长安伟世通发动机管理系统培训手册.pdf

VISTEON CONFIDENTIAL 1 Jianshi Sept 3 2004 Visteon EMS Service Training 伟世通电喷系统维修伟世通电喷系统维修 Visteon EMS Service Training 伟世通电喷系统维修伟世通电喷系统维修 Yang JingjingYang Jingjing Gary LepidiGary Lepidi 2 VISTEON CONFIDENTIAL AgendaAgenda Introductions 自我介绍 Basic Electronics 基本电路知识 Powertrain Control Module 发动机控制单元 Engine Management System 发动机管理系统 Service 维修 3 VISTEON CONFIDENTIAL Basic ElectronicsBasic Electronics Basic Electronics 基本电路原理 Ohm s Law 欧姆定律 INPUTS 输入 Sensors 传感器 Temperature ECT IAT 温度传感器 Pressure MAP 压力传感器 Variable Reluctance CMP CKP 磁电式传感器 Switches 开关 OUTPUTS 输出 Actuators 执行器 Stepper Motor步进电机 Valves Injectors coils电磁阀 喷油器 点火线圈 COMBINATION I O 输入输出组合 Heated Exhaust Gas Oxygen HEGO Sensor 加热型氧传感器 Heater element 加热元件 Oxygen Sensor 氧传感器 4 VISTEON CONFIDENTIAL Powertrain Control Module 发动机控制单元发动机控制单元 Powertrain Control Module 发动机控制单元发动机控制单元 Major System Components 主要组成 Hardware 硬件 PWB Printed Wiring Board 电路板 16 Bit Microprocessor 16位微处理器 2K EEPROM Flash 存储器 Drivers 输出驱动 Module Case 控制单元外壳 J1 Connector 控制单元81针插头 Software 软件 Operating System 操作系统 IVFER In Vehicle Flash and Erase program Low level drivers 底层驱动 Strategy 策略 Combination of all engine features working together 各种控制功能的组合 Calibration 标定 5 VISTEON CONFIDENTIAL Overview of the EMS system 电喷系统概述电喷系统概述 Overview of the EMS system 电喷系统概述电喷系统概述 Basic Engine operation 发动机基本运行原理 Fuel Subsystem 燃油子系统 Ignition Subsystem 点火子系统 IAC Subsystem 怠速控制子系统 Sensor and Actuators 传感器和执行器 6 VISTEON CONFIDENTIAL 7 VISTEON CONFIDENTIAL b c HEGO Sensor Camshaft Position Sensor Crankshaft Position Sensor a Basic Engine Operations 发动机运行原理发动机运行原理Basic Engine Operations 发动机运行原理发动机运行原理 凸轮轴位置传感器 曲轴位置 传感器 氧传感器 8 VISTEON CONFIDENTIAL Engine Cycles 1 of 2 发动机工作循环发动机工作循环Engine Cycles 1 of 2 发动机工作循环发动机工作循环 IntakeIntake进气进气进气进气Compression Compression 压缩压缩压缩压缩 9 VISTEON CONFIDENTIAL Engine Cycles 2 of 2 发动机工作循环发动机工作循环Engine Cycles 2 of 2 发动机工作循环发动机工作循环 Power 做功做功Exhaust 排气排气 10 VISTEON CONFIDENTIAL Fuel and Spark Events 喷油和点火事件喷油和点火事件Fuel and Spark Events 喷油和点火事件喷油和点火事件 11 VISTEON CONFIDENTIAL Engine Misfire 发动机失火发动机失火Engine Misfire 发动机失火发动机失火 Air Fuel mixture did not ignite during power stroke 空气和燃油混合物在做功冲程未 被点燃 Fuel too lean rich 混合物过浓 稀 Spark timing too advance retard 点火时刻过于提前 滞后 Broken spark plug 火花塞损坏 Broken fuel injectors 喷油器损坏 Causes engine stumble and high emission output 造成发动机抖动且排放恶化 No CombustionNo Combustion VISTEON CONFIDENTIAL 12 Jianshi Sept 3 2004 Review of Engine Management System Components 发动机管理系统零部件 概述 发动机管理系统零部件 概述 Review of Engine Management System Components 发动机管理系统零部件 概述 发动机管理系统零部件 概述 13 VISTEON CONFIDENTIAL Sensor CPS 曲轴位置传感器曲轴位置传感器Sensor CPS 曲轴位置传感器曲轴位置传感器 Use for determining engine position spark and fuel timing 用于确定曲轴角度位置 确定点火正时和喷油正 时 CPS sensor failure Engine disable 曲轴位置传感器失效 发动机不能运行 14 VISTEON CONFIDENTIAL Sensor Heater Exhaust Gas Output 氧传感器氧传感器Sensor Heater Exhaust Gas Output 氧传感器氧传感器 EOBD EOBD onlyonly Calc Calc LambdaLambda Upstream HEGO used for closed loop fuel control determine Lambda 前氧用于闭环燃油控制 Downstream HEGO used for catalyst monitor EOBD only 后氧用于催化器监测 EOBD 15 VISTEON CONFIDENTIAL Sensor TMAP 进气温度压力传感器进气温度压力传感器Sensor TMAP 进气温度压力传感器进气温度压力传感器 Two separate sensors in one housing 两个传感器集成在一个 壳体中 Temperature sensor provide engine operating conditions 温度传感器提供发动机 运行情况 Manifold pressure sensor used for speed density calculation 压力传感器用于速度密 度法的计算 Cylinder Air ChargeCylinder Air Charge 气缸充气量气缸充气量气缸充气量气缸充气量 MAP MAP 进气歧管压力进气歧管压力进气歧管压力进气歧管压力 16 VISTEON CONFIDENTIAL Actuator Air Bypass Valve 步进电机步进电机Actuator Air Bypass Valve 步进电机步进电机 Provide idle air control during no driver demand 用于怠速空气控制 Provide dashpot function during tip out 提供快速松开油门时的缓冲 使发 动机运行平顺 Failure of ABV can cause engine stall poor idle engine speed and poor drivability 步进电机失效可能造成发动机熄 火 怠速不良 驾驶性不良 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 ABVABV Throttle BodyThrottle Body To ManifoldTo Manifold 17 VISTEON CONFIDENTIAL Actuator Canister Purge Valve 碳罐控制阀碳罐控制阀Actuator Canister Purge Valve 碳罐控制阀碳罐控制阀 Controls the fuel vapor flow from carbon canister to the inlet manifold 控制燃油蒸汽从碳罐到进气歧 管的流动 Failure may be stuck open close or non responding resulting in either lean or rich fuel mixture 失效后可能持续打开 关闭或对 ECU的控制无响应 可能造成 混合气过浓或过稀 18 VISTEON CONFIDENTIAL Evaporative Subsystem 燃油蒸汽控制系统燃油蒸汽控制系统Evaporative Subsystem 燃油蒸汽控制系统燃油蒸汽控制系统 Carbon canister is design to absorb fuel vapour from the fuel tank 碳罐吸收来自油箱的燃油蒸汽 Canister Purge Valve controls the flow of the fuel vapour flow into or out of the carbon canister 碳罐控制阀控制燃油蒸汽的流动 The system needs to model how much fuel is absorb by the carbon canister 系统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 当燃油蒸汽进入进气歧管时 系统对各缸喷油量进行调整 CAPCAP Canister Purge ValveCanister Purge Valve 19 VISTEON CONFIDENTIAL Powertrain Control Module 发动机控制单元发动机控制单元Powertrain Control Module 发动机控制单元发动机控制单元 Main Brain of Engine Control System 发动机管理系统的大脑 81 pins 共81针 Located in driver s side against the firewall 位于驾驶室仪表板下方 Last item to replace due to low failure rate 最不需要更换的部件 故障率低 20 VISTEON CONFIDENTIAL Fuel Charge Assembly FCA 油轨总成油轨总成Fuel Charge Assembly FCA 油轨总成油轨总成 FCA delivers fuel to the cylinder for each cylinder event 油轨总成将燃油分配到各气缸 Need to maintain fuel rail pressure of 4 bar for proper operation 需要维持在4Bar的压力下才能正确工作 Clogged fuel injector will lead to a lean misfire event 堵塞的喷油器可能造成过稀失火 Stuck open injector will lead to rich misfire or hydrolock 不能关闭的喷油器会造成过浓失火或液力锁止 21 VISTEON CONFIDENTIAL Engine Hydrolock发动机液力锁止发动机液力锁止Engine Hydrolock发动机液力锁止发动机液力锁止 Too much Too much liquidliquid x x Occurs when excess fuel gets into cylinder during an intake stroke 当过多液体进入气缸时发生 Liquid is not compressible 液体不可压缩 By forcing engine turning with compressed liquid in cylinder head severe damage may occur on the connecting rod and cylinder 发动机强制运转会损坏连杆和 气缸 22 VISTEON CONFIDENTIAL Fuel Delivery Module FDM 油泵总成油泵总成Fuel Delivery Module FDM 油泵总成油泵总成 Responsible for maintaining pressure to fuel charge assembly 维持油轨压力 Pressure is maintained at 4 Bar 油压4Bar Failure mode can cause 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 油泵总成失效可能使油路系统压 力下降 喷油器不能喷出足够燃 油 从而导致过稀燃烧 相反 油压过高会使喷油器喷出过多燃 油 从而导致过浓燃烧 23 VISTEON CONFIDENTIAL EMS Architecture 发动机管理系统结构发动机管理系统结构EMS Architecture 发动机管理系统结构发动机管理系统结构 Throttle Position Sensor TPS RR SIGRTN MAPACT TMAP ACT MAP HEGO HO2S11 HO2S12 HTR11 CMS HTR12 Engine Coolant Temp ECT Crank Position Sensor CKP CKP KS KS Cam Position CMP VRSRTN VSS Three Status SW PWRGND Compressor Thermal SWA C Demand SWA C Blower SW Rear Seat A C Blower SW ACCS 57 ACPSW BSW 76 75 59 FLI 35 71 52 32 13 33 14 54 Headlight SW Headlight PWRGND VPWR 77 HLSW 24 17 43 18 A C Temp Sensor 36 ACET 37 73 51 55 16 Fuel Pump Relay 15 VREF VREF VPWR Ignition Switch 点火开关 ECM Power Relay A B C D Stepper Motor 步进电机 Canister Purge Valve 碳罐控制阀 A C Clutch Relay 空调离合器继电器 Fuel Injector 1 喷油器 1缸 Ignition Coil A 点火线圈 A Ignition Coil B 点火线圈 B A C Condenser Fan Relay 空调冷凝器风扇继电器 Water Tank Fan Relay 水箱风扇继电器 M A C Condenser Fan 空调冷凝器风扇 PWRGND FC1 FC2 4 1 CDA CDB Cy1 Cy2 Cy3Cy4 INJ 1 INJ 2 INJ 3 INJ 4 25 64 63 44 9 8 11 10 27 29 IAST A IAST B IAST C IAST D CAN CAN CAN2 CAN2 To Calibration Tool CANP 6 38 19 39 20 Battery 18 916 OBD Connector OBD诊断接口 CAN KLINE 72 74 40 KLINE CASE GND M Fuel Pump FP FPM PWRGND FDM Fuel Gauge Cluster VSS PWRGND Chasis GND To Cluster 到仪表盘 SIGRTN M Water Tank Fan 水箱风扇 VPWR VBAT 41 VBAT ISP PWRGND 26 Theft R 28 56 VEMS MZ 1 0 PCM 45 CTO To Cluster Tachometer 22 KAPWR 2 81 7 MIL 80 PRC VPWR Fuse 3A VBAT MIL 34 Rough Road Sensor 30 ACCR VBAT SIGRTN To A C Clutch 5 3 PWRGND Chassis GND VPWR VPWR VPWRVPWR 10A Fuse 15A Fuse Fuse 15A 20AFuse 20A Fuse K line to be connected directly to the ECU when immobilizer is not present in the system Knock Sensor Chassis GND VBAT 15A Fuse 节气门位置传感器路面传感器进气压力温度传感器 前氧传感器后氧传感器 热敏电阻 冷却液温度传感器 曲轴位置传感器爆震传感器 凸轮轴传感器仪表板车速信号 大灯开关 大灯 三态压力开关 油位计 压缩机热保护开关空调请求开关空调送风机开关 空调后座送风机开关 油泵继电器 MCU IMMO CONTROLLER 防盗控制器 蓄电池 燃油泵 主继电器 发动机故障灯 Fuel Injector 2 喷油器 2缸 Fuel Injector 3 喷油器 3缸 Fuel Injector 4 喷油器 4缸 用于标定工具 若系统中无防盗器 则K线直接与ECU相连 VPWRVPWR FC1 FC2 ACCR 24 VISTEON CONFIDENTIAL Unique Visteon EMS FeaturesUnique Visteon EMS Features KAPWR Keep Alive Power used for engine soak timer to minimize emissions on next start ECU常电供电线路 FPM Fuel Pump Monitor used for diagnostics 油泵监测电路 ISP PRC Ignition Switch Position Power Relay Control 点火开关位置信号输入 Vehicle Mileage Accumulation parameter and timer for when VSS is faulted 车速信号用于里程累计 Fan controlled directly by relay instead of thermistor 风扇由继电器控制 VREF 5V signal return is ground VREF表示5V传感器电源 SIGRTN表示传感器信号地 25 VISTEON CONFIDENTIAL Electrical Subsystem Battery 蓄电池蓄电池Electrical Subsystem Battery 蓄电池蓄电池 Battery Operating Range 蓄电池正常运行范围 Normal is 12 14 volts 12 14V Low battery voltage 蓄电池电压过低 Not charging Alternator or bad connector 未充电 发电机故障或接头损坏 Old battery needs replacing 旧电池需要更换 Cause bad starts and intermittent ECU failure 发动机起动困难且可能有ECU间歇失效 ECU needs 6 volts to operate 发动机控制单元运行需要至少6V 26 VISTEON CONFIDENTIAL Electrical Subsystem Starter Motor 起动电机起动电机Electrical Subsystem Starter Motor 起动电机起动电机 Ignition Switch closed to crank starter motor 点火开关闭合后起动电机 开始拖动 Problem 问题 Low Battery won t turn engine to high enough RPM 蓄电池电压过低则无法拖 动发动机到足够的转速 Need at least 100 rpm to synchronize and start engine 需要大约100rpm才能使发 动机起动 27 VISTEON CONFIDENTIAL Ignition Subsystem Overview 点火系统点火系统Ignition Subsystem Overview 点火系统点火系统 COIL type 点火线圈类型 Distributor less Ignition System DIS Coil Switch is closed to charge the coil 开关闭合时开始给线圈初级充电 Charging coil stores energy in coil Normal peak current is 5 5 Amp 充电能量储存在线圈中 通常的充电截止电流5 5A Primary CoilPrimary Coil OffOff Time Spark Event Time Spark Event 5 5 A5 5 A 28 VISTEON CONFIDENTIAL Ignition Subsystem Spark Event 点火系统点火系统Ignition Subsystem Spark Event 点火系统点火系统 Spark Ignition occur at primary off time 点火发生在初级电流截断时 Failure mode 失效模式 Overcharge causes damage to coil or misfire no spark or failed emission spark retard 初级线圈充电过度会造成点火线圈损坏 或 失火 或排放恶化 Undercharge causes misfire no spark or knock spark advance 初级线圈充电不足可能造成失火 无点火 或爆震 点火过于提前 29 VISTEON CONFIDENTIAL Service 维修维修Service 维修维修 Customer description of problem 客户故障描述 Confirm problem 故障确认 Diagnosing problem 故障诊断 30 VISTEON CONFIDENTIAL Service Tools 维修工具维修工具Service Tools 维修工具维修工具 Multimeter 万用表 Diagnostic Scanner 电喷系统诊断仪 What are On Board Diagnostics OBD 车载诊断系统 Diagnostic Trouble Codes故障诊断代码 Open circuit 断路 Short circuit 短路 Parameter Identifications PIDs 发动机运行参数 31 VISTEON CONFIDENTIAL Diagnostic System 诊断系统诊断系统Diagnostic System 诊断系统诊断系统 32 VISTEON CONFIDENTIAL What is Self Test 自诊断自诊断What is Self Test 自诊断自诊断 This new feature receives commands to perform one of two classes of tests that is commanded by the service technician via an OBD Scan Tool 诊断仪可以向ECU发出请求以执行 KOEO或KOER测试 1 Key On Engine Off KOEO 点火钥匙ON 发 动机不运行 2 Key On Engine Running KOER 发动机运行 33 VISTEON CONFIDENTIAL KOEO DefinedKOEO Defined KOEO portion of the OBD system determines if components are operating within their specified tolerance bands when a service technician 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系统中的一部分 检测 零部件是否工作在正常范围内 当传感器或执 行器工作不正常或失效 KOEO测试并生成自诊 断代码 为维修人员提供有效的技术支持 34 VISTEON CONFIDENTIAL Self Test KOEO Entry Conditions诊断条 件 诊断条 件 Self Test KOEO Entry Conditions诊断条 件 诊断条 件 All the entry conditions below must be met before the above steps are carried out 需满足以下条件 1 Ignition Switch is ON点火开关ON 2 Engine is not running发动机不运行 3 Battery voltage greater than 9 volts电瓶电压大于9伏 4 Vehicle stationary停车状态 5 Don t press brake pedal during KOEO test测试过程中不允许踩刹车 6 AC must be switched off during test空调关闭 7 Engine temperature must be within calibratable range发动机温度在正常 范围内 8 Clutch pedal must be in calibratable position during test 不踩离合器 35 VISTEON CONFIDENTIAL Example KOEO Flow of TestExample KOEO Flow of Test Calibratable Output States are put into off mode and the monitors are checked to ensure they agree If not the corresponding DTC is logged 检测驱动 输出信号在 关的状态下有无故障码 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 检 测驱动 输出信号在开的状态下有无故障码 Most notable test is the activation of the engine cooling fan 特别注意检测风扇是否正常工作 Test duration is approximately 30 seconds 测试大概需要持续30秒钟 36 VISTEON CONFIDENTIAL KOER DefinedKOER Defined KOER portion of the OBD system checks whether components are operating within their specification tolerance 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系统的一部分 检查零部件是否工作在正常范围内 当 传感器或执行器工作不正常或失效 KOER测试并生成 自诊断代码 为维修人员提供有效的技术支持 37 VISTEON CONFIDENTIAL Self Test KOER Entry Conditions诊断条 件 诊断条 件 Self Test KOER Entry Conditions诊断条 件 诊断条 件 All the entry conditions below must be met before the above steps are carried out需满足以下条件 1 Ignition Switch is ON点火钥匙ON 2 Engine is running发动机运行状态 3 Battery voltage greater than 9 volts电瓶电压大于9 伏 4 Vehicle stationary停车