TTEC4843 - EFI Of Car

TTEC4843 - Fuels and Fuel Systems -  practical

15/9/2011 tuesday

start = 1.00pm finsh = 4.30pm

Cleaning Injectors

In todays task we got to learn how to check and clean electronic fuel injectors. first we had 4 injectors to check. and we had our mnufacturers specifications in relation. then we put our injectors in the machine. then we checked for injector

•  leake age and we had 0 drips per minute.
• injector flow rate 360 cc per minute flow rate at 2500 hz.

That shows us our injectors we tested were in good condition we had no leaks, the O rings are good, and they spray nicely . so they are servicable

Air flow meter resistance test- Fuel injection diagnosis.

In todays task we checked the resistance on the air flow meter using ohms meter by checking the potentiometer circuits and determine the airflow sensor condition by comparing the results with the manufacturers specification.

• First thing we did was tested E1 - FC closed had reading of infinity
• E1 - FC open .103 kohms

This shows that if the fuel pump relay is effected on pump operation with a high resistance across the two terminals. this wont give the right measuremnt and the amount of fuel.

Air Temperature sensor Test

In todays task we did testing on a air temeperature senor. and we checked our resistance using a multimeter ( ohms ) first thing we did was check the sensor resistance we did 3 testing.

• Intake air temp. 20'c ( 68'f)      Resistance (kW) 2 to 3 = 1.78 reading
• intake air temp 40 'c ( 104'f)    Resistance (kw) 0.9 to 1.3 = 1.24 reading
• intake air temp 60'c ( 140'f)     Resistance (kW) 0.4 to 0.7 = .07 reading.

this showed us that our air temepature sensor is good and it meet the specifications. but if it didnt meet it spec . replace the air flow meter if the resistance reading are not within specification.

MAP sensor

In todays task we learend how to test an MAP sensor and see if its also holds vacuum.

• first thing we did was get a vacuum pump and a multimeter volts Dc. and see for voltage drop.
• we applied our vacuum pump by putting it in the MAP sensor. and we did five tests  on it.
• First thing we did we applied 10 vacuum mmHg and we had reading of .89 volts
• 20 = 1.51 volts reading
• 30= 2.15 volts reading
• 40 = 2.88 volts reading
• 50 = 3.34 volts reading

That showed us that every time we apply pressure to our MAP sensor our volts start rising up and changing.


Coolant Temperature Sensor Test

In todays task we learend how to check a coolant temperature sensor. first thing we did we had two coolant temerature sensor.  then we added water in a steal bowl and placing a thermometer and gradually heat the water . we had measurements that we had to follow and by using a multimeter (ohms) to check for resistance.

 

Water temperature	Resistance
-20'c	14.6 - 17.8 w
20'c	2.21 2.69 w results= 1.34 ohms
80'c	290 - 35 Results  = 0.44 ohms

This results shows above showing that our resistance droped which we started at 20'c then heated the water too 80'c. that means we got a (N.T.C) negitave  Temperatur coolant. and our results didnt meet the spec . so that means the sensor should be replaced.

Air Flow /Mass Sensor Testing

We tested the hot wire type sensor. and we had a open circuit so we couldnt test it . It was faulty

Throttle position Sensor  (Linear Type)

In todays task we learend how to test a TPS sensor by using a multimeter ohms

 

Clearance between lever and stop screw mm (in.)	Between terminals	resistance (ohms)
0 (0)	vta - E2	200-800 -Results=505 ohms
0.35(0.014) Feeler gauge	Idl - E2	2,3000-or less -Results=70 ohms
0.59 (0.023 Feeler gauge	IDl -E2	infinity -Results=Infinity
Throttle valve fully open	VTa-E2	3,300-10,000 - Results=3300 ohsm
-	Vc -E2	3,000 - 7,000 - Reults=4200 ohms

 

This shows our TPS meet the spec. if the TPS resistance is not correct is by using a screw driver loosn the bolts and gradually turn the sensor clockwise until the ohmmeter deflects then  screw it back with the 2 screws.

TTEC4843 Report:Inputs,outpits,closed loop,

REPORT


1 )Sensor inputs.

• Throttle Position Sensor (TPS)Its measured in Dc volts on multimeter . its measured when the engine is of but the key is still in the on position.   It measured the outputs of the voltage when the throttle closed. and when the throttle is wide open.  this shows that the TPS tells the computer how much air is flowing into the engine and what measurements its given

• MAP sensor: The MAP sensor provides readings to the E.C.U of the pressures inside the manifold which help to calculate air density and the engine's air flow mass.

• HO2S: The oxygen sensors supply the computer with a signal that indicates a rich or lean condition during engine operation. This input information assists the computer in determining the proper air/fuel ratio

• Coolant Tempature (THW or ECT):  Its Measured in DC volts on a multimeter, the THW (thermister water) measures the tempature of the coolant or water that is running through the engine.

• Crank Sensor (CKP):  The crank sensor is used to monitor the position or rotational speed of the crankshaft,  And this information is used by engine management systems to control ignition system timing and other engine parameters measured in AC

.

• MAF: ( Mass Air Flow Sensor) : the mass air flow sensors converts the amount of air drawn into the engine into a voltage signal. And the ECM needs to know intake air volume to calculate engine load. measured in ohms

• Camshaft position (CMP ) sensor:   The camshaft position is a sensor provides the camshaft position information and the signal, which is used by the Powertrain Control Module (PCM) powertrain control module   for fuel and timekeeping. measured in volts.

2) Actuators outputs

• Electronic spark timing ( EST ) The electronic spark timing control system is a reference timing pulse generated in going hand in hand with engine revolutions is delayed in accordance with a voltage supplied from a function generator and its desired spark timing to the engine. Measured in volts
• Echaust Gas Recirculation ( EGR ) Is a system is desgined to reduce the amount of oxides of nitrgen ( nox) created to the engine during operating periods that usually in high combustion tempertures. measured in ohms
• Idle Air Control ( IAC ):    The (ICA) idle air control on fuel injection vehicle. this valve is made that it allows air to bypass the throttle plate by increasing the idle speed. this valve is operated by an electric solenoid or motor. so the vehicle computer controls the amount of opening to regulate idle speed for varying the conditions such as cold air string and air conditioner compressor load. This measured by a multimeter ( ohms )
  

3)Relationship Between Inputs and Outputs:

•  when the TPS goes Up then the fuel injectors start spraying more fuel. 

4)Closed loop fuel control:        

• The fuel loop fuel control is a closed loop that’s operates by using one or more oxygen sensor to adjust the fuel mixture in the engine. By balancing the Air/fuel ratio to an ideal which is 14.7/1 that depends on the load and speed. for example if the ( throttle position sensor ) letting in more air that could affect the closed loop by letting it think the Air/fuel ratio is at a stable where it can actually be running more leaner.

TTEC4843 lander test

TTEC4843 - Fuels

TTEC4843 - Fuels and Fuel Systems -  practical

13/9/2011 tuesday

start = 1.00pm finsh = 4.30pm

 

In todays task we learned how to make a lander test. which shows us hwo to test a lean mixture and a right mixture.

first thing we did was to install the follow components on the O2 sensor PCB board.

The equipment we used to create this was resistors , rectifier diodes, zener diode , capacitors, 3 LED lights , (green , red , yellow)  ,  jumper wires  , (Red, Black, Green) Ic chip LM324,

Then we soldered the the equipments on PCB board.

In conclusion
this gave us an idea of how a lander tester works. its shows the rich mixuter and the lean mixture. when its reving high it turns red that means its a rich mixture. the yellow LED is a signle going between the Red Led and the Green LED. and the green LED it shows its a lean mixture when the car is at a normal revs.

 

TTEC4843 - Fuels

TTEC4843 - Fuels and Fuel Systems -  practical

8/9/2011 tuesday

start = 1.00pm finsh = 4.30pm



idle speed device

 In todays task we learend how to test idle speed devices. 

first thing we did was idle speed device.

what type of cold or fast idle speed control does this vehicle uses? and our one was idle speed control.

Then we moved on by how is the base idle speed ajusted? first thing we used the feeler pin for adjusting the idle speed on the engine.

Then we moved on the next step by checking . is this cold / fast idle speed control activatied by? ECU.

Then we explained the test procedure for checking this control? first thing we did was connecting the TEI and EI terminals togather with a piece of wire to check control.

Then we measured Resistance in the winding.

i used a multimeter on ohms. then we checked for continuity ( resistance ) between the two pins. and our reading was 44.4 ohms which shows there is a continuity.

Then we moved on by using a a digital multimeter measure the duty cycle and frequency that operates the IACV.

Duty 51%

Frequency 0.2444 HZ.

In conculsion

when we check the idle speed control on our egine is was in good condition . then we checked for continuity in the winding between the two pins and we had a reading of 44.4 ohms. which shows us the conttinuity. Then we had our duty test showed us 51 % and the frequancy showed us 0.0244 that showed us how many times it turnes on and off.

Check fuel lines

First we did on the egine was codition of fuel hoses. and our one was = pass

first thing we did was a visual  check on the fuel hoses, checking for any cracks, if they are tight, check for any oil leak , check if its lose, and our visual check on the hoses was in good condition no oil leaks and it was nice and tight.

Checking Fuel Pump (Fuel Injection High Pressure)

In todays task we learend how to work with a high pressure fuel. we used a revelant textbook before carrying out the test.first thing we did was using the manual book to follow the procedure for a fuel pump. first thing we did

• using jumper wire connect terminals' Bt and FP on the diagnostic plug
• turn ingnition on
• remove jumper wire
• starte the engine
• disconnect the vacuum sensing hose from the fuel pressure regulator.
• measure the speed idle
• reconnect the vacuum sensing hose from the fuel presure regulator
• measure the presure at idle
• stop the engine
• check that the fuel presure remains as specified for 5min after engine stoped

Safety precautions to be observed.

• Wear overalls, safety boots, gloves , safety glasses

what are the manufacturers specifications.

• Ignition on : 265 - 305 kpa ( 2.7 - 3.7 kgf /CM2,38 - 44 psi
• Jumper disconnected : 206 - 255 kpa ( 2.1 - 2.6 kgf/cm2 31 - 37 psi
• Ignition Off: 147 Kpa ( 1.5 Kgf/ cm2 21psi

Test results

• Ignition On = 300 Kpa
• The running Pressure Under full engine load ( without manifold = 320 kpa
• maximum output pressure of the fuel pump 87+
• Residual line pressure = 260 kpa

The Fuel pump does meet the manufactures specification

Checking Fuel Pump flow

This shows us of the flow rate in minutes for the pressure regulator for the fuel pump.
method i used was  620 * 6 = 3720 ml perminute. there was no manufacurers specifications.

Locate and identify self test codes and isolate cause.

In todays task we learend how to identify and do self test codes. first thing we did was to check the RPM drop when injectores are discounected. if the winding is not working that could tell us it might be an open circuit. Then we moved on by display the dignostice codes the method we used was turn on the egnition and shorten the dignostic codes which we used a piece of wire connected from TEI to EI. this showed us and understanding if any faults codes or wires is by discournecting the MAP sensor and check the wires from the ECU for faulty wires and any dignostic codes.

That will depend on what is the fault is. this gave us an idea of how to check the injectors and the dignostic codes.

SERVICE AN AIR CLEANER

In todays task we worked on ezzat car which was carburator. first thing we did was . removed the air filter and checked for any damage or excessive dirt or oil contamination to the filter element.

did it pass inspection: no it didnt because there was an air leak in the carburator.

Can it be serviced or does it need repacing: it can be serviced by getting new bushes.

PCV VAlve:

In todays task we did a pcv valve. first thing we check the pcv vavle by clamping the rubber hose ( using a brake hose clamp ) going to the pcv valves does the idle change.? Yes

Then checked if there was any clicking sound. by shacking is and check if it clicks. ? Yes

In conclusion

First thing we did was starting up the engine let it heat up to normal operating temerature. Then we clamped the rubber hose ( using a brake hose clamp ) going to the PCV valve and the idle on the engine changed abit it went dow about 0.5 revs. Because there is no air flowing through the engine. Then we lightly clamped the PCV hose and it shoed there was a clicking sound becasue the plunger was moving freely.

Vacuum Operated EGR Valve

In todays task we learend about the vacuum operated to the egr valve. we did a test on a EGR.

Recoreds of the EGR results.

• Did the engine idle smoothly at normal operating temeperature? yes
• Did the idle spped change with vacuum applied to the EGR valve? yes
• did the valve show any signs of air leaks through the stem seal? no
• in the EGR system working to specification? yes

In conclusion

There was no problems carried out on this EGR system because the EGR system was working to its specifications.

And another method can be used to control an EGR system is by using the ECU to control the EGR vacuum.

ADJUSTMENTS AND EMISSIONS

In todays task we learned about adjustments and emissions. first thing we did was testing a vehicle with a carburetor and without a catalyic converter and recored the results>

• Bring the engine to operating Temperature: yes
• prepare the infra-red gas analyzer as required: yes
• Calibrate the gas analyzer gauges: yes
• set the zero and span settings ( analogue Gagues ) yes
• Fit the sampler hose into the exhausst of the vehicle
• take exhaust gas sample.

And our readingss we had was

ACTUAL BEFORE ADJUSTMENTS.

• H.C. 76 ppm
• C.O:0.05 %
• CO2:14.4%
• O2:11.07%

INDUSTRY STANDARDS

• H.C. 50-500 Ppm
• C.O: 0.5-15
• C.O2: 13-14.5
• O2: 0-2

IN conclusion

The test we did was within the Industry Standards.

EFI Vehicle Test

Actual:

• H.C: 531 ppm
• C.O.: 0.29 %
• CO2: 10.2 %
• O2: 7.1 %

Indusry Standards

• H.C: 5-30
• C.O: 0.05-0.5
• CO2: 13-15.5
• O2: 1.00-3.00

IN conclusion

we couldnt test or adjust because therefor faults and ideals in the car . so we couldnt do any further testing.

Removal And Replacement of diesel Fuel Injectors
In todays Task we learend how to check diesel injectors and replace them.

first thing we did a test on the diesel injectors by using a harbridge Test master machine. then putting each injecor in the machine by checking the spray pattern and if theres any problems with them. we set our machine to a presure of 18 psi .then pumed the injector and we had a nice spray pattern. this showd the spray parrten on the 4 injectors were good and meet the manufacturers specification.  if the injectores are faulty you looking for diesel drop and not good spray pattern.

Bleed air from a diesel injection system

In todays task we learned how to bleed out air from a diesel injection system. first thing we did was removing the fuel pump filter to bleed it out. Then we put it back togather. then we did our air bleeding by removing the fuel line which we pumped out the fuel so all the air and the left over fuel to come out.

Describe the location of all the air bleed screws on your engine.

The engine i was working on only had bleed screw ( not including injector pipe nuts ) it was on the fuel pump on the top close to the fuel return.

Then we checked if the engine starts: YES

ELECTRONIC SHUT OFF VALVE

In todays task we learned how to test a electronic shut of valve.

With the ignition on, used a multimeter to test the voltage coming from the ignition switch to the electronic shut off solenoid.

• What voltage is it: 12.2 v
• Total resistance of the solenoid windings: 19.5 ohms

In conclusion

First thing we did was set our multimeter to volts to check the voltage coming from the ignition to the electronic by shutting of the solenoid and our voltage was 12.2 volts. Then we checked our resistance by setting our multimeter to ohms and our resistance was 19.5 ohms. This showed us our solenoid is in good condition and it was clicking.

Diesel Injector pump Timing.

 In todays task we learned how to time a diesel injector pump.

First thing we ddi was taking out the fuel pump and putting it back togather. then we let it loose abit so we can move it around and checking the spec  for the plunger travel using a dial gadge which we times the injector pump to 0.98.  and the special tools we used for it was a dial gadge.

TESTING GLOW PLUGS

In todays task we learned how to test a glow plug. First thing we went through a test

	plug 1	plug 2	plug 3	plug 4
Current draw	11 amps	11 amps	11 amps	11 amps
colour of glow plug tip	red at the top	red at the top	red at the top	red at the top

In Conclusion

First thing we did was remove 4 plugs and earth them to ground to check weather thy working or not. and we checked 4 of them if they glow or not and the top of the plugs glowed up red. This showed us that our plugs are useable and the engine would start.