AA Bosch Partnership for DIS KTS 570 Training

AA Bosch Partnership for DIS + KTS 570 Training AA Trainer Training – Engine Management Petrol Module 1 AA/SEU | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training § ECU Diagnosis Battery § ECU Diagnosis EM Petrol § ECU Diagnosis EM Diesel § ECU Diagnosis Wheels & Tyres § ECU Diagnosis Braking § ECU Diagnosis Comfort § ECU Diagnosis Servicing 2 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Engine Management Petrol – Contents Engine Fuelling & Emission Control Emission Legislation & OBD Emission Control Catalytic Converter & Lambda Sensors ECU Diagnosis via Engine Control system Practical ECU Diagnosis on Engine Control Systems with KTS 570 ECU Diagnosis via OBD Practical ECU Diagnosis on Engine Control OBD with KTS 570 3 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Engine Management Petrol – Pre Questions 1. What does an Engine Management system do ? Controls all fuelling and Ignition of Engine 2. 3. What Part does an Lambda Sensor play in Engine Management control? Controls fine adjustment of fuelling ( The Air Fuel Ratio) to allow the catalytic converter to work efficiently What is the full text explanation of OBD or EOBD? On Board Diagnosis / European OBD 4. What to you understand by Injection Duration ? The time an injector is held open ( spraying in fuel ) in milliseconds 5. 4 What is the function of (a) Pre Cat and (b) Post cat lambda sensors Pre Cat lambda = Fine control of Air Fuel Ratio Post Cat lambda = Monitoring and diagnosis of catalytic converter Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training ME-Motronic System Overview Single Spark DIS Ignition Coil Secondary Air Pump Electronic Injector Valve Air Temperature Sensor Throttle Valve Actuator with Position Sensor Hot film Air Mass Meter Camshaft (phase) Sensor Secondary air Valve EGR Valve Pre-Cat Lambda Oxygen Sensor Post-Cat Lambda Oxygen Sensor 5 Engine Speed Sensor Pedal Travel Fuel Pressure Sensor Regulator Tank vent valve OBD Diagnostic Plug Fuel Filter Active Carbon Canister ECU Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. In tank Fuel Pump

AA Bosch Partnership for DIS + KTS 570 Training Petrol Injection = Motronic Engine Management system + = + + = At Idle - Injector Open for ? ? 0. 0038 seconds RICH = LEAN = 0. 0037 seconds LEAN = = RICH AA/SEU | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 6 0. 0039 seconds

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control Open Loop Control (1) The ECU makes mixture corrections by adjusting “injection duration” according to main input sensors variables 2 Air 1 = ECU 2 = Sensors 2 Fuel 3 3 = Injectors 1 Engine Speed Air & Engine Temp Air Quantity Exhaust Open Loop No sensor measuring exhaust O 2 feeding back signal to ECU for fuel corrections Fuel Injection Control (Bosch Jetronic systems) ECU Control of Fuelling only. Ignition requirements by separate ignition ECU. Engine Management Control = (Bosch Motronic systems) ECU Control of Fuel Injection and Ignition via a single ECU 8 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control Closed Loop Control (2) 1 = Signal from pre-cat O 2 sensor 2 = ECU 3 = Injectors 4 = Catalytic converter The ECU makes mixture corrections by adjusting injection duration according to the exhaust O 2 levels. Air Fuel 2 3 1 λ 4 Exhaust 1. Pre cat O 2 Sensor = Called Control Sensor ref Bosch Parts. This is Pre OBD. Names = Lambda Sonde , Lambda Sensor. Oxygen Sensor , etc 9 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control The Catalytic Converter: “Catalytic Window” Spark ignition engines are designed to run (in most circumstances) very close to Lambda = 1. Exhaust Emissions before Catalytic Converter Exhaust Emissions after Catalytic Converter This ratio of 14. 7 parts air quantity, to 1 of fuel Is known as the: AFR Air Fuel Ratio or the Stoichiometric ratio. Rich λ=1 Lean Rich Lean 1. What is the significance of the area known as the “catalytic window”? For the catalytic converter to operate effectively on all three gases without damage. 10 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control Oxygen Sensor Function Thimble type LSH oxygen sensor O 2 sensor signal (volts) rich 1. 0 lean Volts 0. 5 0 0. 8 11 0. 9 1. 0. 998 0 1. 1 1. 2 Lambda ratio λ Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Planar type LSF oxygen sensor

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control CO Carbon Monoxide HC Hydrocarbons NOx Oxides of Nitrogen (NO & NO 2) CO 2 Carbon Dioxide H 2 O Water N 2 Nitrogen 1. What is the function of a three way catalytic converter? To further reduce noxious exhaust emissions: CO, HC and NOx 2. How is this achieved? The gases pass through a monolith structure coated with precious metals which creates catalytic chemical reactions 3. What does the chemical reaction do? They recombine gases to form different compounds i. e. CO 2 , H 2 O, Nitrogen 4. Why do we need a Lambda Oxygen Sensor? To enable the engine management to operate at gas levels for catalyst operation 12 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Practical Task: KTS 570 - System Test EM Petrol Module 1 Equipment: Using KTS 570 Standard Accessories. Demonstration vehicle/rig with Bosch Petrol EM system Procedure: Using the equipment above, connect to the Vehicle / Rig and complete the steps listed. Note: Please be aware of correct health and safety procedures before commencing the task. Equipment Test / Check step KTS 570 kit Training Vehicle Test Rig Bosch 1. Connect KTS 570 to Vehicle 2. Enter details to Vehicle Identification in Selection Menu 3. Select Start Diagnosis 4. Select Repair View 5. Select Engine Control 6. Select Error memory 7. Select Actual Values 8. Select and use Lambda Sensor Voltage or Current Values 13 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Completed Y

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control -OBD 1. What items have to be monitored by OBD in order to achieve the standard? A Oxygen sensors and catalytic converter B Exhaust Gas Recirculation (EGR) C Secondary air system D Combustion for misfires 16 A C Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. B D

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control -OBD Malfunction Indicator Lamp (MIL): The dashboard must have a MIL fitted. For Europe it is a yellow coloured light. It will light with ignition “on” and if an error code has been stored in Mode 3 1. Under what circumstances does the MIL flash? For faults that could cause damage to the catalytic converter Examples of MIL types: 17 CHECK POWER TRAIN CHECK ENGINE SERVICE ENGINE Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control -OBD Closed Loop Control (3) The ECU makes mixture corrections by adjusting injection duration according to the exhaust O 2 levels. 1 = Signal pre-cat O 2 sensor Air 2 = ECU Fuel 3 = Injectors 4 = Catalytic converter 5 = Signal Post-cat O 2 sensor 2 3 1 5 λ 4 Exhaust 1. Pre cat O 2 Sensor = Called Control Sensor (ref Bosch Parts) OBD = O 2 Sensor Bank 1 Sensor 1 for inline 4 cylinder Function = rich, lean and lambda = 1 for short term response for fuelling control 5. Post Cat O 2 Sensor = Called Diagnosis Sensor ref Bosch Parts OBD = O 2 Sensor Bank 1 Sensor 2 for inline 4 cylinder Function = Detection of rich , lean change after cat for cat fault monitoring. and long term response for fuelling control 18 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control -OBD MODE 1: Actual Data Displays live, operating data from the system MODE 2: Operating Conditions MODE 3/7: Read Error Memory Displays engine operating conditions during fault recognition (Freeze Frame) 3 = Confirmed emission relevant fault codes 7 = Sporadic non-confirmed errors MODE 4: Erase Error Memory for all Systems MODE 5: Oxygen Sensor Data Deletion of fault codes Oxygen sensor control - circuit values, working data Specific data Vehicle manufacturer MODE 6: Test Data Sporadically Montrd Systems MODE 8: Actuators Test functions (depending on vehicle manufacturer) MODE 9: Vehicle Information 19 Vehicle identification features Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Practical Task: KTS 570 System Test EM Petrol Module 2 Equipment: Using KTS 570 Standard Accessories. Demonstration vehicle / rig with Petrol EM system Procedure: Using the equipment above, connect to the Vehicle/rig and complete the tasks / check steps listed. Note: Please be aware of correct health and safety procedures before commencing the task. Equipment Test / Check step KTS 570 kit Training Vehicle Test Rig 1. Connect KTS 570 to Vehicle Training Vehicle Test Rig to OBD spec 2001> 3. Select Start Diagnosis 2. Enter details to Vehicle Identification in Selection Menu 4. Select Repair View 5. Select OBD ( CARB) and select Direct search 6. Select Mode 3/7 Check for Lambda Sensor Fault 7. Select Mode 1 as priority Lambda Sensor Voltages or Current values ( Bank 1 O 2 Sensor 1 , Bank 1 O 2 sensor 2) 21 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Completed Y

AA Bosch Partnership for DIS + KTS 570 Training Practical Task: KTS 570 System Test EM Petrol Module 2 Contd Equipment: Using KTS 570 Standard Accessories. Demonstration vehicle/rig with Petrol EM system Procedure: Using the equipment above, connect to the vehicle and complete the tasks / check steps listed. Note: Please be aware of correct health and safety procedures before commencing the task. Equipment KTS 570 kit Training Vehicle Test Rig to OBD spec 2001> 22 Test / Check step 8. Select and use Mode 5 Lambda Sensor Voltages or Current values 9. Select and use All other OBD Modes Overview 2. 4. 6. 8 & 9 If supported !! Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Completed Y

AA Bosch Partnership for DIS + KTS 570 Training Engine Management - Fuelling & Emission Control -OBD Bosch Lambda Sensors Direct Fit 23 Features OE quality specification & fit Wide range Bosch OE supplier development Fitting tips 1. Use electrical contact grease very sparingly at plug connectors. Do not block hole. 2. Use a little lambda safe anti-seize grease on thread section. 3. Do not use any silicone based aerosol /lubricants on sensor or inlet /exhaust manifold 4. Support spare cable /cable run with cable ties away from heat careful with tie tightness! Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

AA Bosch Partnership for DIS + KTS 570 Training Petrol Direct Injection Parts Fuel pressure sensor Fuel Rail High Pressure Pump Header of section 25 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Injector

AA Bosch Partnership for DIS + KTS 570 Training Practical Task: KTS 570 System Test EM Petrol Module 3 Equipment: Using KTS 570 Standard Accessories. Demonstration vehicle/rig with Petrol EM system Procedure: Using the equipment above, connect to the vehicle and complete the tasks / check steps listed. Note: Please be aware of correct health and safety procedures before commencing the task. Equipment KTS 570 kit Training Vehicle Test Rig Test / Check step 1. Complete Diagnostic Test on Vehicle Direct Injection MED System 2. Use All Engine Control functions for typical (FSI) MED System VAG FSI ( MED Equipped ) 26 Department | 14/10/2009 | © Robert Bosch Ltd. 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Completed Y