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Manual
Developed by Derek Naidoo..10.97
Gas Analysis
Diagnostics using a 4 Gas Analyser
Before attempting to perform any diagnostics using a 4 gas analyser, it is important to
understand the equipment and the results obtained.
We shall begin with explaining the different gases tested :
Hydrocarbons (HC)
Hydrocarbons are unburned or partially burnt fuel particles. High levels of HC,
measured in PPM (parts per million) in the exhaust gases, is usually due to
malfunctions in the ignition or fuel systems.
Oxygen (O2)
Oxygen is measured as a percentage of the exhaust gases and should be between 1 -
1.5% indicating an efficient combustion and air fuel mixture. Whilst adjustments are
being performed, it is important to note the changes in O2, as a sharp change of
between 0.5 - 1.0 % and 1.0 - 0.5 % will indicate the cross-over point from a rich or
lean mixture respectively. O2 measurement is also useful in detecting leaks and
misfiring as well as the efficiency of combustion.
HC and CO Analysis
Hydrocarbons
The ignition of the air : fuel mixture in the combustion chamber does not result in all
the fuel being burned, hence the HC emmission. Should there be any malfunction in
the system the quantity of Hc will increase.
Normal HC readings range between 0 – 350 PPM, depending on the age and
condition of the vehicle. Low HC readings indicate that most of the fuel is being
burned, and high HC readings indicate a higher quantity of unburned fuel.
Carbon Monoxide
As the air : fuel mixture is ignited, the resulting combustion process produces some
CO as a normal condition. However, if the air : fuel mixture is incorrect, there will be
a larger amount of HC, which will increase the CO, resulting in air pollution and
reduced engine efficiency. Normal idle CO for vehicles with the Motronic 1.5.4
systems is 1 – 1.5 %. Idle CO can vary depending on the management system and can
range from 0 to 3 %
CO2 and O2 Analysis
Carbon Dioxide
Carbon dioxide is a product of combustion. A normal functioning engine should
produce between 13 and 16 % of CO2. If combustion was incomplete or the air : fuel
ratio was incorrect, the quantity of CO2 produced will be minimised resulting in a less
efficient engine. Any dilution of the exhaust gases (secondary air pumps, etc.) will
result in a drop in CO2 content.
Oxygen
The engine inducts approx. 20.7% oxygen, 78% Nitrogen and 0.5 – 2.0% other gases.
During combustion, most of the oxygen is consumed, and if the engine is running
correctly, 0.5 – 2.0% is exhausted. Any more than the 2% oxygen exhausted is
valuable diagnostic information to the technician.
Low O2 levels indicate a rich mixture. (A rich mixture will consume more or all of
the available oxygen during combustion). 0% oxygen indicates that all oxygen was
consumed during combustion, resulting in unburned fuel.
High O2 levels indicate an incomplete combustion process. (Not enough oxygen was
utilised during combustion, resulting in unburned fuel)
Diagnostics
Sequential Injectors are pulsed by E.C.U. once per engine cycle as per spark
plug firing order. ( Astra 20XE )
Single Point
Throttle Body Single injector mounted on throttle body pulsed as per engine
requirement ( Astra 160 TBI )
Operation
Injectors on the Bosch Motronic engine management systems receive battery voltage and are
triggered by the E.C.U. depending on the signals received from the various sensors attached
to the engine. Fuel pressure is constant (M.P.F.I. – 250 to 300 Kpa).
Injector opening frequency (Hz) and duration (pulse width) determine the amount of fuel
being delivered to the combustion chamber. Variations in pulse width and frequency ensure
that adequate fuel is supplied for efficient engine operation.
LONGER PULSE WIDTH = RICHER MIXTURE
SHORTER PULSE WIDTH = LEANER MIXTURE
Pulse rate and width will increase with increased engine rpm and load.
Duty Cycle
Duty cycle is the combination of pulse width and pulse rate, and is expressed as a percentage
of time “ON” and time “OFF” eg. If an injector was on for 10ms and closed for 90ms, the
duty cycle “ON” is 10% and the duty cycle “OFF” is 90%. The total on and off duty cycle
reading should be 100%.
Cranking Injector duration is longer during cranking (richer mixture) for easier starting
and to promote warm-up.
Running Injection pulse is controlled by the E.C.U. depending on the signals received
from the various engine sensors.
TESTING INFORMATION AND TEST PROCEDURES
Engine Cold Ms
Cranking ------------------------------------------ >4
Idle -------------------------------------------3.5 to 4
Engine Warm
Idle --------------------------------------------- 2.5
1000rpm 2.3*
* Gradually leans out,
2000 2.1*
depending on load
3000 2.0*
Sequential injection systems will be less than twice the above values due to single pulsing
per engine cycle.
NOTES.
Comparing mixture content to injector pulse width can identify components and systems to
be tested in a logical sequence.
Example : A rich mixture could indicate high fuel pressure, incorrect manifold pressure,
incorrect coolant temp, etc,etc.
D.N. 12/97
DUPEC ELECTRONICS (PTY) LTD
DEFITA200
MICROCONTROLLER BASED
AND INTERFACE
SPECIFICATION
TRAINING MANUAL
93/5
CONTENTS
1.0 PRODUCT DESCRIPTION
2.0 FEATURES
3.0 PRODUCT IDENTIFICATION AND APPLICATION
4.0 SPECIFICATION
4.1 Electrical
4.2 Environmental
4.3 Fuel delivery
5.0 CONNECTIONS
6.0 SPARK TIMING
6.1 Distributor bypass operation
6.2 Engine speed and crankshaft
position measurement
6.3 Engine load measurement
6.4 Advance angle look-up
6.5 Ignition firing delay calculation
6.6 Dwell time calculation
6.7 Engine water temperature measurement
7.0 FUEL INJECTION
7.1 Air mass to fuel mass ratio
7.2 Air mass measurement
7.3 Speed density concept
7.4 Fuel metering
7.5 Continuous fuel flow rate
7.6 Injector opening and closing times
7.7 Injection timing
7.8 Injection duration
7.9 Correction factors
7.9.1 Injection hardware deficiencies
7.9.2 Engine operating conditions
7.9.3 Intake air temperature
7.9.4 Engine temperature
7.9.5 Cold starting conditions
7.9.6 Post-start and warm-up conditions
7.9.7 Acceleration conditions
7.9.8 Deceleration lean-out conditions
7.9.9 Coasting conditions
7.9.10 Flooded engine conditions
7.9.11 Full load operation
8.0 IDLE SPEED
9.0 IMMOBILISER OPERATION
10.0 DEFAULT MODE SELECTION
11.0 DIAGNOSTICS
11.1 Diagnostic codes
11.2 Volt- and ohmmeter
11.2.1 Battery voltage
11.2.2 Ignition voltage
11.2.3 TPS supply voltage
11.2.4 TPS input signal voltage
11.2.5 CO potentiometer supply voltage
11.2.6 MAP sensor supply voltage
11.2.7 MAP sensor signal voltage
11.2.8 Timing map selector
11.2.9 Fuel mixture selector
11.2.10 EWT sensor
11.2.11 MAT sensor
11.3 Fault finding
11.4 D-TEQ200 PC based tester
11.4.1 Description
11.4.2 Installation
11.4.3 Operation
11.5 C-TEQ200 component tester
11.5.1 Description
11.5.2 Operation
1 PRODUCT DESCRIPTION
The DEFITA200 range of ECU's (Engine Control Units) is
microcontroller based and controls the spark timing, fuel
injection and certain other functions of internal combustion
engines electronically, thus ensuring optimum operating
efficiency.
2 FEATURES
Standard functions:
DEFITA200
160 TBi
MODEL NO.: A020-C
DMC P/N: 93593652
MADE IN R.S.A.
4 SPECIFICATION
The following specification is applicable to DEFITA200 P/N:
A020-C ECU's unless otherwise stated:
4.1 Electrical
4.2 Environmental
I - MAP
II - EWT
III - Battery voltage
IV - Crankshaft position
V - Engine speed
VI - Throttle position
Where ë = Lambda
ë=1
The air mass supplied matches the theoretical amount.
ë<1
A lack of air resulting in a rich mixture. Increased engine
power outputs are obtained for 0.85 < ë < 1.
ë>1
An excess of air resulting in a lean mixture together with a
reduction in engine power output. Optimum fuel consumption
takes place with 1 < ë < 1.2.
ë > 1.3
Lean mixture making it impossible to achieve reliable igni-
tion.
7.2 AIR MASS MEASUREMENT
As we have seen previously the principle of fuel injection
is based on measuring the air mass entering the engine and
calculating the fuel mass required to obtain an A/F ratio of
14.7:1. A number of possible methods exist for measuring
the air mass, but only the speed-density method used for
this TBi system will be described in detail.
a) Speed-density
b) Throttle butterfly angle
c) Flap or vane type
d) Hot-wire meter
e) Hot-film meter
f) K rm n vortex ultrasonic meter.
7.3 SPEED DENSITY CONCEPT
The fuel flow rate becomes lower with reduced battery volt-
age. The ECU compensates for this effect by lengthening the
injection pulses at low battery voltages.
Inductance = 4mH
Resistance = 1.5 ohm
Static opening current = 1.1A *
Static closing current = 0.5A *
When the engine speed is below 450 r.p.m. and WOT is de-
tected the ECU will reduce the base map injection durations
by 40% and ignore all cold and post-start corrections in an
attempt to prevent further flooding.
When the ECU detects a faulty signal from one of its sensors
it will substitute a default signal value to enable the
vehicle to be driven with degraded performance (see para-
graph 10.1).
MAT 31 øC
Disable distributor
bypass operation and
fix spark timing at
10ø BTDC
Code Cause
_____________________________________________________
1.00 20 kPa
2.00 40 kPa
3.00 60 kPa
4.00 80 kPa
4.50 90 kPa
5.00 100 kPa
-20 19,700
-0 5,640
+20 2,410
40 1,177
60 565
80 308
100 186
11.2.11 MAT sensor: The resistance between terminal 17B and
11A on the harness with the ECU removed should be:
-12 9,977
-5 6,540
0 5,627
18 2,290
33 1,241
48 782
62 485