1. Welcome to AfterSalesTraining

2. 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

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

4. Engine Management System Types MEMS 3 1.4 K SERIES 1.6 K SERIES 1.8 K SERIES 1.8 K SERIES VVC SIEMENS 2000 2.0 KV6 2.5 KV6

5. Fuel Delivery System K Series Fuel Tank & Swirl Pot

6. Fuel Delivery System K Series Fuel Pump

7. Fuel Delivery System K Series Filter

8. Fuel Delivery System K Series Injector

9. Fuel Delivery System K Series Pressure Regulator

10. System Inputs MEMS 3 Siemens 2000

11. Crankshaft Position Sensor

12. Crankshaft Signal

13. MEMS 1.6MEMS 1.6 Robust MEMS1.9

14. MEMS 3 Siemens 2000

15. Camshaft Position Sensor

16. Camshaft Signal in Relation to Crankshaft Signal MEMS 3

17. Camshaft Signal in Relation to Crankshaft Signal Siemens 2000

18. Throttle Position Sensor VOLTAGE DEGREE OF THROTTLE BUTTERFLY SIEMENS 2000 MEMS3

19. Coolant & Oil Temperature Sensor Cº 

20. Coolant & Oil Temperature Sensor Cº V

21. Temperature Manifold Absolute Pressure Sensor

23. Heated Oxygen Sensors

24. Oxygen Sensor Operation

25. Oxygen Sensor Signal

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

27. Downstream Oxygen Sensor Signal

28. Fuel Correction

29. Knock Sensors

30. Immobilisation Signal

32. Inputs Inertia Switch PAS Load Switch

33. Inputs Fuel Level Alternator Load

34. Inputs Ignition Switch Air Con Request

35. Inputs Trinary Switch Evaporator Temperature Sensor

36. Inputs Automatic Gearbox Variable Induction Sensors

37. Traction Control

38. Inputs Rough Road/Speedo

39. Outputs MEMS 3 Siemens 2000

40. Stepper Motor

41. Bipolar Stepper Motor

42. Ignition Coils

43. MEMS 3 Ignition Coils

44. Siemens 2000 Ignition Coils

45. 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

46. Injectors

47. Temperature Gauge

48. Tachometer

49. Malfunction Indicator Lamp

50. Outputs Automatic Gearbox Fuel Pump, Main & Air Con Relays

51. Air Conditioning Clutch Operation

52. MEMS 3 Cooling Fan Operation

53. 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

54. Purge System

55. Variable Induction System

59. 2.0 KV6 Torque Performance

60. 2.5 KV6 Torque Performance

61. 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 2000 0%  7.5%

62. 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%

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

64. 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 : -

65. 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

66. 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 : -

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

68. Misfire Detection

69. 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

70. Fuelling Adaption Map Additive Adaptions Multiplicative Adaptions

71. 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.

72. 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

73. 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

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

75. Freeze Frame data

76. P0322 Fault Code Format

77. P0322 Fault Code Format

78. P0322

79. Fault Code Format P0322

80. What is On Board Diagnostics?

81. 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 )

82. O.B.D-I Originated In California In 1982. Implemented By C.A.R.B For Vehicles Sold From 1988. Monitored Oxygen Sensor, EGR System, Fuel Delivery & Engine ECM. No Standardisation Of Diagnostic Plug

83. O.B.D-II C.A.R.B Proposed New Standards In 1989. 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

84. 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..

85. 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 ) - 3.2 G/km Hydrocarbons ( HC ) - 0.4 G/km Oxides of Nitrogen(NOx’s ) - 0.6 G/km

86. 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

87. Exhaust Gas Emission Legislation

88. 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 monoxide2.72.33.21.0 hydrocarbons0.3410.20.40.1 Nitrogen oxides0.2520.150.60.08 On a test cycle equivalent to stage 2000

89. 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

90. Homologation Driving Cycle

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

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

93. 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

94. Suspension Of Drive Cycle Monitoring Fault Causing Open Loop Tuning Engine Temperature Below 85°C Vehicle Speed Out of the Range (3 - 50 Mph) Catalytic Converter Not up to Temperature (350°C) Throttle Pedal Operation Erratic Engine Speed Erratic Lambda Readings Erratic

95. 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

96. 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

97. 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

98. 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