit Non-genuine Coils or Spark Plugs Always Handle HT Leads With the Correct Insulated Tools Always Fit a Spark Plug With a Good Earth to the HT Leads When Cranking & Checking for a Spark

Injectors

Temperature Gauge

Tachometer

Malfunction Indicator Lamp

Outputs Automatic Gearbox Fuel Pump, Main & Air Con Relays

Air Conditioning Clutch Operation

MEMS 3 Cooling Fan Operation

Siemens 2000 Cooling Fan Operation FanSpeed Coolant Temp *C On Off Air Con Request Trinary Switch Input Gearbox Request Coolant Sensor Status, Valid = No Engine Running Status Off< 96_____No ValidYes Slow> 100<96YesNo ValidYes Medium> 106< 102_____Yes Not ValidYes Medium> 115< 112 (Max 10mins) No_____NoValidNo Fast> 112< 108_____ Yes

Purge System

Variable Induction System

2.0 KV6 Torque Performance

2.5 KV6 Torque Performance

Short Term Fuel Trim Looks Directly at Oxygen Sensor Feedback Positive Adaption – Lean Mixture Negative Adaption – Rich Mixture Operates 100% of the Time Injector Pulse Width Start Points MEMS 3 100%  7.5% Siemens %  7.5%

Long Term Fuel Trim Derived From Correlating Short Term Adaptions at Varying Engine Speeds Additive Adaption – Adds a Fixed Amount of Fuel to Map Learnt at Higher Engine Speeds Provides a Base for All Other Fuelling Adaptions Not Active During Purge Periods MEMS 3 0%  1.5% Siemens 2000  1.5%

Ignition Timing MEMS 3 CKP Sensor ECT Sensor TP Sensor IAT sensor ( where applicable) Calculated from : - Dwell Angle : - CKP Sensor Battery Voltage

Ignition Timing Siemens 2000 CKP Sensor TMAP Sensor ECT Sensor TP Sensor (idle only) Knock Sensors Closed Loop Ignition System CKP Sensor Battery Voltage Primary Winding Current (internal EMC connection) Calculated from : - Dwell Angle : -

Closed Loop Fuelling HO 2 S (Upstream of Catalyst) Fuel Injectors To Achieve Closed Loop Fuelling the ECM Uses the Following Components: Closed Loop Fuelling Occurs : - Idle Light Engine Load Cruise

Open Loop Fuelling Cold Start Warm up (Until HO 2 S Is Functional) Full Load Part Throttle Acceleration (Beyond 85° TP) Hot Start (Until HO 2 S Is Functional) Overrun Fuel Cut off HO 2 S Failure Open Loop Fuelling Occurs : -

Ignition Problems Fuelling Problems Electrical Problems Crankshaft Sensor Problems Mechanical Problems Air Restriction or Leak Problems Misfire Causes 4.4

Misfire Detection

Misfire Detection Disable Parameters SystemConditions Idle Speed>= 500 Rpm Engine LoadUnstable or Fluctuating Throttle Pedal PositionUnstable or Fluctuating Air Conditioning RequestSuspended for 5 Seconds Engine Start upSuspended for 5 Seconds Ignition MovementIgnition Delay on (Knock Control,traction or Torque Request Rough RoadRough Road Detected Fuel Tank LevelFuel Tank Level Below 15% (May Disable or Record & Remain Active

Fuelling Adaption Map Additive Adaptions Multiplicative Adaptions

MEMS 3 Crankshaft Adaptation Learning Sequence With the Engine Warm, Above 86ºC & Select 2nd Gear Accelerate the Vehicle Until the Engine Speed Reaches at Least 5,000 Rpm Release the Throttle Fully and Allow the Vehicle to Decelerate Until the Engine Idle Speed Is Reached (or Just Above) Without Applying the Brakes Repeat the Above Procedure Several Times to Ensure That the New Value Has Been Recorded Check for Any Fault Codes After This Procedure Using Testbook, Clear Any Misfire Faults.

Siemens 2000 Crankshaft Adaptions Reset Procedure Connect Testbook Select – Reset Crankshaft Adaptions (If Not Fitting a New ECM) Run Engine Until at Coolant Temperature Exceeds 90°c Accelerate Engine up to 5000 Rpm Release Throttle and Allow to Return to Idle Repeat Above Until Testbook Displays You Have Been Successful Clear Any Misfire Detection Faults Logged During This Exercise

Resetting Throttle Adaptions Switch on Ignition Depress Throttle Pedal From Fully Closed to Fully Open 5 Times in a 10 Second Period Wait 20 Seconds Without Touching Throttle Switch off Ignition for 20 Seconds

Fault Diagnosis T4 Diagnostic Equipment Fault Code Retrieval Freeze Frame Data Diagnostic Fault Finding Trail

Freeze Frame data

P0322 Fault Code Format

P0322 Fault Code Format

P0322

Fault Code Format P0322

What is On Board Diagnostics?

O.B.D System Objectives To Detect Faults Relevant To Exhaust Emissions To Store Fault Codes ( In ECM ) To Display Faults ( MIL Lamp ) Fault Retrieval ( Via Diagnostic Equipment )

O.B.D-I Originated In California In Implemented By C.A.R.B For Vehicles Sold From Monitored Oxygen Sensor, EGR System, Fuel Delivery & Engine ECM. No Standardisation Of Diagnostic Plug

O.B.D-II C.A.R.B Proposed New Standards In Issued By Us.E.P.A To Be Phased In During 1994 Compulsory In 1996 Mil Lamp To Illuminate When Emissions Exceed 1.5 Times The Federal Test Procedure (F.T.P) Limit Including :- Random Misfires - Causing A Rise In HC's & A Drop In Catalytic Converter Efficiency

An Air Leak Detected In The Sealed Fuel System A Failed Key Sensor Or Other Emission Related Device Standardisation Of Diagnostic Plugs & Trouble Codes O.B.D -II Cont..

E.O.B.D Known As Euro - 3, Developed From EU -1 & EU -2 Regulations Adopted O.B.D-II Standards For Compulsory Implementation On 2000 My As Per EC Directives Limits For Euro-3 Legislation For Cars Up To 2500 Kg :- Carbon Monoxide ( Co ) G/km Hydrocarbons ( HC ) G/km Oxides of Nitrogen(NOx’s ) G/km

Catalytic Converter Catalytic Converter Heater (Where Applicable) Misfire Detection Fuel System HO 2 Sensors Secondary Air System (Where Applicable) Fuel Filler Cap Captive Or Monitored (Where Applicable) E.O.B.D Monitors

Exhaust Gas Emission Legislation

Emission Levels As Legislated by Directive 98/69/EG Pollutant (G/km) 1996/97 corrected values 2000 corrected values Max levels before a mil fault recorded 2005 indicative values Carbon monoxide hydrocarbons Nitrogen oxides On a test cycle equivalent to stage 2000

Homologation All Motor Manufacturers Are Required To Homologate Vehicles Produced For Each Different Market Any Vehicle Must Meet Any Active Law Or Directive Vehicle Crash Test Occupant Safety Braking Steering Emission Levels

Homologation Driving Cycle

ECM Monitor Groups Permanent Monitoring : - Misfire Detection Fuel System (Injector Duration / Ho2 Sensor Feedback) Electrical Circuits for Emission Related Interfaces

ECM Monitor Groups Cycle Monitoring : - Catalytic Converter HO2 Sensor Performance Coolant Temperature Sensor Warm up Curve

Service Drive Cycle Start Car From Cold Drive Car (Uninterrupted) Until Normal Operating Temperature Is Reached Switch off Car Allow Power Down Sequence to Take Place Return to a Cold Engine Condition

Suspension Of Drive Cycle Monitoring Fault Causing Open Loop Tuning Engine Temperature Below 85°C Vehicle Speed Out of the Range ( Mph) Catalytic Converter Not up to Temperature (350°C) Throttle Pedal Operation Erratic Engine Speed Erratic Lambda Readings Erratic

MIL Lamp Illumination Fault Type A Catalyst Damaging Misfire MIL Light on Immediately & Flash (Whilst Fault Present) Stores Fault Code, History Code, Failure Record Readiness Flag Raised

First Occurrence of Fault – Code & Data Stored - No MIL Light Readiness Flag Raised Next Drive Cycle, Same Fault - No MIL Light Third Drive Cycle, Same Fault, MIL Light On MIL Lamp Illumination Fault Type B

Extinguishing MIL Lamp Testbook / T4 After Repair ( prior to drive cycle ) 3 Consecutive Clear Drive Cycles Diagnostic Trouble Code Cleared After 40 Clear Drive Cycles Where Same Operating Conditions Are Met Cleared After 80 Clear Drive Cycles Where Same Operating Conditions Are Not Met

Resetting Readiness Flags Carry Out Testbook Diagnosis Repair Fault as Necessary Clear Fault Codes Carry Out Relevant Drive Cycles Retest With Testbook (to Ensure Drive Cycle Has Been Successful) Hand Back to Customer