Main text-mmm - SAIPAeng.saipayadak.org/CarDocument/RM/PDx100RM2C21.pdf · The fuel delivery system used on new Saipa engine, equipped with siemens injection system, is of Multi Point

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PDx100RM2C/2/1

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Injection Fuel Delivery System(Siemens Kit)

Guidance and Diagnosis Manual

SAIPA

Technical & Engineering Department

Injection Fuel Delivery System /siemens kit


Table of contents-Foreword 5 -Introduction 7-System Components 9 -Description of the System 11-Position of system parts and assemblies 12 -Introduction of the system 13-Diagram of total functions 14 -Fuel delivery system 17 -Air delivery system 22 -Double ignition coil 24-Electronic Control Unit 25 -Sensors 29 -Actuators 33-The schematic diagram of injection kit 35-Description of the connectors integrated with the system 36 System Components Trouble –Shooting 37 -Introduction 39 -Cross section of ECU connector 40-Injector No 1 41-Injector No 2 42-Injector No 3 43-Injector No 4 44-Coil 1 & 4 45 -Coil 2 & 3 46 -Engine speed sensor 47-Air intake manifold pressure sensor 48 -Vehicle speed sensor 50 -Stepper motor 51 -Throttle position sensor 52 -Main relay 53 -Fuel pump relay 54 -Air temperature sensor 55 -Coolant temperature sensor 57 -Camshaft position sensor 58 -Canister purge valve 59 -Oxygen sensor heater 60 -Oxygen sensor 61 -A descriptive diagram of the system 63 -A schematic diagram of injection kit 64 -ECU Connector’s cross section 65Comment form 66



ForewordThis manual was prepared by the experts and specialists in technical & Engineering department of Saipa yadak Company to be used as a guide by repairers of new saipa vehicles equipped with fuel injection delivery system (Siemens kit) . we hope that the repairers and specialists having carefully read this manual and through continuous refer to it as a general guide, while getting familier with the diagnostic tool and its usage become acquainted with the diagnosis techniques and coordinate their own methods with that provided herein and , in addition to save the time , achieve to the qualitative development what all of us have focused on it . As is common in all new issues, there may be some mistakes and errors in this manual, we here would like to ask all the kind readers to provide us with their valuable comments (enclosed to this manual please find a comment form, kindly fill in it and send us the form). This company shall reserve all rights attached to this manual including copyright.

Saipa yadak Company Technical & Engineering Department

Foreword5



Introduction Saipa Company has equipped its vehicles with Siemens injection systems in order to diversify the

injection systems integrated with its vehicles and act in line with the pollution control measures considered under environmental protection plans. This injection system will provide for permitted

fabrication of this vehicle under environmental standards during the years to come considering the capability of the injection system to be covered by ECE R83-03 (Euro II) standards. The new injection system is a development of Siemens injection system incorporated in Kia models of that vehicles Saipa company has included Siemens SIM 2 K injection system kits in Saipa cars on a collaboration with SASCO CO, the Asian agent of Siemens in south Korea . Among the technical advantages of the new Siemens injection system compared to the two other injection systems available ( Kia design of injection systems and JCAE design of the same ) are reduction in fuel consumption, greater Capability for acceleration , improvement in overall functions of the system, and reduction in the cost price of the injection Kits. This system uses two separate coils for distributor less injection ( DL I). The damages from engine knock have been removed in this system. This kit is equipped with OBD II Diagnostic system and any malfunction of injection system is discovered by the driver through a malfunction indicating lamp ( MIL). The details of Siemens injections system SIM 2K having been integrated with Saipa cars , will be given hereunder. The descriptions will include system components, troubleshooting of the system and some illustrations of the system components.

Introduction7



System Components



Description of the system The schematic diagram of the system is layout of input and output components making up the overall design of the system. The fuel supply & engine ignition control system is in the center of this system. This unit controls all the inputs and outputs of the system to improve the functions of the engine. Siemens engine management system having been designed and integrated in injector system Saipa vehicles by sasco , includes fourmainparts:g1-Fuel delivery system

2-Air delivery system 3-Ignition system 4-Electronic control unit, sensors and actuators

The components of each unit are given under the following table

11 Description of the system


Position of system parts and AssembliesSchematic Diagram shows the position of parts and assemblies of the system 1-Carbon Canister 2-Double Ignition coil 3-Camshaft 4-Camshaft sensor 5-Ignition plug 6-Injector 7-Fuel pressure regulator 8-Canister plug valve 9-Air filter 10-Throttle body angle sensor 11-Stepper motor 12-Manifold air pressure and air temperature sensor (MAP+ATS) k 13-Fuel filter 14-Water temperature sensor 15-Knock sensor 16-Oxygen sensor 17-Catalyst converter 18-Gearbox 19-Vehicle speed sensor

20-Engine speed sensor 21-Double relay 22-Main switch 23-Battery 24-Electronic control Unit ( ECU)k 25-Fuel tank 26-Fuel pump 27-Malfunction indication lamp (MIL) k 28-Tachometer

12 Position of system parts and Assemblies


Introduction of the System A microprocessor is placed in Fuel Delivery control unit . The microprocessor and all its relevant parts have been assembled on a printed circuit . The needed air intake is adjusted by throttle valve, which in turn is controlled by the drivers . j For the purpose of optimization of the system during all times and under all conditions, ECU controls the . operations of ignition coil and injector The engine management system also adjusts the air intake through controlling the throttle position . Throttle control also promotes capabilities of driver and starting with a closed throttle will be easy .j The excess fumes of fuel tank are also sent to intake air manifold . The engine control system controls the canister purge valve and the process of transfer of the excess fume is done without affecting the capability of the driver (through the closed circuit of the system) . j

Electronic Control Unit (ECU) h As you see in the following figure, the unit receives signals from a number of sensors and transforms them to the digital display .j A/D is an electronic circuit, which transforms the analog signals received from sensors to the digital ones. The reason for use of A/D in ECU is that the microprocessor circuits are activated by digital signals .j The intake air manifold, in comparison with old carburetor engines, uses a new design which optimized for increasing engine torque and power. The fuel delivery is done by four injectors (each delivers the fuel to one of cylinders), which have been connected to fuel rail. At any time, two of these injectors which in turn consists two ignition is done by double ignition coils with four outlets which in turn consists two coils .k The application of oxygen sensor (Lambda Sensor) together with catalyst manifold converter, result in decrease in the pollutant emission.g

13Introduction of the System


Schematic Diagram of the System

14 Diagram of total functions


15

Sensors and Actuators related with ECU

Diagram of total functions


16

A Diagram of General Functions of The Systems

Diagram of total functions


Fuel Delivery System The fuel delivery system used on new Saipa engine, equipped with siemens injection system, is of Multi Point Fuel Injection (MPFI) type .h The system consists of four injectors, which are situated immediately before intake valve and the fuel is directly injected into intake manifold . g Because of mixed fuel control and taking the mixture ratio, MPFI system operates in an optimum way . The engine operation conditions are determined by ECU, which receives the needed signals from different sensorsand injectors. On the basis of the received signals, the engine operation is controlled and optimized . jFuel delivery system consists of injectors, fuel pump, pressure regulator, fuel filter, fuel rail, and fuel ducts. h

1-Fuel Pump The pressure of fuel pump is more than the pressure needed for fuel system; this eliminates fuel deficit, which commonly happens as a result of speed change in the vehicle. The outlet duct is equipped with a check valve that maintains the fuel pressure at a fixed rate throughout the duct whenthe vehicle is switched off. h Fuel pump is installed in the fuel tank and is floating in the fuel at all times. This reduces pump noise and does not allow formation of bubbles also protects the pump against strokes of other objects .h The needed voltage for fuel pump to operate is 12V, which is supplied through double relay and fuelinertia switch as per following timing criterion :hW-When the switch is on for 3 to 5 seconds, anda-at all times that the engine is running. h

2-Fuel filter Fuel filter is located on left hand of the engine under brake booster and near the fuel rail .j The fuel passes through this filter and all the particles are removed from it, which is the firstaction for protection of injectors. h The filters are capable to remove particles with 8 to 10 micron diameters and they should be replacedevery 20,000 kilometers of travel.j

Another filterisplaced in the tank,which should be never lubricated

17Fuel Delivery System


3-Hoes and fuel delivery line The steel pipes of fuel delivery system and rubber hose are extended from the tank to the engine where fuel filter is located. The fuel is transferred to fuel rail through a rubber hoes which is fixed to the rail by a clamp the connection of fuel filter to fuel rail and also fuel rail to the excess fuel return pipe is by use of flexible rubber pipes and a clamp.g

Note The rubber tubes for fuel delivery should never be lubricated. Such tubes are made of special materials that are resistant to the corrosion from fuel and high pressure. They should be replaced by ordinary tubes.h

18 Fuel Delivery System


1-Fuel tank 2-Tri-way control valve 3-Separator A- Main fuel hoseB – Excess Fuel Return Hose C- Fuel fume hose 4-Fuel rail 5-Pressure regulator 6-Fuel filter 7-Injector

Fuel Delivery system



Schematic view of location of some parts of fuel delivery system

1-Tri-way control valve 2-Separator 3-Fuel tank 4-Canister 5-Canister purge valve 6-Air Intake

20 Fuel Delivery System


4-Fuel Rail Like sagem injection fuel delivery system, in this system the fuel rail is located at the center of the engine in central space of air intake manifold assembly near cylinder head and four injectors; fuel pressure regulator and fuel intake and outflow hoesare installed on it. h Fuel rail is fixed on air intake manifold by use of screws .lIn fuel rail the pressured fuel is ready to be delivered to the injectors; at the time of activation of each of injectors, the fuel is entered into injector and is injected in powdered frominto intake port and eventually, into the cylinder. h

g

5-fuel pressure regulator The fuel pressure regulator maintains the fuel pressure rate in the fuel rail (at inlet of the injectors) at a fixed level (3.5 bars) considering theair pressure in the air intake manifold assembly Consequently, at all times the fuel with a fixed pressure is ready at inlet of the injectors and , notwithstanding different conditions and speeds of engine, the fuel is delivered continuously . Also a check valve is installed on the fuel delivery route above the fuel pumpwhich prevents from return of fuel into the tank; h

therefore, the pressure is continuously maintained at a fixed level. This will ease the start up of the engineand prevents from formation of gas barrier in fuel delivery ducts

6-Injector The fuel delivery systems of pride engines is equipped with siemens' injection system of MPFItype which for each cylinder there is an injector Injectors inject the fuel in powdered form into inlet of cylinders. Injectors are located between fuel rail and intake air manifold and are sealed by use of O rings placed on both ends of them and are fixed on fuel rail by clamps. At the time of activation ofeach of injector, the fuel is injected into cylinder inlet in powdered form; the injectors used in siemens system are of top feed type. h



Air Delivery system

1-Throttle body assembly 1-1Throttle Body- On this body, butterfly valve, stepper motorand throttle valve potentiometers have been installed, which control the throttle position.j

1-2-Air By- Pass Valve-1i(Stepper Motor)j In addition to intake air butterfly valve, throttle body has an additional duct which the air is by-passed through it. The amount of air intake through this route, which is measured by an ECU, is controlled by a stepper motor considering the operationconditions of the engine for the following purposes: l 1-Creation of choked status as the engine coolsdown and the throttle is closed.h 2-Adjust the idling speed at the time of engine overload (when cooler and other devicesare on).l 3-Regulate the air-fuel mixing process at the timeof idle speed.h 4-Prevent from rapid blockage of air duct when the driver, at high speeds, suddenly releases the accelerator pedal.l Stepper motor transforms 12 V pulses of ECU to a linear movement in line with longitude axis to regulate the additional air intake.k

22 Air Delivery system


1-3-Throttle valve Potentiometer-1 This potentiometer sends to ECU the instantaneous position of throttle to be used for detection of idlepositions, total load and acceleration and speed reduction processes.h The feed voltage of the sensor is 5V which is supplied by ECU.j

2-Intake Manifold The intake manifold assembly in Pride engineequipped with injection system contains airintake manifold, speed reduction duct, fuel rail,j injectors, throttle valve, pressure sensor, intake air temperature sensor, and end of brake boosterhoes , canister valve and water temperature sensor. h

23Air Delivery system


Double Ignition coil system The double ignition coil in Siemens injection kit is of double ignition type with electronic control and itincludes the following components: h

1-Ignition Coil The ignition coil supplies the needed electric voltage for ignition plugs and contains four leads which are connected to the ignition plugs through two internal coils The ignition in 1st and 4th and also in 3rd and 2nd are simultaneous On the other words, the ignition plugs of both of cylinders that one is in combustion phase and the other one is in end of exhaust phase act simultaneously. The ignition time and duration of dowel time are controlled as per data received from ECU The ignition coil is installed on cylinder head like sagem kit. h

2-HT Leads HT leads are used for connecting the ignition plugs to the coils and combusting the fuel in cylinder.j The used HT leads are parasite resistant.l

24 Double Ignition coil system


Electronic Control Unit (ECU) k In siemens system, the operation is controlled and managed by use of an ECU .j Based on signals that are received from different sensors, ECU controls time and duration of fuel injectionby injectors, time and duration of ignition, idle position of engine, the knocking level of engine and also theoperations of fuel fume emission controlling equipment. j In addition, ECU also controls the operations of electric fuel pump and malfunction indicating system. j The ECU operates on the basis of an initial calibration that is done by the manufacturer considering the engine and vehicle specifications . jThe following parameters are monitored by ECU : jo Engine speed o Manifold pressure and intake air temperature o Throttle valve position o Water temperature o Vehicle speed o Ratio of intake air to fuel o Engine knocking level o Air conditioning system function o Battery voltageECU uses the above parameters to control the following functions: l o Time and duration of fuel injection o Ignition time and dowel duration o Idle working of engine o Fuel pump operation o Canister purge valve operation o Fuel injection cut-off for prevention from elevation of engine speed o Malfunction indicating lamp operationIn addition, which data that are sent to ECU, are used for displaying the following information: k

25 Electronic Control Unit


General specification of Electronic Control Unit ( ECU) in Siemens System:k Fuel injection system : MPFI (full sequential ).jECU type : SIM 2K –3X

Ignition System

400V CLAMPED LOGIC DRIVEN 14 A 1GBT

The diagnostic system that may be mounted:kOBD-11, K- LINE

Processing System : 16 Bits

The system used for communicating withother ECU’s :j CCP INTERFACE, LEV, CAN 16MHZ : ( Clock )j

Memory:FLASH Memory = 4 Mbit for the program

Calibrationdata and SRAM= 64k bit





ECU Operation under Different Conditions

o- ECU Operation at the time of Starting At the time of starting, ECU sends activation command to injectors in the form of pulse (stepper wave) witha fixed width. jConsequently, the injectors inject the fuel alternatively. j The amount of the injected fuel I determined by taking into account the engine speed, water temperature and also temperature and pressure of the intake air . Also the excess air is determined by the stepper motor andby use of the engine operation parameters. k After starting, the idle speed is determined by use of water temperature .p

o- ECU Operation in Different Engine Speeds At the time of instantaneous change in engine speed (acceleration and speed reduce), the duration of injectionis determined by taking into account the changes in the following parameters: l - engine speed (which is detected by engine speed sensor) l -throttle valve position (is detected by throttle position sensor) k -intake air pressure (is detected by intake air pressure sensor) l -water temperature (is detected by water temperature sensor) k

o- ECU operation at the time of fuel injection cut-off A. At the time of speed reduction, when the driver suddenly releases the accelerator pedal, ECU cuts-off thefuel injection due to the following reasons: l -Fuel consumption reduction -Reduction of pollutant emission B. For the purpose of prevention from excess engine speed elevation, the fuel injection is stopped when theengine speed reaches around 5500 rpm. j

o- ECU operation at the time of Resume of Fuel injection After fuel cut-off, when the engine speed reduces to a safe level, the unit activates the fuel injection to preventform shot down .k ECU Memory ECU has two kinds of memories :k -permanent memory -RAM memory The data on permanent memory are not cleared as a result of power failure; this memory stores the tables ofengine operation, thereby ECU processes the signals that are received from different sensors. k The RAM memory data are cleared a short time after power switch off. k



Sensors For the purpose of measurement of different parameters of engine operation, a number of sensors are used innew fuel injection engines of new Saipa cars; the operation and position of these sensors are described asfollows: l

1-Engine Speed &crankshaft position sensor This sensor is installed on clutch case and measures engine speed and also TDC of 1st and 4th cylinders and sends the signals to ECU. The flywheel, which is connected to the crankshaft, moves and, proportional to its speed, creates a magnetic field and each speed has its own voltage, which is sensed by this sensor and sent to ECU in the form of signal .k The signals sent by this sensor are used by ECU for processing several parameters including fuelinjection, ignition time, etc. k

2-Camshaft Sensor This sensor determines the TDC position of 1st cylinder and sends a signal to the ECU in different from signals sent by engine speed sensor .k It is installed on camshaft . l

29Sensors


3-Manifold Pressure and Intake Air Temerrsensor This sensor continuously measures the data of manifold pressure and intake air temperature andsends the relevant signals to ECU. l The feed voltage of the sensor is 5V, which is supplied by ECU . Proportional to the measured pressure by the sensor which is measured by a piezo-electronic device installed in the sensor (the electric resistant of the device is changedproportional to the measured pressure) . l The ECU uses the different return voltages, which are changed as a result of different pressures, forprocessing the following data: l -the intake air mass -ratio of fuel to intake air, proportional to engine load and ambient pressure -advance ignition The used resistant in the sensor is of NTC type (its resistance is increased proportional to temperature increase) and its operation range is between 40 to 50 . ECU used the signals sent by this sensor forprocessing the intake air mass. k

4-Water Temperature Sensor This sensor measures the temperature of coolingwater and sends the relevant data to ECU .l The sensor is equipped with NTC resistant and has a connector with two supports .l

30 Sensors


5-Vehicle Speed Sensor This sensor is installed on mileage indicator gear of Saipa car and creates a signal proportional to the gearbox shaft speed and , as a result, measures thevehicle speed. k

6-Oxygen Sensor Oxygen sensor is installed on exhaust manifold in outflow fumes duct between the engine andcatalytic converter. l This sensor measures the concentration of the fuel-air mixture and sends the relevant signals toECU. lECU uses the signals sent by this sensor forprocessing the following parameters: l C-Calculating of fuel and air mixture .k A-Adjustment of fuel and air mixture for optimumoperation of the engine. k The optimum operation indices of fuel-air mixture are stored in the permanent memory of ECU and used for appropriate operation of catalytic converter .k Proportional to the concentration of fuel-air mixture, ECU receives a signal with a range of 0 Volt from oxygen sensor and uses the same and the indices in the permanent memory for adjusting the fuel and air intake for proper operation of catalytic converter .l T-The lean mixture creates a Voltage less than 0.5 volt T-The over-rich mixture creates a Voltage more than 0.5 volt .l

31Sensors


7-Knock Sensor The sensor sends the signals of engine knock to the ECU . The knock is a vibration , which is occurred as a result of early combustion of the fuel –air mixturein the cylinder .l In case of such occurrence in cylinder ,the ECU controls the advance by use of signals it receives from knock sensor and , simultaneously , increasesthe fuel –air mixture ratio .;l

32 Sensors


Actuators The following actuators are installed in the new fuel delivery system of Saipa cars for controlling the engineoperation conditions: l

1-Double Relay The relay carries out the electric feed of the injection system under different conditions of engine operationincluding switch off, switch on and running . ;l

Double relay is connected to the main power supply wire by use of a 15-way connector and has three phasesof operation: k

A- Switch- off During switch off period, a 12 V currency is fed to ECU through 10th terminal of the double relay for storage of its data .j

B- Switch – on In switch on position, ECU supplies the neededvoltage for 2 to 3 seconds to the following parts: j

-CEU -Fuel pump -Injectors -Double ignition coil -Canister purge valve -Resistant of oxygen sensor heater

C- Running Position In running position, the needed Voltage is suppliedto all the parts of the system .k

2-Canister purge Valve The fuel fumes of fuel tank are recovered incanister by use of canister purge valve which is in turncontrolled by ECU. j Whenever the valve is open, the fumes of canister are transferred to the engine through air intake ductand used in the cylinders. j

33Actuators


3-Malfunction Indicating Lamp ( MIL)k This lamp, which is installed within the cabin and on dashboard and is controlled by ECU, turns on at the time of any problem in the injection system and warns the driver of the existing problem .j

The Schematic Diagram of Siemens Injection Kit Schematic diagrams of Siemens injection kit, that illustrate the relation of ECU with sensors and actuators, have been provided at the end of this manual. The mounting point of ECU in this vehicle is the same as that of Sagem System that is, under dashboard.j

34 Actuators


Description of connectors of Siemens Injection Kit

35The schematic diagram of injection kit


36 Description of the connectors integrated with the system


Diagnosis of system

37


38


Introduction :h This chapter includes methods of troubleshooting of the parts and components of Saipa vehicles with Siemens injection kits. This section describes the faults that may emerge in the parts and components of injection system and given steps discovery of causes and troubles shooting. Please note the following factsprior to beginning diagnosis process: h 1-It has been supposed in compilation of this manual that the operator has familiarity with Siemens injection system package including the description of sensors and actuators. Please study carefully theworkshop manual of Siemens injection system before you take use of this pamphlet .j 2-BOB, is the initiatives of Break out box, or interface connector; by using it you can easily access to ECU pins. If you have not this tool, then use a pin; insert the pin into the concerned wire and carry out your neededtests. h 3-Please carry out the diagnosis process carefully and allot to it appropriate time and follow the steps andinstructions carefully. g 4-Multi-meter (Ohmmeter, Voltmeter and Ampere Meter) is an essential tool in diagnosis process of all parts. Itis evident that you have to be fully familiar with the use of this tool before to begin to diagnosis. g 5-Never connect the wires carrying 12 DC current to sensors and actuators.g 6-When the switch is on or the engine is running, never cut the connector. h 7-ECU connector consists of A and B parts . In order to find the pin in question with ECU , you should check the related connector as illustrated in the next page and specify the pin in question considering the marks .g 8-Ensure to disconnect the connectors of the injectors when you are going to measure ignition system and /orcompression.g 9-When a fault emerges with the system that the fault- finding system is able to discover, the fault is recorded in the memory ( error memory ) and the error is not erased even after the fault has been removed until the system erases the same. There fore, remember to erase the error once after each trouble has beenremoved. k10-Pay attention to the following upon electrical evaluation of the vehicle: k

11-The battery should be fully charged .h 12-Never use the supply sources with more than 16 VDC currency! nm

39Introduction


Cross Section of ECU Connector

40 Cross Section of ECU Connector


41Injector no 1

Injector no I


42 Injector no 2

Injector no II


43

Injector no III

Injector no 3


44 Injector no 4

Injector no IV


45

Coil I&IV

Coil1&4


46

Coil II&III

Coil 2&3


47Engine speed sensor

Engine speed sensor


48 Air intake manifold pressure sensor

Air intake manifold pressure sensor


49Air intake manifold pressure sensor


50 Vehicle speed sensor

Vehicle speed sensor


51Air by pass valve(stepper motor) g

Air by pass valve(stepper motor) g


52 Throttle position sensor

Throttle position sensor


53Main relay

Main relay


54 Fuel pump relay

Fuel pump relay


55Intake air temperature sensor

Intake air temperature sensor

56 Intake air temperature sensor



57 Coolant temperature sensor

Coolant temperature sensor


58 Camshaft position sensor

Camshaft position sensor


59Canister purge valve sensor

Canister purge valve sensor


60 Oxygen sensor Heater

Oxygen sensor Heater


61 Oxygen sensor

Oxygen sensor


62


Date : .........................

Telephone : ......................

Comments :

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Dealers’ name & code:......................

Signature : ......................................

COMMENT FORM

66COMMENT FORM


Documents

Main text-mmm - SAIPAeng.saipayadak.org/CarDocument/RM/PDx100RM2C21.pdf · The fuel delivery system used on new Saipa engine, equipped with siemens injection system, is of Multi Point