EM4 PDF For Cao Thang TB

ENGINE MANAGEMENT – EM4
Non-Bosch Engine Management Systems
Name : ______________________________
Company : ___________________________
Date : _______________________________
Automotive Aftermarket
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1 copying and passing on to third parties.
TOYOTA - TCCS
Toyota TCCS
Toyota Computer Control System
Evolution – Toyota EFI system
1. 1979 4M-E Supra carried the company's first EFI, which was
basically Bosch L-Jetronic.
1. 1983 injected Starlets and Celicas added self-diagnostic capability,
2. 1983 starting with the 5M-GE engine, TCCS (Toyota Computer

Controlled System) on the Supra and Cressida was
introduced. The TCCS system controlled not only the fuel
injection, but also the spark advance, idle speed control and
EGR, and was gradually adapted for all models.
System Overview – Special features
1. External ignition end stage

2. Load detection by way of Air mass meter
3. Sequential fuel injection
4. Distributorless ignition system
5. Non return fuel supply system
6. Cold Start Control Performed by the ECM
7. Zirconium dioxide heated type Oxygen Sensor
8. Exhaust Gas Recirculation
9. ECM Substitutes Fixed Values in the Event of an Abnormal Signal from a
Sensor
10. Limp Home Capability
11. Pin Designations on the Control Unit vary between Manual and Automatic
Transmissions because the ECM controls both the Fuel and the
Transmission
TCCS – Computer Engine Control Overview

RPM Signal Fuel Injectors
Airflow/Airmass Sensor Ignition Primary
MAP Sensor Idle speed
Engine Coolant Temperature (ECT) Oxygen Sensor Heater
Intake Air Temperature Sensor (IAT) Fuel Pressure
Battery Signal Purge Valve
Throttle Position Sensor EGR Valve
Knock Sensor PAIR
Oxygen Sensor/Sub-Oxygen Sensor Intake Air Control
Vehicle Speed Sensor Variable Induction
EGR Gas Temperature Sensor ECU Turbocharger
Engine Cranking Signal Supercharger
Switches Transmission
A/C Switch Relays
Park/Neutral Switch A/C Amplifier
Brake Switch Circuit Opening Relay
4WD Switch Fuel Pump Relay
Electrical Load Signal CHECK ENGINE Light (MIL)
Turbo Pressure Sensor Diagnostic Connector (DLC)
Diagnostic Connector (DLC)
Engine Mangement Toyota

with
Toyota Corolla Altis 1.8i as example
Information on fault diagnosis and system checking

is always to be taken from the valid ESI[tronic]-SIS instructions
System Description
1. Air Induction System
- Air Mass Meter
- Idle Speed Control
2. Variable Air Induction System
- Variable Valve Timing Control
3. Fuel Supply System
- Electric Fuel Pump and relay
- Injection Valve
- Coolant Temperature Sensor
4. Ignition System
- Direction Ignition System
- Crankshaft Position Sensor
- Camshaft position Sensor
5. Knock Control System
6. Emission Control System
- Lambda Sensor
- Fuel Evaporative Regeneration Valve
7. Self-diagnosis
System Overview – Air / Fuel Pipe Diagram

Toyota Corolla Altis 1.8i (1ZZFE)
1 2
1. Fuel evaporation regeneration valve

3
2. Throttle valve position sensor
3. Engine control unit
8
4. Idle speed actuator
5. Air cleaner
7
6. Air mass meter
6 7. Air temperature sensor
8. Charcoal canister
5
System Overview – Air / Fuel Pipe Diagram

Toyota Soluna Vios 1.5i (1NZFE)
1 2 3 4 5 6
1. Electric fuel pump relay
2. Fuel evaporation regeneration
valve
3. Throttle valve position sensor
4. Air cleaner
5. Air mass meter with air temp
sensor
6. Idle speed actuator
7. Charcoal canister
8. Electric fuel pump
9. Injection valve
10. Lambda sensor (bank 1, sensor 1)
11. Three way catalytic converter
12. Lambda sensor (bank 1, sensor 2)
7 8 9 10 11 12
Air Induction System – Air Mass Meter
1. Load is detected by measuring air mass flow

drawn in by the engine in the air mass meter .
2. Intake air temperature sensor is integrated into
the air mass meter and detects intake air
temperature.
1 3. In case of air temperature sensor failure, a
substitute value is introduce and the ECU will
2
be switched to emergency operation.
1. Air mass meter

2. Air temperature sensor
Air Induction System – Idle Speed Control

a
1. The idling speed is adjusted when

electrical equipment is switched on.
Load included:
- AC system
- Dipped beam
- Power window motor
c
- Power steering
b
2. The idle speed actuator is actuated
by ECU.
1. Air inlet a. Throttle valve
3. The principal quantity influencing idling
2. Air outlet b. ECU
speed is coolant temperature.
3. actuator c. Idle speed actuator
Variable Air Induction System – Variable Valve Control
The signal input of the following

Components to the ECU calculate an
optimal valve timing
a for the engine:
1. Crankshaft position sensor
2. Air mass meter
3. Throttle position sensor
4. Engine coolant temperature sensor
5. Vehicle speed sensor
6. Camshaft position sensor
a Variable valve timing controller
Variable Valve Control –

- Variable Valve Timing
Camshaft Control
The variable valve timing permits an increase in
torque in the lower engine speed ranges and
increased engine power in the upper engine
speed ranges. The variable valve timing alters
the relative position of the exhaust camshaft
with respect to the inlet camshaft in line with the
engine operating conditions.
The engine management can recognize the
current position of the component inlet
camshaft from the reference signal camshaft
position sensor
Variable Valve Control -– Camshaft control solenoid valve

ADVANCE
The oil pressure acts on the advance side of the camshaft actuator. The
camshaft is advanced.
RETARD
The oil pressure is routed to the retard side, the camshaft is turned in the
retard direction.
LOCKING
The camshaft has attained the specified angle. The ports of the camshaft
control solenoid valve are closed off. Oil circulation through the camshaft
actuator is prevented.
Fuel Supply System – Non return fuel supply

d
• The fuel supply system is of the non-

return type.
e c • There is heated fuel from the engine
flow back to the fuel tank.
• Lower fuel temperature reduces
b
a
evaporative emission.
• The electric fuel pump and fuel
pressure regulator are located next to
or in the fuel tank.
a. Electric fuel pump

b. Fuel pressure regulator
c. Injection valve
d. Fuel rail
e. Fuel filter
Fuel Supply System – Electric fuel pump relay
K1.2
K1.2 Electric fuel pump

relay
Electrical fuel pump relay can
be checked by measuring :
a. Voltage supply at connector
b. Resistance of the relay
Fuel Supply System – Electric fuel pump
Electrical fuel pump can be checked by measuring :

1. Actuation voltage
2. Resistance of the pump motor
Others possible fault:

Low fuel level and pressure
Main relay/pump relay or ECU defective
Fuel pipe damaged
Fuel Supply System – Injection valve

a
a o-ring
b o-ring
d b c grommet
d insulator
c
1. Solenoid operated type injection valve

2. ECU actuated the electric solenoid
3. Injection duration is determined by
the ECU
Injection valve can be checked by measuring :

1. the power supply voltage to the injection valve
2. the resistance of the injection valve
Fuel Supply System – Coolant temperature sensor

Coolant temperature sensor is the main injection
time correction quantity
It is also used as correction quantity for the
ignition Map, cold start enrichment and the engine
Warm-up phase.
Coolant temperature sensor can be checked by

measuring :
1. The resistance of the sensor
2. The signal voltage with ignition on
Intermediate resistance and voltage value can be

taken from the characteristic curve.
A Resistance Characteristic Curve

B Voltage Characteristic Curve
Ignition system – Direct Ignition System
A1.1 Engine control unit

T2.1-2.4 Ignition coil module 1-4
E1.1-1.4 Spark plug/ cylinder 1-4
Ignition system – Crankshaft position sensor

1 = Engine speed signal
2 = Reference mark pulse
a = Crankshaft – position sensor
b = Crankshaft ring gear
C = Crankshaft ring gear 2
The crankshaft position sensor detects the engine

speed and position of reference mark.
The reference mark forms the basis for calculating
ignition timing.
The engine speed is one of the main quantities
Influencing the ignition point map and the injection
time.
Crankshaft position sensor can be checked by

measuring :
2. The signal voltage during cranking or engine
a b c running
Ignition system – Camshaft position sensor

The signal from the camshaft position sensor informs the ECU of the point in
which cylinder 1 is in its power stroke. By way of synchronization with the signal
from the crankshaft position sensor. The ECU then calculates the point at
which the other cylinders are in their power strokes.
Use of camshaft position sensor permits implementation of the following
functions/ control operations:
1. Sequential injection
2. Knock control
3. Distributor less ignition system
Knock Control System – Knock sensor
B7.4 Knock sensor
The knock sensor detects and engine

knocking
By way of retard correction of ignition point.
The knock signals are detected and
converted into a piezo-electric voltage and
evaluated by the ECU.
Knock sensor can be checked by measuring

:
2. The knock signal with oscilloscope
Emission Control System – Lambda Sensor a

Lambda Window
If mixture change (rich/lean) takes place in
Lambda window (8), this produces a step change in
Lambda-sensor voltage (2).
Lambda heater
The lambda heater assures that the sensor will attain the
minimum operating temperature soonest possible. It takes
20-30 sec to reach the necessary temperature after starting
engine.
1 Ambient air 5 Ceramic element

2 Lambda sensor voltage 6 Lambda <1
3 Electrodes 7 Lambda >1
4 Exhaust gas 8 Lambda window
A1.1 ECU
Emission Control System – Lambda Sensor b
Lambda sensor can be checked by measuring :

1. The resistance of the sensor heater
2. The power supply voltage to the sensor heater
3. The sensor signal voltage with oscilloscope during
engine warm and engine speed 2500 rpm.
The signal voltage of the lambda sensor should
fluctuates between 0-1V.
B1.11 Lambda sensor

Emission Control System – Fuel evaporative regeneration valve
Fuel vapors from the tank are absorbed The evaporation regeneration valve
in the filter filled with activated charcoal is activated by the ECU
The evaporative regeneration valve can be checked by measuring:

1. The voltage supply from ECU to the evaporative regeneration valve
2. The resistance of the evaporative regeneration valve
Self - diagnosis
The self-diagnosis data are evaluated using
the diagnostic tester with CAS (i.e. KTS 5XX,
650)
The diagnostic socket is available under the

driver’s seat. This is a standard OBD
Engine check connector.
light The connection details are as below:
Battery +ve Pin 16

Battery -ve Pin 4
K - line Pin 7
Diagnosis terminal
NISSAN - ECCS
Nissan ECCS
Electronic Concentrated Control System
NISSAN ECCS – Special features
1. ECCS is similar to Bosch Motronic engine management system

2. Hot Film Mass Air Flow Sensor
3. Optical Crankshaft Position Sensor
4. External Switching Transistor for Ignition Coil Primary Circuit
5. Knock Control
6. Air Regulator controls COLD idle RPM
7. Auxiliary Air Control Valve controls WARM idle RPM
8. Fast Idle Control Device Solenoid increases idle RPM with A/C ON
9. ECU substitutes fixed values in the event of an OPEN Engine Coolant Temperature
Sensor circuit
10. Limp Home Mode: Engine speed will be limited to 2400 RPM if MAP Sensor fails
11. Self-Diagnostics
NISSAN ECCS – Computer Control System Overview

Inputs Outputs
Crankshaft Position Sensor (CPS) Fuel Injectors
Mass Air Flow Sensor (MAF) Power Transistor-Ignition Coil
Engine Coolant Temperature (ECT) Idle Control Devices
Intake Air Temperature Sensor (IAT) Oxygen Sensor Heater
Battery Voltage (and Ignition) Purge Valve
Throttle Position Sensor EGR Valve
Knock Sensor(s) Power Valve
Oxygen Sensor(s) (heated) Swirl Control Valve
Vehicle Speed Sensor ECU Valve Timing Control
EGR Temperature Sensor (Calif. Only) Fuel Pressure Control
Fuel Temperature Sensor Fuel Pump Control Module
Switches Wastegate Control (Turbo)
A/C Switch Relays
A/C Thermo Control A/C
Inhibitor Switch (A/T) Cooling Fan (Multi-stage)
Neutral Safety Switch (M/T) Fuel Pump
Brake Switch CHECK ENGINE Light (MIL)
Power Steering Pressure Switch Diagnostic Connector (DLC)
Diagnostic Connector (DLC)
Nissan ECCS
with
Nissan Cefiro 3.0 V6 24V as example

System Description
• The ECCS operates with multipoint injection.

• Load detection is primarily based on the engine speed, air mass and the position of
the throttle valve.
• The ECU controls the ignition times and the ignition angle.
• The Idle speed switch is integrated into the Throttle valve position sensor.
Other functional systems include :

• Immobilizer system
• Ignition system
• Fuel supply system
• Knock control
• Idling speed control
• EGR system
• Lambda control
• Evaporative emission control system
Air / Fuel Pipe Diagram
A5.12 = A/C control unit

A7.1 = Instrument cluster
G1 = Battery
H2.1 = Engine fault lamp
J24.1 = Charcoal canister
S1.85 = Start inhibit switch
X9.2 = Diagnosis socket
Y3 = Electric fuel pump
Fuel Supply System
• The electric fuel pump conveys the fuel via fuel filter
to the fuel rail.
• The fuel pressure regulator maintains the fuel
pressure at a constant level irrespective of the
delivery rate.
• The injected fuel quantity is governed by the injection
time.
J23.1 Fuel pressure regulator

J23.2 Fuel filter
J23.5 Fuel rail
Y1.x Injection valves
Y3 Electric fuel pump
Ignition System
• The distributorless ignition system (RUV) is a static
ignition system which controls the ignition point
electronically by way of the ECU.
• Each ignition circuit is assigned a separate ignition
coil module integrated with ignition driver stage.
• The ECU calculates the optimum ignition point on
the basis of a stored map.
• The correction quantities include the intake air
temperature, the coolant temperature and the
knock sensor signal.
A1.1 Engine control unit

B4.4 Crankshaft position sensor
B4.7 Camshaft position sensor
B7 Knock Sensor
T1.1 Ignition coil 1
Idling Speed Control System
• The idling speed control feature controls the

idling speed as required, to suit :
-Cold starting
-Warm-up phase
-Overrun, and
-During switched on of others electrical equipments
Load include;
-A/C system
-Dipped beam
-Power window
• The actuator is actuated by the ECU.
• The principal quantity influencing idling speed
1 = Throttle valve housing
is coolant temperature.
2 = Bypass duct
3 = Spindle
J1.18 = Throttle valve
Y5.1 = Idle speed actuator
LAMBDA CONTROL
SELF-DIAGNOSIS
The self-diagnosis data are evaluated using the
diagnostic tester with CAS (i.e. KTS 5XX, 650)
The diagnostic socket is available under the driver’s

seat. This is a standard OBD connector.
The connection details are as below:
Battery +ve Pin 16

Battery -ve Pin 4/5
K - line Pin 7
The diagnosis socket is located in

driver’s footwell on right beneath
dashboard.
F2 = Fuse box
J17.88 = Brake pedal
X9.2 = Diagnosis socket (OBD)
Engine Management “ MPI 1.1”

with
Proton Waja 1.6i as an example

PROTON WAJA : SYSTEM LAYOUT

4G18 SOHC for Proton Waja 1.6i
A
B
J
I
H
G
E
D C
F
PROTON WAJA : SYSTEM LAYOUT
A. Manifold Absolute Pressure sensor

B. Throttle Position Sensor (with Idle Position Switch)
C. Purge Control Solenoid Valve
D. EGR Control Solenoid Valve
E. EGR Valve
F. Pre- and Post- Oxygen sensor
G. Coolant Temperature Sensor
H. Fuel Injector
I. Positive Crankshaft Ventilation valve
J. Fuel Pressure Regulator
PROTON WAJA : ECU PIN ASSIGNMENT

Proton Waja 1.6i
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 81 82 83 84 85 86 51 52 53 54 55 56 57 58 59 60 61
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 86 87 88 89 90 91 62 63 64 65 66 67 68 69 70 71 72
PROTON WAJA : SELF-DIAGNOSIS
The self-diagnosis data are evaluated using the


Battery +ve Pin 16

Battery -ve Pin 4
K - line Pin 7
16 pins OBD
PROTON WAJA : SELF-DIAGNOSIS – Engine warning lamp

function
Malfunction components will be indicated by the

engine warning lamp :

2. Oxygen sensor
3. MAP sensor
4. Intake air temperature sensor
5. Coolant temperature sensor
6. Crank angle sensor
Caution :
Engine warning lamp will on when
7. Cam angle sensor
terminal for ignition timing adjustment 8. Ignition timing adjustment signal
is bridged for ignition timing adjustment.
9. Injection valve
PROTON WAJA : FAIL-SAFE MODE
There is a fail-safe system built into the EMS ECU. During the fail-safe mode, a substitute
value or pre-set logic control from ECU will substitute the function of certain main malfunction
components so that the vehicle can still be driven:
Malfunction components Substitute values

Intake air temperature sensor 45 degree C
Coolant temperature sensor 80 degree C
Cam angle sensor Fuel cut off. Engine cannot start
Ignition coil power transistor Fuel cut off. Engine cannot start
Throttle position sensor Injection timing unchanged during acceleration
MAP sensor Injection and ignition timing replaced by TPS
signal.
Idle speed control is not performed
Oxygen sensor (pre- & post-) Closed-loop control is not performed
Engine Management “ EMS 400”

with
Proton Wira 1.5i as an example

EMS 400 : SYSTEM LAYOUT

4G15 SOHC for Proton Wira 1.5i Hatchback
D
E
Air Inlet A B C
H F
Fuel
tank Fuel
pump
J G
L I
N
K
M
P O
EMS 400 : SYSTEM LAYOUT

A. Intake Air Temperature sensor
B. Throttle Position sensor (with idle position switch)
C. Manifold Absolute Pressure sensor
D. Purge Canister
E. Electric Purge Valve
F. EGR Control Valve
G. EGR Valve
H. Fuel Pressure Regulator
I. Fuel Injector
J. Positive Crankshaft Ventilation valve
K. Coolant Temperature sensor
L. Knock sensor
M. Pre- and Post- Oxygen sensor
N. Ignition Coil Module
O. Crankshaft sensor
P. Camshaft sensor
EMS 400 : SYSTEM DESCRIPTION
1. MAIN FEATURES:
• Sequential injection
• Distributorless ignition system
• Ignition coil with integrated ignition driver stage
• Load detection is primarily based on engine speed, the position
of the throttle valve position sensor and intake manifold pressure
2. Other functional systems include :

• System power supply
• Fuel supply system
• Ignition system
• Idling speed control
• Knock control
• Evaporative emission control system
• Lambda control system
FUEL SUPPLY SYSTEM
• The electric fuel pump conveys the fuel via fuel filter
to the fuel rail.
• The fuel pressure regulator maintains the fuel
pressure at a constant level irrespective of the
delivery rate.
• The injected fuel quantity is governed by the injection
time.
J23.1 = Fuel pressure regulator

J23.2 = Fuel filter
J23.5 = Fuel rail
Y1.x = Injection valves
Y3 = Electric fuel pump
IGNITION SYSTEM
A1.1 = ECU
B4.4 = Crankshaft position sensor
B4.7 = Camshaft position sensor
B7 = Knock sensor
T2 = Ignition coil module
• The ignition coil module supplies ignition circuits

1 / 4 and 2 / 3 with ignition energy.
• On actuation of ignition coil module by the ECU, one
cylinder pair is simultaneously with ignition spark by
the ignition coil.
• The ECU calculates the optimum ignition point
base on a stored map with the engine speed and
load as the principal map quantity.
• Other correction quantities include the intake-air
temperature, the coolant temperature and the knock
sensor signal.
• Any misfiring is detected by the Self-diagnosis of the
system.
IDLING SPEED CONTROL

• Idling speed control is implemented in the ECU to
control the idling speed as required.
• Its function is to suit cold starting, warm-up phase,
overrun and whenever electrical equipments is
switched on.
• In the event of deviations bet. specified and actual
idling speed, correction is implemented by way of
the ignition and throttle valve angle.
Principal input variables:

•Coolant temperature
•Engine speed
•Accelerator position
•Vehicle speed
1 = input variables
2 = ignition Output variables:
A1.1 = ECU •Throttle valve angle
A20.1 = Throttle valve control unit •Ignition angle
EMS 400 : SELF-DIAGNOSIS
Location of diagnosis socket The self-diagnosis data are evaluated using the

Battery +ve Pin 16

Battery -ve Pin 4
K - line Pin 7
16 pins OBD
EMS 400 : SELF-DIAGNOSIS – Engine warning lamp function
Malfunction components will be indicated by the

Engine warning lamp engine warning lamp :

2. Oxygen sensor
3. MAP sensor
4. Intake air temperature sensor
5. Crank angle sensor
6. Cam angle sensor
7. Purge solenoid
8. Throttle body actuator
9. Ignition coil
10. Coolant temperature sensor
EMS 400 : FAIL-SAFE MODE
There is a fail-safe system built into the EMS ECU. During the fail-safe mode, a substitute
value or pre-set logic control from ECU will substitute the function of certain main malfunction
components so that the vehicle can still be driven:
Malfunction components Substitute values

Intake air temperature sensor 40 degree C
Coolant temperature sensor 80 degree C
MAP sensor Back up by Throttle position sensor
O2 sensor Closed-loop function not activated

EM4 PDF For Cao Thang TB

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ENGINE MANAGEMENT – EM4

Non-Bosch Engine Management Systems

Toyota Computer Control System

Evolution – Toyota EFI system

1. 1983 injected Starlets and Celicas added self-diagnostic capability,

2. 1983 starting with the 5M-GE engine, TCCS (Toyota Computer

System Overview – Special features

1. External ignition end stage

TCCS – Computer Engine Control Overview

Engine Mangement Toyota

Information on fault diagnosis and system checking

System Overview – Air / Fuel Pipe Diagram

1. Fuel evaporation regeneration valve

System Overview – Air / Fuel Pipe Diagram

Air Induction System – Air Mass Meter

1. Load is detected by measuring air mass flow

1. Air mass meter

Air Induction System – Idle Speed Control

1. The idling speed is adjusted when

Variable Air Induction System – Variable Valve Control

The signal input of the following

a Variable valve timing controller

Variable Valve Control –

Variable Valve Control -– Camshaft control solenoid valve

Fuel Supply System – Non return fuel supply

• The fuel supply system is of the non-

a. Electric fuel pump

Fuel Supply System – Electric fuel pump relay

K1.2 Electric fuel pump

Fuel Supply System – Electric fuel pump

Electrical fuel pump can be checked by measuring :

Others possible fault:

Fuel Supply System – Injection valve

1. Solenoid operated type injection valve

Injection valve can be checked by measuring :

Fuel Supply System – Coolant temperature sensor

Coolant temperature sensor can be checked by

Intermediate resistance and voltage value can be

A Resistance Characteristic Curve

Ignition system – Direct Ignition System

A1.1 Engine control unit

Ignition system – Crankshaft position sensor

The crankshaft position sensor detects the engine

Crankshaft position sensor can be checked by

Ignition system – Camshaft position sensor

Knock Control System – Knock sensor

B7.4 Knock sensor

The knock sensor detects and engine

Knock sensor can be checked by measuring

Emission Control System – Lambda Sensor a

1 Ambient air 5 Ceramic element

Emission Control System – Lambda Sensor b

Lambda sensor can be checked by measuring :

B1.11 Lambda sensor

Emission Control System – Fuel evaporative regeneration valve

The evaporative regeneration valve can be checked by measuring:

The diagnostic socket is available under the

Battery +ve Pin 16

Electronic Concentrated Control System

NISSAN ECCS – Special features

1. ECCS is similar to Bosch Motronic engine management system

NISSAN ECCS – Computer Control System Overview

Information on fault diagnosis and system checking