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1、 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机Alpha II Alpha II 发动机简介发动机简介Direction : Point out some changed items such as ;Individual Ignition System, CVVT system, Surge Tank and
2、move on to next slide.没有CVVT的Alpha 发动机已经用于 LC 上。新Alpha 发动机的主要不同是： - 使用CVVT 系统 - 独立点火系统 - 稳压箱容积 - 进气歧管曲率半径和管径 - 节气门喉口尺寸由48mm 扩大到 52mm - 增加缸体强度 - DTC CAN通讯 -2片芯片 集成一体PCM (ECM 与 TCM) - PCM 位置 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be
3、used for the training purpose. 2005.01.07 Alpha 发动机发动机Engine Engine 系列系列MC 有3种发动机. 其中2个型号是汽油发动机，1个是CRDI柴油发动机。MC的汽油发动机不是第一次在HMC车辆上使用。没有CVVT系统的发动机已经在LC 1.6车辆中被采用。Alpha 1.6 和 1.4 DOHC发动机，是由HMC设计的，现在HMC和KMC都在生产。在韩国的牙山工厂中有这种发动机的装配线。这种发动机相当广泛地被使用在HMC的车辆中，从1993年起，使用这种发动机的车辆包括：Matrix，Gets，Accent，XD Elantra
4、和其他一些车辆。所以它在质量上，和可靠性上都经过了检验。现在，现代公司正在发展这种引擎的第3代，项目名称是有新的正时链系统的Gamma发动机， Gamma发动机将在2006年面世.MC使用的是第二代Alpha 发动机。 Alpha 发动机的基本型号是1.5L排量，但是它有三种衍生的型号1.3,1.4 和 1.6升。1.5 和1.6 升发动机都有 CVVT 系统，1.3和1.4 升升发动机没有。北京现代的MC车辆只有1.6 升有CVVT的发动机，1.5L有CVVT的发动机是韩国国内使用的。 U1.5L CRDI是很新的柴油发动机。主要是欧洲和韩国国内使用。它1.5L的排量能令人惊异的产生110
5、马力。它的CRDI CP3 系统有 VGT turbo 涡轮控制器。 它有 3 种型号- 1.1,1.5 和 1.6L，满足欧4排放标准 。 Alpha 2 1.6 liter with CVVTU 1.5 liter CRDI with VGTDirection : Introduce 3 engines characteristic one by one with chart. In case of NAS 1.6 with CVVT engine will be used. HMC & KMC reserves all rights of disposal such as copying
6、 and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机主要不同主要不同-1-11.6 Intake Camshaft Target Wheel1.6 Cylinder Head主要移动部件，例如活塞、活塞环、凸轮轴、曲轴、连杆、气缸盖、气缸盖衬垫和气缸体，任何部件都不能在1.4和1.6升之间共用。为区分1.6 到 1.4的气缸体，参考4号气缸体找出编码字母如1.4D/1.5D 或1.6D，1.4和1.5气缸体可以交换变更，但1.6升不
7、能变更。不能变更的主要原因是采用了CVVT系统，且加大了1.6升缸径尺寸。只能共用排气和进气机构。在未配备石墨涂层活塞的发动机过程中，存在噪音和机油消耗问题，为解决此问题，使用石墨涂层活塞，提高润滑，减少敲击噪音。1.6升中凸轮轴信号轮配有4个信号凸缘。从低到高、从高到低每次要经历180度，以此提高CVVT控制的控制精度。而1.4升中仍然使用定位销式信号轮。Direction : Explain some changed items from 1.5 liter base engine of Alpha. All moving parts which are mentioned here ca
8、n not be inter changeable. HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机其中，一个大变化是1.6升中PCM的位置分布。 PCM 位于空气滤清器壳后。且因特定的位置分布使用了防水PCM。发动机室PCM分布方式的使用能缩减导线长度，减少生产成本，减少导线线束电气问题且便于维修。1.6中，MC
9、使用了Bosch M7.9.1 版本软件，而JB 使用了配备CVVT系统的 Bosch M7.9.8 版本。M7.9.8的主要特性是2片CPU、400MHz内部时钟、防水、24通道A/D 转换器、2 CAN 模块、154端子连接器、集成式轮速传感器接口、768 K快速存储器等。只有在汽油发动机上进行DTC诊断时使用CAN通信协议代替了KWP2000，因此要使用hi- ds scan 与PCM进行通信，您必须使用CAN接口模块。使用CAN协议，通信速度从10kbps增加到38.4kbps。在16 OBD 2连接器中配有两个用于CAN通信的端子。当您需要进行通信时，您必须使用此端子。CVVT 系统
10、与2.0系统的非常类似。曲轴驱动排气凸轮轴。通过链条连接排气凸轮轴上的CVVT执行器和进气凸轮轴。1.6L发动机使用独立点火，以提高发动机控制的效率和准确性。功率三极管在ECM内部.Direction : Describe PCM location with advantages and CAN protocol for DTC. 主要不同主要不同- -2 2 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used fo
11、r the training purpose. 2005.01.07 Alpha 发动机发动机最大限度延迟最大限度提前进气门排气门持续角度: 228持续角度: 236TDCBDCATDC 10BBDC 4682TDCBDCATDC 8ABDC 56122TDCBDCBTDC 32ABDC 16CVVT CVVT 参数参数1.6 升发动机的气门正时如上所示。“CVVT 定位位置”是进气门开启持续角度的一半位置，进气门最大提前位置在ATDC 82，最大延迟位置为ATDC 122。有两种类型的火花塞，NGK和Champion可供使用 。建议4个气缸全部使用一种类型的火花塞。Direction : E
12、xplain Intake valve opening timing and spark plugs. HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机进气传感器进气传感器MC使用磁感应式CKP传感器。一般来说，当你使用Bosch EMS系统时，CKP传感器类型选用磁感应式，而不是Siemens的霍尔IC型。目前没有
13、任何CKP传感器电路板可以共用霍尔式或磁感应式。Bosch优先选用磁感应式传感器的主要原因是它不需要任何电源支持传感器工作。例如在崎岖路面上行驶的霍尔IC型CKP传感器车辆，如果控制模块突然发生至传感器的电源切断故障时，发动机会立即熄火。相反地，因为感应式传感器不需要电源，发动机仍能继续运行。1.6升发动机使用空气流量计计算进气量，1.4升发动机使用进气歧管绝对压力传感器计算进气量。对于MAF传感器，传感器供应商由Bosch变更为Siemens。先前的Bosch HFM 5 类型倒流检测MAF传感器，虽然它的精确度较高但传感器易于因外来杂质损坏，而导致燃油系统故障。而与Bosch的传感器相比，
14、Siemens MAF传感器虽然精确度降低了，但传感器的可靠性提高了。在您安装MAF传感器时，要必须注意安装方向。其它传感器或执行器除最新采用的独立点火系统外，与以前的发动机没有区别。 Direction : Explain CKP sensor and MAF sensor here. Others dont have any change. MAF for 1.6 literMAP for 1.4 liter HMC & KMC reserves all rights of disposal such as copying and passing on to third parties.
15、This book should be used for the training purpose. 2005.01.07 Alpha 发动机机无回油燃油控制系统无回油燃油控制系统1. Application - MC 1.6 CVVT or 1.4 Non CVVT: 2. Objectives - Understanding RLFS system - Understanding available vehicle - Understanding fuel filter maintenance interval - Field problem discussion3. Required m
16、aterials - Workshop manual - EMS and Troubleshooting book4. Procedure - Discuss what the RLFS is with your co-worker(partner) - Share your experience in field case - Write down its advantages and available vehicle - Find out maintenance interval in workshop and write down it5. Time to complete : 15
17、minutes6. Reference : - Workshop manual - EMS and Troubleshooting bookNotice Caution Available VehicleXD, LC, FC, MC汽油汽油滤滤芯更芯更换换周期周期 60,000 KM (依照不同地依照不同地区区情情况况)优点:燃油在燃油箱和加热的燃油总管之间流动，与RLFS（燃油压力调节器在燃油箱内部的燃油泵总成内）相比，传统回油式燃油压力调节系统会产生更多高温蒸汽。如图中所示缩减燃油循环管路，RLFS维持较低的燃油温度并减少了2530%的蒸汽。RLFS的主构件是燃油泵总成，包括在燃油箱内的燃
18、油压力调节器和燃油滤清器。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机燃油泵分解状态燃油泵分解状态1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding how to disassemble fuel pump module - Understa
19、nding how to replace fuel filter - Checking fuel system related items3. Required materials - 1 set of fuel pump module - 1 set of fuel filter4. Procedure - Write down your procedure5. Time to complete : 15 minutes6. Reference : Notice Caution Procedure :1.Descrewed two bolts hidden in rear seat2.Dis
20、connect fuel pump connector3.Carefully open fuel tank cap and take out the fuel pump module4.Disassemble one by one carefully and replace fuel filter HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.
21、07 Alpha 发动机机1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Understanding fuel pump operation circuit - Understanding fuel cut valve - Understanding fuel pump actuation test in hi-scan pro - Measuring each points voltage3. Required materials - Multi meter - Hi-scan pro 4. Procedure -
22、 Refer to MC ETM in MFI Control - Set Ignition key on condition - Check fuel pump operation sounds for 3 5 seconds - Make fuel pump actuation test with hi-scan pro - Find each point out which marked here - Measure the voltage by condition - Write down the result 5. Time to complete : 15 minutes6. Re
23、ference : - MC ETMNotice Caution (V)Ig. On0B+B+B+0 B+StartingB+ 0B+B+B+B+ 0运运转0B+B+B+0电池主继电器燃油泵继电器PCM断油开关燃油泵 : When Ig on, only 1.5 2 seconds fuel pump goes on condition Real measuring is around 12.50 for B+ and 0 for 0.8 0.9V 燃油泵电路燃油泵电路 HMC & KMC reserves all rights of disposal such as copying and
24、passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机燃油燃油压力力测量量1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Measuring fuel pressure - Understanding how to use fuel pressure measuring adaptor3. Required materials - Fuel pressure gauge
25、- Fuel pressure measuring adaptor - Test relay 4. Procedure - Set fuel pressure measuring adaptor on fuel delivery pipe - Attaching pressure gauge - Measuring the pressure following the practice condition - Use test relay for fuel pump operation - Write down the result5. Time to complete : 20 minute
26、s6. Reference : - Workshop manualNotice Caution 燃油燃油压力力(kg/)Ig. On3.5 3.0Starting3.5急加速急加速3.5 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 CVVT or 1.4 Non C
27、VVT 2. Objectives - Understanding fuel pump current consumption3. Required materials - Amp Meter - Hi-scan pro or other oscilloscope - General tools - MC ETM4. Procedure - Prepare oscilloscope - Set this to power line to fuel pump - Measure current consumption during fuel pump operation - Write down
28、 on the table5. Time to complete : 15 minutes6. Reference : - Hi-scan pro optional manualNotice Caution 电流流 (A)最大最大11.2平均平均4.5最小最小3.5燃油泵电流消耗燃油泵电流消耗 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07
29、 Alpha 发动机机部件位置部件位置1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding each parts location - Understanding how to disconnect each connectors3. Required materials4. Procedure - Check sensors or actuators location - Check engine room junction box - Disconnect each parts one by one - Write d
30、own correspond parts name to the picture5. Time to complete : 15 minutes6. Reference : -Notice Caution 1.PCM2.MAF Sensor5. TP Sensor6. ECT Sensor7. CMP Sensor8. CKP Sensor9. Frt. Oxygen Sensor11. Knock Sensor12. Vehicle Speed Sensor14. ISA15. PCSV16. OCV17. Ignition Coil HMC & KMC reserves all right
31、s of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机驱动皮带的安装与调整驱动皮带的安装与调整1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Understanding drive belt components - Understanding drive belt tension adjustment
32、mechanism - Understanding how to replace drive belt - Understanding how to inspect it3. Required materials - 1 unit of JB with good condition - General Tools 4. Procedure - Refer to Workshop manual - Checking drive belt tension depressing by finders with specific force and feel the tension first - D
33、isassemble all drive belts - Inspect these - Reassemble correctly - Write down the procedure 5. Time to complete : 30 minutes6. Reference : - Workshop manualNotice Caution 3条条正正时皮皮带，1条条（A）连动力力转向，向，1条条（B）连空空调压缩机，一机，一条条（C）连发电机。皮机。皮带B和和C容易混淆，容易混淆，维修修时注意做注意做标计。皮带皮带C C比皮带比皮带B B稍长一点。稍长一点。照片是每根皮带的调整机构，与照片是
34、每根皮带的调整机构，与beta 2.0 L发动机相似。机相似。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机正时皮带的安装正时皮带的安装1. Application : - MC 1.6 CVVT 2. Objectives - Understanding how to align timing belt syste
35、m - Understanding each components name(A D)3. Required materials - Alpha 1.6 CVVT Engine - General Tools 4. Procedure - Refer to Workshop manual - Write down the procedure 5. Time to complete : 30 minutes6. Reference : - Workshop manualNotice Caution 正正时皮皮带部分，上部分，上图表示各正表示各正时位置。位置。由于曲由于曲轴正正时皮皮带和和CVVT
36、正正时皮皮带的的齿轮传动比不同，比不同，将将曲曲轴每每转4圈才能圈才能将将曲曲轴和和CVVT系系统的正的正时点都点都转回原位。回原位。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机正时皮带的参数正时皮带的参数1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objec
37、tives - Understanding timing belt alignment - Understanding belt tension3. Required materials - Alpha 1.6 CVVT Engine - General Tools 4. Procedure - Refer to Workshop manual - Inspect each marking position - Inspect belt tension following the workshop manuals direction - Write down the result 5. Tim
38、e to complete : 30 minutes6. Reference : - Workshop manualNotice Caution Belt Tension为了降低为了降低Alpha Alpha 发动机机正时皮带的噪音问题，正时皮带的噪音问题， MCMC使用的使用的 AlphaAlpha 发动机采用了发动机采用了加厚的皮带。注意与以前使用加厚的皮带。注意与以前使用AlphaAlpha 发动机的其他机的其他车辆的正的正时皮皮带相相区区别。检查皮带的张紧度：检查皮带的张紧度：方法方法1 1：可以采用参考皮带与螺栓的相对：可以采用参考皮带与螺栓的相对位置的方式。用位置的方式。用4.5k
39、g.m4.5kg.m的力按压皮带，的力按压皮带，皮带应偏向螺栓中心线附近，到达半径皮带应偏向螺栓中心线附近，到达半径的一半附近。的一半附近。方法方法2：使用：使用标准的皮准的皮带张紧力量力量规。请参参考相考相关关的技的技术通通讯. HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机汽缸汽缸压缩压力力11. Applicat
40、ion : - MC 1.6 or 1.4 2. Objectives - Measuring cylinder compression 3. Required materials - Compression gauge - General tools 4. Procedure - Warm up the engine - Take out ignition system - Setting the compression gauge - Replace start motor relay with test relay - Measure the compression - If neces
41、sary, oil the cylinder and measure it again - Write down the result5. Time to complete : 20 minutes6. Reference : MC EM-9Notice Caution Not to touch spark plug when it is hotNo.1No.2No.3No.4干燥干燥(Kg/)12.5 1312.5 1312.5 1312.5 13加机油加机油(Kg/)13.514.213.514.213.514.213.514.2Good/BadGoodGoodGoodGoodCompre
42、ssion test result can be different by tools and conditions. Rationality check for 4 cylinder is useful. HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 or 1.4
43、2. Objectives - Measuring cylinder compression with amp meter 3. Required materials - Amp meter - Hi-Scan Pro 4. Procedure - Set the Hi-Scan pro with amp meter to battery positive terminal for start motor - Using scope function, measure the current consumption by start motor during cranking - Compar
44、e each cylinders output voltage - If necessary, take out one spark plug, and test it again - Write down the result5. Time to complete : 15 minutes6. Reference : - - Hi-Scan Pro optional manualNotice Caution No.1No.2No.3No.4Voltage(V)0.61.51.51.5Good/BadBadGoodGoodGoodTest is done after removing No.1
45、 spark plug. Amp meter setting is 10mV/A so 1.5 V means 150A current consumption by start motor for that cylinder.汽缸汽缸压缩压力力2 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机轴承的承的选择和和测量量
46、1.Application : - Alpha 1.6 or 1.4 engine 2. Objectives - Understanding how to set main moving parts such as piston, rings con-rod and crankshaft - Understanding bearing selection - Measuring clearance both con-rod and main bearing3. Required materials - Engine block with main moving parts - General
47、 tools - Torque wrench - plastic gauge4. Procedure - refer to workshop manual - Set crankshaft to cylinder block - Measure the clearance with plastic gauge - Set pistons to crankshaft - Measure the clearance with plastic gauge - Measure the bore size with cylinder bore gauge 5. Time to complete : 45
48、 minutes6. Reference : - Workshop manual EM75 - 83Notice Caution 连杆轴承连杆轴承连杆轴承的油膜间隙是连杆轴承的油膜间隙是0.022 0.022 0.040mm. 0.040mm. 有有5 5种不同尺寸的种不同尺寸的轴承可选用。轴承可选用。连杆自身有连杆自身有 A A, , B B，C C三种，尺寸标记在连杆三种，尺寸标记在连杆下部的曲轴盖旁边。下部的曲轴盖旁边。 曲曲轴主主轴承承曲轴主轴承的油膜间隙是曲轴主轴承的油膜间隙是0.018 0.018 0.036mm0.036mm（0.0220.0400.0220.040）。）。轴承分
49、轴承分5 5种颜色。种颜色。左图是塑料测隙规测量的方左图是塑料测隙规测量的方法。法。 缸缸径径缸径尺寸刻印在汽缸体底部缸径尺寸刻印在汽缸体底部的第的第4 4缸处。它有缸处。它有 3 3 种大小种大小标识标识 a a，b b和和C C。1.6 L 1.6 L 排量排量的是标识的是标识 b b，缸径尺寸为，缸径尺寸为76.5176.5176.52mm76.52mm。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used f
50、or the training purpose. 2005.01.07 Alpha 发动机机真真空空 (负值) 压力的力的测量量1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding vacuum pressure measuring - Understanding leakage checking3. Required materials - PV350 with adapter - Hi-scan pro4. Procedure - Connect adapter between vacuum line - Connec
51、t hi-scan pro - Following the optional manual, move on to manual scope section with pressure - Set PV350 with a channel - Measure the vacuum pressure - Following the condition write down the result 5. Time to complete : 15 minutes6. Reference : - Hi-scan pro optional manualNotice Caution 条条件件压力力 (cm
52、Hg)怠速怠速-35 -37急加速急加速-35 到 +26 急急减减速速+6 到 -45 然后 -35 怠速怠速WOT WOT 到到 急减速急减速(全真空)PV350PV350是是hi-scan prohi-scan pro的一种选装件，使用它可以测量进气的真空压力。的一种选装件，使用它可以测量进气的真空压力。当存在漏气时，稳压腔中测量的压力将接近空气压力，但燃烧是正常的当存在漏气时，稳压腔中测量的压力将接近空气压力，但燃烧是正常的。因此它可以作为诊断的参考。因此它可以作为诊断的参考。 HMC & KMC reserves all rights of disposal such as copy
53、ing and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机电流流测量量1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding each components current measuring such as - Starter Motor - Charging Current - Dark Current3. Required materials - AMP met
54、er - Hi-scan pro - 1 unit of MC4. Procedure - Set AMP meter with hi-scan pro - Measure each components current consumption - Write down the result5. Time to complete : 15 minutes6. Reference : - Hi-scan pro optional manualNotice - In case of charging current, measure this form alternation Positive s
55、ide in 5 minutes after vehicle starting.Caution 项目目电流流(A)漏漏电电流流 (Ig. Off)0启启动机机 (启启动)150 170充充电电流流 (发电机机)启启动5分分钟后后2832 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机电瓶瓶测试仪Micro 570型
56、电瓶测试仪能对电瓶、启动机、和发电机进行充电和启动测试。 注意：由于电池可能对人产生一定的伤害，所以操作者注意：由于电池可能对人产生一定的伤害，所以操作者要特别小心，并对眼睛进行要特别小心，并对眼睛进行适当保护。适当保护。功能功能 电瓶测试 - 电瓶的单独测试 - 电瓶的装车测试 启动机测试 充电测试 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.0
57、1.07 Alpha 发动机发动机按按键功能功能Micro 570的按的按键功能功能为：按方向键向上下滚动主菜单按回车键进行选择按菜单键阅读上次的测试结果和设定时间测试仪会询问是对电瓶进行“单独测试”还是“装车测试”。按方向键进行选择，并按回车键。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机选择测试标准：CCA
58、：冷启动标准，SAE，-18CCCP：冷启动标准，SAE，韩国标准，-18C电瓶瓶测试 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机结果果 处理方法理方法Good battery（好电瓶）无需处理。Good recharge（好，充电）好电瓶。需要充电后再使用。Charge & Retest（充电，并重新测试）电
59、瓶没有充好电。需要充电后重新测试。 （未完全充满的电瓶可能显示很多不正确的测量值。)Replace battery（更换电瓶）更换电瓶并重新检查充电系统。(如果电瓶线束未正确的连接可能会导致显示“REPLACE BATTERY”，所以在更换电瓶前，应首先去除电瓶导线，将测试仪直接连到电瓶上进行测试)Bad cell-replace（电池单元损坏，更换）充电并从新测试电瓶。如果测试结果显示“REPLACE BATTERY”，则更换电池并检查充电系统。电瓶瓶测试结果果 HMC & KMC reserves all rights of disposal such as copying and pas
60、sing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机启启动机和充机和充电系系统结果果 处理方法理方法Cranking voltage normal（启动电压正常）启动机工作正常Cranking voltage low（启动电压低）启动电压低于正常水平。检查电瓶，并重新测试。Charge battery（电瓶充电）电瓶充电电流太低。检查电瓶，并重新测试。Replace battery(更换电瓶)更换电瓶。如果电瓶显示“Good and fully c
61、harged” （正常并充满），但车辆不能启动，检查是否连接好线束、启动机，并进行维修和更换。如果车辆没有启动，还须检查供油系统。当当对完成完成对电瓶瓶的的测试后，按照后，按照屏屏幕的提示幕的提示继续测试充充电系系统系系统。详细情情况况请参参考考“使使用手用手册册”对启启动机和机和充充电系系统的的测试结果，如下：果，如下： HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purp
62、ose. 2005.01.07 Alpha 发动机机电瓶瓶测试仪的使用的使用1. Application : - MC 1.6 or 1.4 2. Objectives - Utilization of battery tester3. Required materials - Micro 570 tester - 1 unit of battery - 1 unit of JB4. Procedure - Referring to workshop manual - Test battery with battery tester both out of battery and in veh
63、icle - Test Starting and Charging one by one after finishing battery test - Write down the result5. Time to complete : 15 minutes6. Reference : - Workshop manual - Micro 570 user manualNotice Caution 项目目显示示结果果(显示示屏屏上上)电池池Good / Bad启启动机机Good / Bad充充电Good / Bad HMC & KMC reserves all rights of disposa
64、l such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机启启动系系统电路路图1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Understanding starting operation circuit - Measuring each points voltage3. Required materials - Multi me
65、ter - Hi-scan pro - ETM 4. Procedure - Refer to MC ETM in starting Control - Set Ignition key on condition - Find each point out which marked here - Measure the voltage by condition - Write down the result 5. Time to complete : 15 minutes6. Reference : - MC ETMNotice Caution (V)Ig. On000012启启动121201
66、212点火钥匙开关发动机仓继电器盒室内接线盒ICM继电器BCM启动机AT档位开关 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机冷却风扇控制逻辑冷却风扇控制逻辑APT传感器代替了三元压力开关。1.6车辆使用2个冷却风扇。APT传感器发动机冷却液温度空调开关车速传感器 HMC & KMC reserves all r
67、ights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机高速控制高速控制Hi-Speed On(V)000120电瓶电瓶主继电器主继电器散热器风散热器风扇继电器扇继电器散热器散热器风扇电风扇电机机散热器风散热器风扇保险扇保险空调风空调风扇继电扇继电器器2空调风空调风扇继电扇继电器器1空调压缩空调压缩机保险机保险空调风扇空调风扇电机电机 HMC & KMC reserves
68、 all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机Low-Speed On(V)01212126低速控制低速控制电瓶电瓶主继电器主继电器散热器散热器风扇继风扇继电器电器散热器散热器风扇电风扇电机机散热器风散热器风扇保险扇保险空调风空调风扇继电扇继电器器2空调风空调风扇继电扇继电器器1空调压缩空调压缩机保险机保险空调风扇空调风扇电机电机 HMC & KMC
69、 reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机Alpha II 发动机管理系机管理系统Alpha 2 发动机的ECM安装在发动机仓内。为测量大气压力，PCM顶端有一个小的通气孔。因为防水的原因，务必不要对此部分解体和破坏。 HMC & KMC reserves all rights of disposal such as copyi
70、ng and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机M7.9.8 ECUM7.9.1 ECUECM 比比较MC的Alpha发动机使用了从M7.9.1到M7.9.8的几个版本的PCM.M7.9.1有121个针脚，81个是发动机控制使用，左侧的40个针脚是变速箱控制。M7.9.8有151个针脚，针脚没有像M7.9.1 有区域划分。Can 协议是另一个重要的变化。A区域的No.12和No.27是CAN通讯使用的。如果测量No.12和N
71、o.27 管脚的电阻，应该是120左右。No.12是Can high，No.12是Can low。Ig. On后，Can high信号是2.5到3.5V变化， Can low信号是2.5到1.5V变化。详细波型见后。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机输入和入和输出出M/T 输入信入信号号ECU PIN N
72、O.With OBD-IIWith ABSABS SignalK 64Without ABSWheel Speed SensorK 79, K 58(K 64 open)Without OBD-IIWith ABSVehicle Speed SensorK 64Without ABSK 64Auto 输入信入信号号PCM PIN NO.With OBD-IIWith ABSABS SignalK 20Without ABSWheel Speed SensorA 60, A 45Without OBD-IIWith ABSVehicle Speed SensorK 20 Without ABSK
73、 20 右前WSS车辆传感器信号识别有所区别。当在车辆上应用车辆传感器信号识别有所区别。当在车辆上应用ABSABS或或 OBDOBD系统时，使用轮速传感器代替系统时，使用轮速传感器代替VSSVSS获得车速信号。获得车速信号。轮速传感器同时用于缺火检测如象征性的加速。装配在T/M壳上的VSS仅用于仪表盘车速信息用途。信号输入线根据车辆规格有很大不同。参考上表输入端子配置。Direction : Make them understand for vehicle speed signal recognition. HMC & KMC reserves all rights of disposal s
74、uch as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机针脚的拆卸脚的拆卸1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding how to take out a pin from the connector 3. Required materials - Components connectors - Small sharp pin (ne
75、edle)4. Procedure - Choose 3 more connectors for each group and take one or two more pins out from that connect5. Time to complete : 15 minutes6. Reference : Workshop manual FL10 FL14Notice Caution 注意: MC的ECM 是在发动机室中，而且它是防水的，因此PCM的每个针都很是很紧固地固定在PCM上，拆卸PCM的针脚很困难，需要非常细和锐利的专用工具SST。要对PCM的针脚进行调整时，首先要将钥匙转到
76、Ig. OFF的位置，并要理解正确的检查和修理过程。当测试针脚的联接情况和电压时，务必将探针插入现束侧的插头里。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机ECM Pin Assignment1. Application : - MC 1.6 CVVT with A/T 2. Objectives - Unders
77、tanding each pin assignment 3. Required materials - MC ETM - Multi meter4. Procedure - Find out each assigned function pins in each connector - Measure voltage at ig on and idling - Write down the result5. Time to complete : 30 minutes6. Reference : Notice Caution 功能功能Pin. No.Ig. On时电压(V)Idling时电压(V
78、)GNDK(1,2,3,8,9,31,38,51,73)O0点源点源K6A561212继电器控制器控制A9A3700120MAP S(仅1.4)K84.31.2传感器感器参参考考电压(V)A43, A58 55喷油嘴控制油嘴控制A36,A48,A50,A5212120TPS信信号号K750.50.250.9CMP传感器信感器信号号K41120.412前前O2传感器感器K350.450.070.8后后O2传感器感器K130.450.070.8(K)(A) HMC & KMC reserves all rights of disposal such as copying and passing o
79、n to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机MFI Circuit(V)Ig. off1212000Ig.On120.78121212发动机电控系统 +B到燃油泵继电器主继电器电池电压主继电器控制CVVT控制阀喷油嘴控制主继电器ON电压接线盒ECM HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book sh
80、ould be used for the training purpose. 2005.01.07 Alpha 发动机发动机磁感应型的CKP传感器磁感应型的CKP传感器产生正弦交流信号,它不需要外界的点源。当信号轮的每个齿转过传感器时，就会产生一个正弦交流信号。信号轮转的越快，正弦信号的幅值就越大。传感器和信号轮的距离是一个很关键的因素。距离越大，信号越弱。信号线是相互扭在一起的，并包以屏蔽线来防止其牡绱鸥扇判藕拧B车型的CKP在怠速时显示39V的信号。 Hall 效果效果 HMC & KMC reserves all rights of disposal such as copying an
81、d passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机CKP & CMP传感器感器功能：ECM使用CKP磁感应式传感器的信号计算发动机转速，来控制喷油时间，点火时间，误点火，CVVT的可变气门正时。CMP是霍尔式的IC传感器，并向ECM传递信号，和CKP信号一起判定TDC的位置。相关的DTC : P0016, P0335, P0336, P0337, P0338, P0339, P0340, P0341, P0342, P03431. Appl
82、ication : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms5. Time to complete : 15 minu
83、tes6. Reference : - MC ETM - MC Workshop manualNotice Caution CKPPCM管脚No.描述1C01-2 55信号 High2C01-2 40信号 LowCMPPCM管脚No.描述1Main RelayB+2C01-1 41信号3C01-1 38地 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training pur
84、pose. 2005.01.07 Alpha 发动机机同步信号同步信号1. Application : - MC 1.6 CVVT 2. Objectives - Measuring CKP and CMP synchronizing waveform 3. Required materials - Hi-Scan Pro 4. ProcedureSynchronizing - Use Hi-scan pro oscilloscope function - With manual scope, measure CKP and CMP synchronizing waveformSynchron
85、izing related Current Data - Capture with flight record function - Choose specified items - Analyzing whether it show any data during starting5. Time to complete : 20 minutes6. Reference : Notice Caution hi-ds scan当前数据中的同步点(CKP/CMP)（Syncro.State (CKP/CMP) ）是ECM对同步关系的逻辑判断。“ON” 意味着没有同步故障。在出现启动故障时，这个信号
86、非常有用。凸轮轴位置（camshaft position）是针对CVVT的检查点。最初它显示-8 deg。右侧图中的数据将会改变。ItemIg. On(V)I怠速怠速(V)CKP2.53 -210CMP0.09012 信信号号输出出电压 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机Starting Point上图
87、是路试仪的记录结果。当发动机启动后，ECM收到CKP信号。当CKP和CMP信号同时到达ECM后，喷油和点火才开始。从图上看出，由于信号轮的实际形状，实际上CMP信号与理想的形状有一点差别。这个只是有CVVT的1.6发动机的情况。1.4发动机仍然使用锁销式信号轮。Synchronizing 1Synchronizing 2同步参考信号同步参考信号 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the tr
88、aining purpose. 2005.01.07 Alpha 发动机机VSS 传感器感器功能：VSS对ECM计算车辆速度来说是一个关键的部件，这点对A/T车辆尤其重要。VSS也用于计算AT的换档模式和换档时间控制。与传统的VSS不同，JB车的VSS信号仅用于仪表盘显示。当点火开关转到ON位置时，ECM自动从相关的传感器测试VSS信号。对没有OBD2调整(EOBD)和ABS系统的车辆, ECM和仪表盘同时使用VSS传感器的信号。如果不是，VSS的信号仅用于仪表盘。 相关DTC : P05011. Application : - MC 1.4 or 1.6 2. Objectives - Un
89、derstanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop man
90、ualNotice Caution VSSPCM针脚No.描述1地地2IG 1B+3C01-1 20信号WSS 1C01-2 45信号 +WSS 2C01-2 60信号 - 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机VSS VSS 波型波型1. Application : - MC 1.4 or
91、 1.6 2. Objectives - Measuring VSS waveform 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure VSS waveform - Using Hi-Scan pro current data check VSS data during driving5. Time to complete : 20 minutes6. Reference : Notice Caution h
92、i-scan pro中显示的车速值是从WSS得到的。所以，即使断开变速箱上的VSS，显示值也不会受影响。但是，仪表盘收到影响。这是新车型的一个重要变化。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机ECM中的车速信号是从哪个传感器得到的，要分清车辆是否有ABS，或是否有OBD 2。不能认为地更该这个信号，因为OB
93、D 2系统使用的WSS的信号是正弦信号，而仅有ABS系统的WSS信号是方波。VSS VSS 波型波型发动机电控系统 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机VSS VSS 波型波型 HMC & KMC reserves all rights of disposal such as copying and pa
94、ssing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机氧化锆式氧传感器氧化锆式氧传感器 使用氧化锆式氧传感器。它由氧化锆、铂电极和一个加热器组成。氧传感器比较大气中和排气中的氧含量，产生电压信号。氧化锆元件一侧暴露在排气流中，另一侧通过导线与大气相连。每一侧都有一个与氧化锆元件相连的铂电极。铂电极传导产生的电压。铂电极或氧化锆元件的污染或腐蚀可能会减小电压信号输出。当排放氧含量高时，氧传感器输出电压低。当排放氧含量低时，输出电压高。排气流和大气之间
95、的氧含量差别越大，电压信号越高。根据氧含量，ECM能确定空燃比浓或稀，从而调整燃油混合气比率。浓混合气几乎消耗所有的氧气，所以电压信号高，在0.6 1 V范围内。而稀混合气意味着在燃烧后剩余氧含量较高，所以电压信号低，在0.4 0.1V范围内。在通过化学方法计算的理论空燃比(14.7:1)的状态下，输出电压接近0.45V。.传感器电压空气废气PT-外电极PT-内电极 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used
96、 for the training purpose. 2005.01.07 Alpha 发动机机相关DTC : P0031,P0032, P0036, P0037, P0038, P0135, P0141 是加热器失效。P0130P0134, P0136P0140是氧传感器失效。P0171 P0172是断油失效。P0420是三元催化失效P2096, P2097, P2232是三元催化失效(后氧传感器)1. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding eac
97、h pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution 前 O2 传感器PCM针脚No.描述1C01-2 (31)
98、传感器 地2C01-1 (35)信号3C01-2 (34)加热器控制4Main RelayB+氧传感器氧传感器 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 CVVT 2. Objectives - Measuring Frt. and Rr. O
99、xygen sensor waveform - Measuring heater control line duty from start to idle 3. Required materials - Hi-Scan Pro 4. Procedure Frt. and Rr. sensor waveform - Use Hi-scan pro oscilloscope function - With manual scope, measure Frt. and Rr. sensor waveform Heater control waveform - Use Hi-scan pro osci
100、lloscope function - With manual scope, measure Frt. and Rr. heater control waveform - Analyzing 5. Time to complete : 20 minutes6. Reference : Notice Caution 氧传感器相关的DTC很多，了解他们的功能很重要。后氧传感器位于催化转化器的后侧，检查催化器是否正常工作。在没有加速或减速情况下，催化转化器后氧密度必须在规定范围内，输出电压为0.5 V左右。如果后氧传感器输出与前氧传感器输出类似，说明催化转化器性能不良。 GoodBadFrontRe
101、ar氧传感器波型氧传感器波型 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 or 1.42. Objectives - Understanding oxygen sensor related items - Understanding heater controlli
102、ng - Understanding fuel trim3. Required materials - Multi meter - Hi-scan Pro4. Procedure - Measure the resistance for heater controlling. (White two lines) - Set hi-scan pro to the car and check specific current data 5. Time to complete : 15 minutes6. Reference : - ETM - Workshop manualNotice Cauti
103、on 加加热器器电阻阻项目目Idle15003000功能功能A/F Closed LoopA/F Closed Loop空燃比闭环控制空燃比闭环控制Ononon开环或闭环控制开环或闭环控制前氧传感器前氧传感器0.120.79空燃比闭环控制空燃比闭环控制短期燃油修正短期燃油修正 -5.71.7-4.5喷油调整喷油调整长期燃油修正长期燃油修正 怠速怠速1.00.40.2喷油调整喷油调整长期燃油修正长期燃油修正 部分部分负荷负荷-0.7-0.7-0.7喷油调整喷油调整喷油时间喷油时间 (ms)(ms)2.82.92.4喷油时间喷油时间AFS (kg/h)AFS (kg/h)8.117.131.8AF
104、S 体积数数据流分析据流分析Frt. :8.6Rr. :9.4氧传感器数据流氧传感器数据流 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机短期燃油修正短期燃油修正可能条件可能条件进气泄露燃油压力略低喷油嘴损坏或焦结冷却水温度传感器损坏PCSV 故障或泄露AFS 损坏 催化转化器堵塞或损坏燃油污染燃烧因如下机械性故障
105、而改变，如：- 火花塞- 压缩压力- 进气和排气门- CVVT 系统 功能：影响最终喷射持续时间的燃油修正值有两类，即短期燃油修正和长期燃油修正(长期怠速或长期部分负荷)，可以通过hi-ds scan当前数据进行观察。短期燃油修正，是根据氧传感器的反馈，在基本喷射持续时间上加或减的临时值。长期燃油修正是计算基本喷射持续时间的一部分，它储存在ECM的存储器内。因为短期燃油修正以氧传感器的反馈为基础，所以它仅在闭环控制中有用。它迅速地反映氧传感器的变化。如果短期变化接近0%，只需稍微校正或无需校正。当短期百分比值为正值时，ECM通过增加喷射持续时间增加燃油。当短期百分比值为负值时，ECM通过缩减喷
106、射持续时间减少燃油。短期值是临时值，点火开关OFF时删除。同时短期值用于改变长期燃油修正。当短期值持续低于或高于期望值时，ECM在长期燃油修正上加上或减去此值。 短期燃油修正短期燃油修正 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 or 1.4 2. Objecti
107、ves - Understanding Short term value in current data - Make lean or rich condition and check short term change 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro current data function - Choose related items and check the changes when problem happens - Discuss this your group5. Time t
108、o complete : 20 minutes6. Reference : Notice Caution 当短期燃油修正显示正的15.6%时，它意味着燃油调整地过长。下次的喷射时间也会被影响而加长。这时应该检查是否有空气泄漏，点火是否正常等。氧感应器显示不平顺的波型，则反映了燃料调整的问题。空燃比没有问题时，应该显示平整的信号。一般来说，发动机的转速在15001800rpm时，测量的信号比较准确。短期燃油修正短期燃油修正 HMC & KMC reserves all rights of disposal such as copying and passing on to third parti
109、es. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机长期燃油修正长期燃油修正 长期燃油修正长期燃油修正 长期燃油修正储存在ECM存储器内，因它是计算基本喷射持续时间的一部分，点火开关OFF时不会将其删除。它影响闭环控制和开环控制时的喷射持续时间。ECM使用短期燃油修正值改变长期燃油修正值。它不能对瞬间的变化做出迅速的反应，仅在ECM决定使用短期燃油修正值改变长期燃油修正值时发生变化。如短期燃油修正一样，当长期值为0%时，表明基本喷射持续时间无需修正。正百分比表明ECM要增加燃油喷射量；而负百
110、分比表明ECM要减少燃油喷射量。长期用于在发动机工作的整个范围内控制喷射持续时间。它分为两类；长期怠速和长期部分负荷。在小于920 rpm且空气量为24 kg/h时监测为长期怠速。因为吸入空气量相当少，要利用加或减控制。与长期怠速不同，在发动机负荷的30 75%且空气量为40 200kg/h时监测为长期部分负荷。为此利用多重校正控制。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the trainin
111、g purpose. 2005.01.07 Alpha 发动机机右图是和燃油修正有关的项目。当遇到燃油修正有关的问题时，要仔细检查这些项目。 行驶纪录功能在实车测试时非常有用。使用hi-scan pro的记录功能，可以以占空比的型式记录氧传感器的信号。如果发动机工作在理想空燃比附近，会记录下平坦和稳定的信号。如果不是，记录的波型会想左图一样抖动。1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding long term value in current data - Make lean or rich condition a
112、nd check short term change 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro current data function - Choose related items and check the changes when problem happens - Discuss this your group5. Time to complete : 20 minutes6. Reference : Notice Caution 长期燃油修正长期燃油修正 HMC & KMC reserves
113、 all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机氧氧传感器反感器反应检查1. Application : - MC 1.6 or 1.4 2. Objectives - Measuring Frt. oxygen sensor waveform at 1,800 rpm - Analyzing its response time from 0.3 to 0
114、.6 and 0.6 to 0.3 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure the response time from lean to rich and rich to lean 5. Time to complete : 20 minutes6. Reference : -Notice Caution 反映时间 : 50 ms反映时间测试是另一种诊断氧传感器的方法。使用解码仪的示波器的功能，测量氧
115、传感器从低到高(0.3到0.6V)的反映时间。反映时间 : 110 ms但是对反映时间，没有特定的参数值。需要比较各种试验结果。一般，从高到低的反映时间比从低到高的时间稍长。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机使用使用TPSTPS的的WOTWOT测试测试1. Application : - MC 1.4 o
116、r 1.6 2. Objectives - Understanding oxygen sensor waveform with TP signal - Measuring response time from lean to rich3. Required materials - Hi-scan pro4. Procedure - Use Hi-scan pro oscilloscope function - Increase engine rpm to 4000 - Make fuel cut condition releasing accelerator pedal - Depress A
117、ccelerator pedal to WOT - With manual scope, measure the response time from lean to rich 5. Time to complete : 15 minutes6. Reference : Notice Caution 方法：联合TPS传感器，检查氧传感器的反应时间。首先进入断油状态，增加发动机转数到约4000rpm，再突然松油门进入断油状态。当发动机的rpm到达约2000，踩下油门WOT。在氧传感器的显示中，在断油时，是混合汽过稀；当WOT时，是混合汽过浓。这样，可以测试从过稀到过浓的氧传感器的反映时间。一般来
118、说JB车型是 200mS 300ms. HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机270m/s530m/s当断油时，前后氧传感器都是接近0V。当断油后用WOT，氧传感器接近1V。比较TPS的上升时间和氧传感器信号，可以查看氧传感器的反应时间。Fuel Cut使用使用TPSTPS的的WOTWOT测试测试 HMC
119、& KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机MAF 传感器感器功能： MAF传感器将发动机吸入的空气量转换成电压信号传送到ECM。ECM 需要知道空气来计算发动机负荷。在计算喷射多少燃料，喷射时间，和变速箱的换档时间时都需要这个信号。Siemens热膜式MAF使用在JB车中。在怠速时，显示1V左右，意味着约8.2kg/ h。
120、相关DTC : P0068, P0100, P0101, P0102, P0103, (P0112 & P0113 for IATS)1. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin description - Write down sensor function
121、- Write down Related DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution MAFPCM 针脚No.描述1C01-1 8地2主继电器B+3C01-1 10MAF信号4GND地5C01-1 32IATS信号 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties
122、. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 CVVT 2. Objectives - Measuring MAF waveform3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure sensor waveform of MAF with TPS from id
123、le to WOT - Analyzing current data5. Time to complete : 20 minutes6. Reference : Notice Caution 在怠速时，MAF显示1V左右，意味着约8kg/h或更少的空气流量。当遇到与燃油有关的问题时，检查此值。项目目怠速怠速WOTMAF(V) 1 3.5空空气气量量(kg/h)8.3227.5TPS(V)0.33.9 信信号号输出出电压MAFTPSMAF 传感器波型感器波型 HMC & KMC reserves all rights of disposal such as copying and passing
124、 on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.62. Objectives - Understanding sensor simulation - Understanding related items 3. Required materials - Hi-scan pro4. Procedure - Use Hi-scan pro simulation function - Analyzing relat
125、ed current data - Discuss the result with group member5. Time to complete : 15 minutes6. Reference : Notice Caution 项目目1.5V2.0V描述描述喷油油时间5.70喷油增加点火点火时间6.80增加短期燃油修正短期燃油修正-250负值控制ISA 占空比占空比 29.50增加发动机机转速速7200增加结果讨论：结果讨论：当用 1.5 V模拟时(在怠速时，通常显示1V左右)，ECM被这个假信号欺骗。即使实际上被吸入的空气量与以前相同，喷射时间被延长了，造成空燃比过浓，并使短期燃油修正为
126、负值。如果发生相同的问题,没有与MAF相关的DTC，但可能会产生与短期燃油修正相关的DTC。当然有的车辆有合理性检查的这一功能,它将会有MAF的DTC。为了要检查 MAF是否正常,模拟是很有用的。另外也以能检查控制配线。MAF 传感器模感器模拟 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机在MAP里，在参考压力腔
127、中有一个硅膜片。膜片的一侧是参考压力（完全真空或某一较准值）；另一边是要测量的压力。膜片的电阻随压力变化而改变，ECM测量电压值。下图显示的是ECM的A/D 转换器的功能。 A/D 转换器和故障诊断MAP 传感器感器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机功能：进气歧管的压力直接与发动机的负荷有关。ECM 需要
128、知道进气歧管压力来计算汽缸的进汽量。在点火时，它基本显示4.3V(100kPa)的大气压力，当发动机运转时，它显示1.4V左右(35kPa)。当它有故障时，此信号被TPS和发动机转速信号取代。相关DTC : P0106, P0107, P0108, (P0112&P0113 for IAT Sensor)1. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4.
129、Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution MAPPCM 针脚No.描述1C01-1 10Map信号2C01-2 43参考值(5V)3C01-1 32IAT 信号4C01-1 8地 电路图 现束连接器
130、MAP 传感器感器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机当转到Ig ON的时候, 通过MAP，ECM首先识别大气压力，正常值约4.24.3V。这样，可以检查MAP是否失效。将解码仪选数据流中MAP传感器的项目，在上述情况下检查是否4.2V左右。I项目目Ig.On(V)怠速怠速(V)MAP4.2 1.4TPS0
131、.30.3 信信号号输出出电压MAPTPS1. Application : - MC 1.4 2. Objectives - Measuring MAP waveform3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure sensor waveform of MAP with TPS from idle to WOT - Analyzing current data5. Time to complete : 20
132、 minutes6. Reference : Notice Caution MAP 传感器波型感器波型 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.62. Objectives - Understanding sensor simulation - Understand
133、ing related items 3. Required materials - Hi-scan pro4. Procedure - Use Hi-scan pro simulation function - Analyzing related current data - Discuss the result with group member5. Time to complete : 15 minutes6. Reference : Notice Caution 项目目1.5V2.0V描述描述喷油油时间5.70喷油增加点火点火时间6.80增加短期燃油修正短期燃油修正-250负值控制ISA
134、 占空比占空比 29.50增加发动机机转速速7200增加结果讨论：结果讨论：当用 1.5 V模拟时(在怠速时，通常显示1V左右)，ECM被这个假信号欺骗。即使实际上被吸入的空气量与以前相同，喷射时间被延长了，造成空燃比过浓，并使短期燃油修正为负值。如果发生相同的问题,没有与MAP相关的DTC，但可能会产生与短期燃油修正相关的DTC。当然有的车辆有合理性检查的这一功能,它将会有MAF的DTC。为了要检查 MAP是否正常,模拟是很有用的。另外也以能检查控制配线。MAP 传感器模感器模拟 HMC & KMC reserves all rights of disposal such as copyin
135、g and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机TPS传感器感器功能: TPS 安装在节气门阀体上，并把节气门的角度用可变电阻转换成电信号(电位计)。当节气门打开，输出信号的电压增加。ECM 使用这个信号识别发动机状态(怠速或WOT)，A/F修正，动力增加修正和断油控制等。正常的电压范围是0.2到4.8V。在怠速时，JB车是0.3V。P0068 是在 MAF 和 TPS 之间的发动机负荷合理性检查(NAS)产生的故障码 。相关DT
136、C : P0068, P0121, P0122, P01231. Application : - JB 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - JB ETM4. Procedure - Using JB ETM find each pin description - Write down sensor function - Write down Related DTC and failure sympto
137、ms5. Time to complete : 15 minutes6. Reference : - JB ETM - JB Workshop manualNotice Caution TPSPCM针脚No.描述1C01-1 75信号2C01-2 58参考电压(5V)3C01-1 51地 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 200
138、5.01.07 Alpha 发动机机即使没有怠速开关信号，ECM也会使用逻辑判断发动机是否在怠速状态。在右图中，由于软件的问题，解码仪的数据流项目中“Adapted throttle”显示一个错误的数值。正常值应该是10%左右。TPSIg. OnWOT输出出(V)0.3 3.9 信信号号输出出电压1. Application : - MC 1.6 CVVT 2. Objectives - Measuring TP Sensor waveform3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscillosc
139、ope function - With manual scope, measure sensor waveform with TPS from idle to WOT - Analyzing current data5. Time to complete : 20 minutes6. Reference : Notice Caution TPS传感器感器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for t
140、he training purpose. 2005.01.07 Alpha 发动机机项目目0.6V1V描述描述喷油油时间2.62.7没有变化点火点火时间40.542最大提前角短期燃油修正短期燃油修正4.82.7正值控制ISA 占空比占空比 4145增加发动机机转速速22003200增加结果讨论：结果讨论：为了要检查 MAF是否正常,模拟是很有用的方法，它可以同时检查几项内容。首先，可以检查控制线束。因为模拟时，信号是从检测仪，而不是传感器输入到ECM。而且可以模拟车辆的实际反应情况。当进行表中的TPS模拟时，点火信号被提前了。这引起发动机转速和 ISA 打开的占空比增加。 TPS 0.6V 表
141、示不再是怠速了，这时ECM的主要控制目的是增加扭矩。1. Application : - MC 1.62. Objectives - Understanding sensor simulation - Understanding related items 3. Required materials - Hi-scan pro4. Procedure - Use Hi-scan pro simulation function - Analyzing related current data - Discuss the result with group member5. Time to com
142、plete : 15 minutes6. Reference : Notice Caution TPS传感器模感器模拟 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机爆振传感器爆振传感器 功能：爆震现象主要是不良的震动和噪声，它可能造成发动机的损坏。爆震传感器安装在缸体上来检测发动机的爆震。从缸体上传来的爆震震动的压力
143、传递到压电元件上。ECM检测爆震传感器的幅值和频率，来控制点火时间。举例来说，当爆震发生时，推迟点火时间来避免爆震。相关 DTC : P0326, P0327, P0328, P1550, P15561. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using JB ETM write down each pin descript
144、ion - Write down sensor function - Write down Related DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution 爆振传爆振传感器感器PCM针脚No.描述1CO1-2 30信号 high2C01-2 15信号 Low 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing
145、 on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机MBT(最小点火提前，以产生最佳扭矩)是点火时间的调整以产生最大扭矩, 而且点火时间被安排在紧临爆震的位置。 没有爆震控制，点火时间会安排在滞后的位置，它不会产生最大扭矩，这是为了要确保稳定性，所以产生比较低的扭矩。另一方面，使用爆震传感器，点火点可以设定在爆震范围附近，从而有效的提高发动机的输出。爆震在缸体中产生高频率(5-10khz)的震动，爆震传感器安放在缸体的外壁上，也能感应到相同频率的振动。爆震
146、传感器的输出信号包含各种不同的频率成份，选通的滤波器过滤信号，然后用此信号来判断爆震。爆震只在燃烧的汽缸中发生, 因此只在爆震判定时期内进行判断，这样避免由于噪音引起的误判断。当爆震被发现的时候 , ECU 推迟点火。然后在一定时间内没有爆震发生的情况下，慢慢提前点火角。这样是一种反馈控制。最大滞后范围 : 12当发生爆震时，首先推迟3 ，然后以0.75度的步幅提前角度爆振控制爆振控制 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book shou
147、ld be used for the training purpose. 2005.01.07 Alpha 发动机机当爆振发生，点火时间被推迟，同时会显示DTC。1的点火角和50 rpm的效果类似。所以点火时间推迟意味着动力损失。当严重的爆振发生时，活塞或其他运动部件可能会严重损坏。左图是和爆振传感器相关的项目。 如果爆振发生，点火时间被推迟，比较正常值和爆振传感器损坏时的值。1. Application : - MC 1.4 or 1.6 2. Objectives - Understanding Knocking control3. Required materials - Hi-Scan
148、 Pro 4. Procedure - Use Hi-scan pro dual display function - Analyzing current data with DTC5. Time to complete : 20 minutes6. Reference : Notice Caution 爆振传感器爆振传感器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training pur
149、pose. 2005.01.07 Alpha 发动机发动机NTC电阻阻ECM 需要温度信息来调整多种系统。正常的发动机工作温度和将这些温度正确地输入ECM非常重要。举例来说，为喷射适量的燃料，ECM必须知道正确的发动机温度。温度传感器在测量发动机冷冻液的温度(ECT传感器)，进气温度(IAT传感器)，和CVVT系统中的机油温度(OT传感器)。在 Alpha 2 发动机中，没有OT传感器。No. 3 Pin for No. 3 Pin for IATIAT在 Alpha二代 1.4 发动机中，IAT集成在MAP中；1.4 发动机中，IAT集成在AFS中。IAT在冷启动时检测大气温度，当发动机热机
150、后，检测进气温度。当它发生故障时，ECM在应急模式下将使用默认值。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机IAT传感器感器1. Application : - MC 1.6 CVVT or JB 1.4 2. Objectives - Measuring sensor output voltage - Meas
151、uring sensor resistance - Understanding current data 3. Required materials - Hi-Scan Pro - Multi meter 4. Procedure - Using multi meter measure the voltage by temperature and resistance - Using hi-scan pro current data analyzing related items5. Time to complete : 20 minutes6. Reference : -Notice Cau
152、tion IAT集成在MAF中，当IAT显示过热的温度，喷油量会被限制，导致空燃比过稀。但在通常情况下，它对发动机的控制没有很大的影响。IAT2040输出出(V)2.6 1.7k k2.41.1 输出信出信号号电压1.6 CVVT1.4 DOHC HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机ECT传感器感器功能：EC
153、T传感器测量发动机冷冻液的温度。在计算点火时间，喷射时间，可变气门正时和变速箱的换档时间等时ECM都需要这个信号。ECM总是检查这个信号，看是否是发动机各种的正常温度。相关DTC : P0117, P01181. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin desc
154、ription - Write down sensor function - Write down related DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution ECTPCM针脚No.描述1C01-1 77信号2仪表台温度测量3C01-1 73地 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on t
155、o third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机ECT值可以很容易的从 hi-scan pro里看到。当温度低时，会增加喷油以补偿热壁效应。 如果不对这种低温下的缺少燃料的情况做补偿，启动会被滞后，或者会发生启动困难的情况。ECT2080输出出(V)3.6 1.2k k2.40.32 输出信出信号号电压1. Application : - MC 1.6 CVVT 2. Objectives - Measuring sensor output voltage - Me
156、asuring sensor resistance - Understanding current data 3. Required materials - Hi-Scan Pro - Multi meter 4. Procedure - Using multi meter measure the voltage by temperature and resistance - Using hi-scan pro current data analyzing related items5. Time to complete : 20 minutes6. Reference : -Notice C
157、aution ECT传感器感器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机项目目1V2V3VSymptom温温度度.()696033喷油油时间(m/s)2.72.42.7点火点火时间(BTDC)6.88.314.2短期燃油修正短期燃油修正(%)1.1-0.81.1ISA 占空比占空比 (%)29.630.331.5
158、发动机机转速速8008401,040结果讨论：结果讨论： ECM被假信号欺骗。一般，当温度低时，会增加喷油以补偿热壁效应。热壁效应是指由于燃油温度低，喷射进汽缸的燃油粘在汽缸顶部和汽缸外的进气道上。温度低时，燃油也不容易流动。由于同样的原因，点火时间也被提前，这样发动机的转速会上升到失常的程度。1. Application : - MC 1.62. Objectives - Understanding sensor simulation - Understanding related items 3. Required materials - Hi-scan pro4. Procedure -
159、 Use Hi-scan pro simulation function at 90 more degree in ETS. - Analyzing related current data - Discuss the result with group member5. Time to complete : 15 minutes6. Reference : Notice Caution ECT传感器模感器模拟 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. T
160、his book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机基本基本RPMRPM和和合理性合理性检查检查上图显示了上图显示了ECMECM中点火时间和基本怠速中点火时间和基本怠速rpmrpm的控的控制图。当温度低时候，点火时间提前，造成发制图。当温度低时候，点火时间提前，造成发动机转数增加。动机转数增加。1 1 度的点火提前，基本相当于度的点火提前，基本相当于5050rpmrpm。因为空燃比的关系，当在低温范围中。因为空燃比的关系，当在低温范围中时，它变成过浓的情况。时，它变成过浓的情况。 左图表示了左图表示了
161、OBD 2OBD 2系统中的合理性检查。在驾系统中的合理性检查。在驾驶一定距离后，检查驶一定距离后，检查 ECTECT的输出值，如果在目的输出值，如果在目标值和真实值之间出现特定的差别，会判定标值和真实值之间出现特定的差别，会判定ECTECT故障。故障。空燃比点火区间基本怠速的 RPM冷却液温度空燃比点火时间RPM HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose.
162、 2005.01.07 Alpha 发动机机点火点火线圈圈检测1. Application : - MC 1.6 CVVT 2. Objectives - Understanding individual ignition system with cigar type coil 3. Required materials - Multi meter - General tools4. Procedure - Take out ignition system carefully - Measure coil resistance - Measure supplying voltage and c
163、ontrol line voltage at Ig. On - Write down the result5. Time to complete : 20 minutes6. Reference : -Notice Caution Be careful not to touch spark plugsat hot temperature点火线圈点火线圈 连接器连接器No.1No.2No.3No.4电压 / 012.9012.9012.9012.9好好 / 坏坏(Ig. On)GGGGGGGG线圈圈 ()0.90.90.90.9好好 / 坏坏GGGG HMC & KMC reserves all
164、 rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding how to inspect ignition system - Understanding spark test - Understanding power balance test wit
165、h hi-scan pro3. Required materials - General tools - Spark Tester - Hi-scan pro4. Procedure Spark test - Take out ignition coil - Make spark test - Eye checking the firing adjusting the distance - Write down the result Power Balance Test - Set hi-scan pro to the vehicle - Using flight record with rp
166、m in in current data record its changing - Disconnect each connector one by one - Analyze its change - Write down the result 5. Time to complete : 15 minutes6. Reference : -Notice Caution 线圈圈1234好好 / 坏坏GGGG 点火点火测试汽缸汽缸1234rpm下降下降520560560560好好 / 坏坏GoodGoodGoodGood 动力平衡力平衡测试点火点火线圈圈测试 HMC & KMC reserve
167、s all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机初初级线圈波型圈波型1. Application : - MC 1.6 and 1.42. Objectives - Measure the primary coil waveform3. Required materials - Hi-scan pro 4. Procedure - Set Hi-scan
168、 pro to the vehicle - Using oscilloscope function, measure the primary coil5. Time to complete : 15 minutes6. Reference : -Notice Caution 初级线圈波型汽缸号初级线圈波型汽缸号怠速怠速 (Voltage/ms)(Voltage/ms)1234 点火点火结束束 (V)14141414 最大最大 (V)198198198198点火点火时(V)0000 持持续时间 (ms)1.761.761.761.76 HMC & KMC reserves all rights
169、of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机点火点火线圈圈电流消耗流消耗1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding current consumption by ignition coil - Understanding how to use AMP meter3. Required mater
170、ials - Hi-scan pro - Amp meter - T connector4. Procedure - Connect T connector in ignition system - Set hi-scan pro with amp meter - Using scope function, measure each coils current consumption - Compare whether it is good or bad - Write down the result5. Time to complete : 15 minutes6. Reference :
171、- Hi-scan pro optional manualNotice Caution 初级线圈初级线圈No.1No.2No.3No.4电流流(A)9.289.128.489.20好好 / 坏坏GGGG HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机点火时间汽缸号点火时间汽缸号1234怠速怠速 (BTDC)555520
172、00 (BTDC)414141411. Application : - MC 1.6 or 1.4 2. Objectives - Understanding ignition current data3. Required materials - MC 1.6 or 1.4 - Hi-scan pro 4. Procedure - Connect hi-scan pro to the vehicle - Go to current data and analyze its current data by condition - Write down its result5. Time to
173、complete : 15 minutes6. Reference : - Workshop manualNotice Caution 点火控制点火控制 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机火花塞火花塞检查1. Application : - MC 1.6 or 1.4 2. Objectives - Und
174、erstanding how to check spark plug3. Required materials - General tools - Additional spark plug - Torque Wrench - Multi meter - Thickness gauge4. Procedure - Take out spark plug from the vehicle - Eye check its condition and choose one on the right chart and write down its number - Measure each resi
175、stance - Measure each clearness - Writhe down the result5. Time to complete : 15 minutes6. Reference : - Workshop manualNotice Caution 火花塞火花塞No.1No.2No.3No.4情情况况k4.44.444.644.6间隙隙(mm)1.11.11.11.1型型号号BKR5ES-11( ) RC10YC4( )好好 / 坏坏GoodGoodGoodGoodBrand new180 turnUsed180 + 30 turn more HMC & KMC reser
176、ves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机喷油嘴油嘴功能：电控喷油嘴是一个电磁阀，它在各种的发动机负荷和转速下，精确地喷射燃料量以达到最佳燃烧。 为了满足系统的空燃比要求，ECM依据汽缸的进气量和氧传感器的信号，控制电磁阀的打开时间来调整喷油量。电磁阀的快速反应特性对精确的控制喷油是很重要的。相相关关DTC : P0201, P0202, P0
177、203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P02711. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin description - Write down sensor function -
178、 Write down related DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - JB ETM - JB Workshop manualNotice Caution Injector No.1PCM Pin No.Description1Main RelayB+2C01-2 50No.1 control 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third par
179、ties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机喷油嘴测试喷油嘴测试 - 1- 1 1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding injector checking methods - Understanding injectors line to line voltage measuring - Understanding injectors resistance3. Required materials
180、- Multi meter - 1 unit of MC4. Procedure Voltage measuring - Disconnect injector connector - Measure supplying voltage and ground. Compare with others - Write down the result Injector resistance - measure each injectors resistance - Write down the result 5. Time to complete : 15 minutes6. Reference
181、: - Workshop manualNotice Caution 喷油嘴油嘴 /连接器接器No.1No.2No.3No.4电压 / 133.4133.4133.4133.4好好/坏坏(Ig. On)GGGGGGGG喷油嘴油嘴()14.114.114.114.1好好/坏坏GGGG HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha
182、发动机机1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding injector checking methods - Understanding injectors operation - Understanding how to check injector leakage3. Required materials - 1 unit of MC - 1 unit of stethoscope - General tools4. Procedure Leakage checking - Remove fuel delive
183、ry pipe from the vehicle - Make Ig. On to let fuel pump operate for 3 5 seconds - Check whether injector has leakage or no - Writhe down the checking result Operating sound checking - Checking with stethoscope - Touch stethoscope on a injector - Check the operationWrite down the result5. Time to com
184、plete : 15 minutes6. Reference : -Notice Caution 泄漏泄漏 / 汽缸汽缸1234好好 / 坏坏GGGG喷油嘴测试喷油嘴测试 - 2声声音音 / 汽缸汽缸1234好好 / 坏坏GGGG 运转声音运转声音 泄漏测试泄漏测试 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1.
185、Application : - MC 1.6 or 1.4 2. Objectives - Understanding injectors checking methods - Understanding injectors operation - Understanding how to use vacuum pump - Understanding hi-scan pros actuation test3. Required materials - 1 unit of test injector - vacuum pump - hi-scan pro - extension wire fo
186、r shorting injector to battery4. Procedure - Apply vacuum to the injector - Check whether there is any vacuum leakage or no. - Supply 12V to the injector - Check what happen to the gauge of vacuum - If it is abnormal, write down the result - Perform actuation test with hi-scan pro and check injector
187、s operation sound5. Time to complete : 15 minutes6. Reference : -Notice Caution 泄漏泄漏 / 汽缸汽缸1234好好 / 坏坏GGGG执行行 / 汽缸汽缸1234好好 / 坏坏GGGG 使用解码仪的执行操作使用解码仪的执行操作喷油嘴测试喷油嘴测试 - 3 泄漏测试泄漏测试 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the
188、training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding how to diagnosis injector problem - Disconnect each injector terminal one bye one - Using flight record function, capture the drop rpm - Write down the result3. Required materials - Hi-scan pro - 1
189、unit of MC4. Procedure - Connect hi-scan pro to the vehicle - Go to the flight record function - Choose specific current data such as “engine rpm - Disconnect each injector connector one by one - Writhe down the result5. Time to complete : 15 minutes6. Reference : -Notice Caution 汽缸汽缸1234Rpm下降下降5605
190、60560560好好 / 坏坏GoodGoodGoodGood喷油嘴测试喷油嘴测试 - 3 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机喷油油时间 / 汽缸汽缸1234怠速怠速 (ms)2.82.82.82.82,000 (ms)2.52.52.52.5断断油油 rpm6,500重新重新喷油油 rpm1,2801.
191、Application : - MC 1.6 or 1.4 2. Objectives - Understanding injectors current data3. Required materials - MC 1.6 or 1.4 - Hi-scan pro 4. Procedure - Connect hi-scan pro to the vehicle - Go to current data and analyze its current data by condition - Write down its result5. Time to complete : 15 minut
192、es6. Reference : - Workshop manualNotice Caution 喷油嘴测试喷油嘴测试 - 4 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding how to mea
193、sure injector waveform - Analyze its signal3. Required materials - Hi-scan pro with oscilloscope - 1 unit of MC - T-Connector4. Procedure - Operate hi-scan pro with oscilloscope function - Measure injectors waveform from control line to ECM - Analyze its signal - Write down its result5. Time to comp
194、lete : 15 minutes6. Reference : -Notice Caution 状状态 / 汽缸汽缸 暖机暖机状状态的怠速的怠速1234 不不喷油油 (V)13.613.613.613.6 喷油油 (mV)-800-800-800-800 峰峰值电压 (V)70.470.470.470.4喷油油时间(ms)3.23.23.23.2喷油嘴波型喷油嘴波型 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used
195、 for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding injectors current consumption3. Required materials - AMP meter - Hi-scan pro - 1 unit of MC - T connector 4. Procedure - Connect AMP meter to hi-scan pro - Conduct 0” set first - Connect AM
196、P meter Injector 12 V supply line - measure current consumption at idle 5. Time to complete : 15 minutes6. Reference : - Hi-scan pro optional manualNotice Caution 怠速怠速 / 汽缸汽缸1234电流流 (A)0.8160.8560.8240.824a b (ms)1.61.561.521.52持持续时间 (ms)2.82.82.82.8ab喷油嘴电流消耗喷油嘴电流消耗 HMC & KMC reserves all rights of
197、disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机CVVT系系统凸凸轮轴皮皮带轮输出凸出凸轮轴输入凸轮轴输入凸轮轴CVVTCVVT正正时皮皮带链轮正正时链滞滞后后提前提前发动机旋转方向驾驶条条件件进汽汽门正正时原因原因低低负荷荷时滞后稳定燃烧高高负荷，高速荷，高速时滞后提高输出特性高高负荷，低速荷，低速时提前提高扭矩中速中速条条件件提前提高燃油消耗性能 HMC & KMC reser
198、ves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机P PDDROTORVANEHOUSING VANE提前滞后P PDDP P排气BDCTDCBDC点火进气V/LiftC/Angle排气BDCTDCBDC点火进气V/LiftC/AngleC/Angle排气BDCTDCBDC点火进气V/Lift滞后提前 保持保持保持保持CVVT工作工作 HMC &
199、KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机OCV功能 : 与固定凸轮轴进排气角度不同，CVVT可以连续调整最佳的凸轮轴进排气角度。它由发动机的机油油压控制。OCV中连有一个电磁阀，它控制供给到CVVT总成的油的数量和方向。如果目标角度和实际差3度以上，会进入失效保护，显示P0011或P0012的DTC。相相关关DTC : P0
200、011, P0012, P0075, P0076OCVPCM 针脚No.描述1C01-2 49OCV 控制2主继电器B+1. Application : - MC 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down r
201、elated DTC and failure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机OCV 控
202、制控制1. Application : - MC 1.6 CVVT 2. Objectives - Measuring OCV Duty waveform 3. Required materials - Hi-Scan Pro - MC ETM4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure the OCV control line duty - If necessary, write down signal characteristic5. Time to complete :
203、15 minutes6. Reference : -Notice Caution OCVOCV是由是由ECMECM用用PWMPWM控制，控控制，控制的占空比由于发动机负荷制的占空比由于发动机负荷不同而不同。进气凸轮轴的不同而不同。进气凸轮轴的对大提前位置大约在对大提前位置大约在180018002500rpm2500rpm范围。但是转数范范围。但是转数范围不是固定的，因为转速不围不是固定的，因为转速不是控制是控制ocvocv阀的唯一因素。阀的唯一因素。另一主要因素是发动机负荷另一主要因素是发动机负荷( (从吸入空气量从吸入空气量/ /rpmrpm) )决定。决定。解码仪的数据流中，解码仪的数据流
204、中，Cvvt Cvvt status (Cvvtstatus (Cvvt状态状态) on) on表示表示它没有问题。如果有问题，它没有问题。如果有问题，会显示失效保护状态，同时会显示失效保护状态，同时cvvtcvvt的活动。油温是从的活动。油温是从ECTECT传感器计算的参考值。传感器计算的参考值。AlphaAlpha发动机的发动机的cvvtcvvt系统，系统，没有油温传感器。没有油温传感器。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book
205、should be used for the training purpose. 2005.01.07 Alpha 发动机机CVVT 实操操 -11. Application : - MC 1.6 CVVT 2. Objectives - Understanding basic inspection methods3. Required materials - General scan tool - Air gun with compressor - Assembled CVVT module with intake camshaft 4. Procedure - Refer to works
206、hop manual, check and test each CVVT related items such as - Timing Chain Alignment - Auto Tensioner - Oil Filter clogging - CVVT module rotation etc5. Time to complete : 40 minutes6. Reference : Notice Caution 吹吹气气试验 机油机油滤清清器堵塞器堵塞检查 自自动张紧器器检查 正正时链检查 HMC & KMC reserves all rights of disposal such as
207、 copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机1. Application : - MC 1.6 CVVT 2. Objectives - Understanding how CVVT operates with current data - Understanding OCV controlling by engine rpm - Understanding CVVT status3. Required mate
208、rials - Hi-Scan Pro4. Procedure - Connect hi-scan pro to the vehicle - Choose CVVT related items in current data - Using flight record function, record those data for some times - Analysis data - Write down it5. Time to complete : 15 minutes6. Reference : - Workshop manual - CVVT system training gui
209、de bookNotice Caution 项目目 / rpm怠速怠速150030004500凸凸轮轴位置位置25.50.53.812.6CVVT 占空比占空比 (%,Open)7424342 #1缸缸调整角整角124.1124.1124.1124.1CVVT 实操操 -2 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机
210、机1. Application : - MC 1.6 CVVT 2. Objectives - Understanding OCV checking methods 3. Required materials - Multi meter - Power extension cable4. Procedure Test 1 - Disconnect OCV connector - Measure resistance - Write down it - Check each connectors voltage - Write down the resultTest 2 - Warm up th
211、e engine and test this at idle condition - Disconnect OCV connector - With power extension cable supply 12 voltage directly from battery - Check the engine condition and write down its symptom 5. Time to complete : 15 minutes6. Reference : - Workshop manual - CVVT system training guide bookNotice Ca
212、ution 23 测试 1 测试 2现象现象: :在怠速时，不管在怠速时，不管ECMECM的控制，的控制，人为地直接给人为地直接给OCVOCV供电，供电，CVVTCVVT将把进气门调整到最大将把进气门调整到最大提前位置。多吸进的空气会提前位置。多吸进的空气会使发动机在怠速时转速波动。使发动机在怠速时转速波动。1.电阻阻 : 7.62. 输出出电压 - No.1 针脚脚对地地电压 : 3.2V - No.2针脚对地电压针脚对地电压 : 13.2VCVVT 实操操 -3 HMC & KMC reserves all rights of disposal such as copying and pa
213、ssing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机凸凸轮轴位置提前大位置提前大约30度。一度。一个个CKP齿大大约是是6度的度的CKP角度。角度。CVVT 实操操 -3 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpos
214、e. 2005.01.07 Alpha 发动机机ISA功能功能 : ISA: ISA是为了在各种负荷下稳定怠速转速。负荷情况会被很多因是为了在各种负荷下稳定怠速转速。负荷情况会被很多因素影响，例如：发动机温度，空调开闭，电路负荷和动力转向等。现素影响，例如：发动机温度，空调开闭，电路负荷和动力转向等。现在使用的是双线圈的在使用的是双线圈的ISAISA。怠速时，控制线圈打开的占空比约为。怠速时，控制线圈打开的占空比约为252528%28%。当目标转速和实际有。当目标转速和实际有100100rpmrpm左右时，左右时，ECMECM设定设定P0506P0506或或P0507P0507的的DTCDTC
215、。相相关关 DTC : P0506, P0507, P1505 P15081. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and f
216、ailure symptoms5. Time to complete : 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution ISAPCM Pin No.Description1C01-2 6Open control2Main RelayB+3C01-2 22Close control 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book sh
217、ould be used for the training purpose. 2005.01.07 Alpha 发动机机ISA 波型波型ISA是为了在各种负荷下稳定怠速转速。 目前，客户对燃油消耗率非常关心，所以必须降低怠速转速。JB车使用CVVT的发动机是650rpm。此时在没有电器负荷时，控制线圈打开的占空比约为26%。ISA怠速怠速WOT占空比占空比(%)28.4 93.9 输出信出信号号电压1. Application : - MC 1.4 2. Objectives - Measuring ISA waveform3. Required materials - Hi-Scan Pro
218、 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure the waveform of ISA at idle to WOT - Analyzing current data5. Time to complete : 20 minutes6. Reference : Notice Caution HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This
219、book should be used for the training purpose. 2005.01.07 Alpha 发动机机PCSV功能：功能：PCSVPCSV阀是计量到温压腔的空气和汽油蒸气的装置。阀是计量到温压腔的空气和汽油蒸气的装置。 因为被以因为被以计量器计量的整肃流程。计量器计量的整肃流程。PCSVPCSV因为反应速度比喷油嘴慢很多，所以通因为反应速度比喷油嘴慢很多，所以通常工作在固定的占空比上。通常，常工作在固定的占空比上。通常，PCSVPCSV阀的控制频率是阀的控制频率是8 8到到2020HzHz。相相关关 DTC : P0444, P0458, P0459, P049
220、6, P04971. Application : - MC 1.4 or 1.6 2. Objectives - Understanding circuit diagram - Understanding each pin assignment3. Required materials - MC ETM4. Procedure - Using MC ETM find each pin description - Write down sensor function - Write down Related DTC and failure symptoms5. Time to complete
221、: 15 minutes6. Reference : - MC ETM - MC Workshop manualNotice Caution PCSVPCM 针脚No.描述1主继电器B+2C01-2 8PCSV 控制 电路图 现束连接器 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机PCSV 波型波型PCSV怠速怠速3
222、000Duty(%)015 23.6 输出出电压信信号号1. Application : - MC 1.4 2. Objectives - Measuring ISA waveform3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure the waveform of ISA at idle to WOT - Analyzing current data5. Time to complete : 20 minute
223、s6. Reference : Notice Caution 当发动机的负荷增加时，当发动机的负荷增加时，PCSVPCSV阀通常会打开。正常温度的电阀通常会打开。正常温度的电阻：阻：16 ohmn16 ohmn。当分离插头时，。当分离插头时，控制线的输出电压是控制线的输出电压是3.5 V3.5 V。当它控制不正常时，如不正常当它控制不正常时，如不正常的打开，由于多进了空气和燃的打开，由于多进了空气和燃料，燃油调整会改变，怠速控料，燃油调整会改变，怠速控制被破坏。制被破坏。 HMC & KMC reserves all rights of disposal such as copying and
224、 passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机ISA 和和 PCVS当当发动机有机有负荷荷时，PCSV阀基基本是最大的本是最大的100% 打打开开。 HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 20
225、05.01.07 Alpha 发动机发动机防防盗盗系系统 - Smartra功能：功能：MCMC使用使用SmartraSmartra防盗系统。防盗系统。ECMECM替代替代ICMICM控制防盗系统。控制防盗系统。ECMECM和和ICMICM中数据流和钥匙编中数据流和钥匙编码方法完全不同。与防盗系统相关的码方法完全不同。与防盗系统相关的 DTC DTC 在在 Smartra Smartra 中在发动机部分被显示。中在发动机部分被显示。防盗天线 10A 保险通讯线天线12V电源地 HMC & KMC reserves all rights of disposal such as copying a
226、nd passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机机在数据流中，能看见钥匙状在数据流中，能看见钥匙状态。其中有，钥匙匹配，态。其中有，钥匙匹配，PINPIN码输入码输入, , 应急模式的修应急模式的修改密码等功能。密码是改密码等功能。密码是4 4位位数字，只有应急模式使用。数字，只有应急模式使用。当忘记密码时，需要首先使当忘记密码时，需要首先使模块中立化。模块中立化。解码仪中有一个防盗系统的解码仪中有一个防盗系统的区段。在这里可以匹配钥匙区
227、段。在这里可以匹配钥匙, ,设置密码设置密码, ,初始化防盗系统初始化防盗系统等。注意等。注意PINPIN码应该严格地码应该严格地被控制。被控制。Hi-scan Pro 操作操作1. Application : - MC 1.6 or 1.4 2. Objectives - Understanding current data - Understanding actuation function - Understanding JB Immo. System - Utilizing hi-scan pro operation 3. Required materials - Hi-Scan Pr
228、o 4. Procedure - Use Hi-scan pro current data function - If necessary, use flight record function for better practice - Discuss the result with your group5. Time to complete : 120 minutes6. Reference : Notice Caution HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose. 2005.01.07 Alpha 发动机发动机防防盗盗系系统防防盗盗系系统开开始工作始工作通过通过SmartraSmartra 模块的钥匙芯模块的钥匙芯片和片和ECMECM的通讯的通讯
