Published by Hyundai Motor company, september 2005 Engine Alpha II Engine

2 Alpha II Engine Introduction Alpha engine is already used in LC 1.6 liter without CVVT. Main differences form 1.6 liter are - Using CVVT system - Individual Ignition System - Surge tank Volume - Intake runner length and size - Throttle bode size (48 to 52mm) - Cylinder Block Strength - Can communication for DTC - PCM (ECM with TCM) with 2 chips inside - PCM Location Direction : Point out some changed items such as ; Individual Ignition System, CVVT system, Surge Tank and move on to next slide.

3 Engine Line Up MC has 3 types of engine. 2 for gasoline. 1 for Diesel CRDI. As already mentioned, MCs gasoline is not for the first used in HMC. It is alredy adopted in LC 1.6 with non CVVT model. In case of Alpha 1.6 and 1.4 DOHC, it is designed by HMC and now producing both HMC and KMC. The assembly line of this engine is in Ulsan plant. This engine has been quite widely used in HMC side. Available model of this engine is Matrix, Gets, Accent, XD Elantra and so on from Thats why it has a lot of reliability in quality. Now we are developing 3th generation of this engine. Project name is Gamma with timing chain system. You can see this Gamma engine from In case of MC 2 nd generation of Alpha engine is used. Basic mode of Alpha is 1.5 but it has three more 1.3, 1.4 and 1.6 liter. Except 1.3 & 1.4 liter both 1.5 and 1.6 liter have CVVT system. But only 1.6 liter with CVVT engine is used for MC export. 1.5 liter with CVVT is only for domestic. U 1.5 liter CRDI engine is quite new one. Main target area of this is for European and domestic. Amazingly it can produce 110 ps target horse power with 1.5 liter. New technology with this is VGT turbo charger with CRDI CP3 system. It has 3 line-up by engine displacement. 1.1, 1.5 and 1.6 liter. Later we will introduce euro 4 emission engine with this. Alpha liter with CVVT U 1.5 liter CRDI with VGT Direction : Introduce 3 engines characteristic one by one with chart. In case of NAS 1.6 with CVVT engine will be used.

4 Changed Items Intake Camshaft Target Wheel 1.6 Cylinder Head In case of main moving parts such as piston, piston ring, camshaft, crankshaft, connecting rod, cylinder head, cylinder head gasket and cylinder block, any parts can not be shared together between 1.4 and 1.6. To distinguish cylinder block from 1.6 to 1.4, refer to no. 4 cylinder block side to find encrypted letter such as 1.4D/1.5D or 1.6D. 1.4 and 1.5 cylinder block can be changeable not for 1.6 liter. The reason why those can not be inter changeable is mainly from adopting CVVT system and enlarged cylinder bore size in 1.6 liter. Only Intake and exhaust valve mechanism related items can be shared. Graphite coated piston is used so as to increase lubrication and decrease slapping noise since there was some noise and oil consumption problems before with alpha engine without any graphite coated piston. Camshaft target wheel in 1.6 liter has 4 target wheel. Each duration from low to high, high to low has 180 degree increasing more control accuracy with CVVT control. In case of 1.4 liter dowel pin type target wheel is still used. Direction : Explain some changed items from 1.5 liter base engine of Alpha. All moving parts which are mentioned here can not be inter changeable.

5 Changed Items-2 One big change from 1.6 liter Alpha is PCM location. PCM is located just after air cleaner housing. Also water proof PCM is used because of the location position. Using engine room side PCM location can have advantages such as reducing wire harness length so as to decrease production cost and wire harness electrical problem and maintenance easy, In case of Alpah 1.6, Bosch M7.9.1 version of software is used but MC uses Bosch M7.9.8 version with CVVT system. Main features of M7.9.8 are 2 chips CPU, 400MHz internal clock, waterproof, 24 channel A/D converter, 2 CAN Module, 154 pin connector, wheel speed sensor interface integrated, 768K flash memory and so on. To make communication to PCM with hi-scan pro, you must use can interface module since CAN communication protocol is used instead of KWP2000 for DTC only in Gasoline engine. Using can protocol communication speed is increased from 10kbps to 38.4kbps. There are two terminals for CAN communication in 16 OBD 2 connector. So when you try communication, you must use this. CVVT System is quite similar to Beta 2.0s. Exhaust cam shaft is driven by crankshaft. Between intake and exhaust, chain is used with CVVT actuation. Individual ignition system is applied to 1.6 liter only so as to increase efficiency and accuracy in control. TR is in ECM side. Direction : Describe PCM location with advantages and CAN protocol for DTC.

6 Full RetardFull Advance Intake ValveExhaust Valve Duration : 228˚ Duration : 236˚ TDC BDC ATDC 10˚ BBDC 46˚ 82˚ TDC BDC ATDC 8˚ ABDC 56˚ 122˚ TDC BDC BTDC 32˚ ABDC 16˚ Specification Valve timing for 1.6 liter engine is as shown in the table. The half value of 82 degree in full advance or 122 degree in full retard is used as CVVT set position. Two types of spark plugs are used, NGK and Champion. Using one type of spark plug for all 4 cylinders is recommended. Direction : Explain Intake valve opening timing and spark plugs.

7 Parts List Inductive type CKP sensor is used. Typically when you use Bosch EMS system, CKP sensor type is from inductive type contrary to Siemens of hall IC type. Of course these days there isnt any board to share both hall or inductive in CKP sensor. Main reason why Bosch prefer to use inductive type is it doesnt need any power supply for sensor operation. For example a vehicle is driving on rough road, suddenly micro cut off happens in power supply to sensor then the vehicle will stall immediately because of no power to sensor in hall IC type. On the other hand, since inductive type doesnt need any power supply the vehicle will still move. When it comes to MAF sensor, sensor supplier is changed from Bosch to Siemens. In case of previous Bosch HFM 5 type revere flow detection MAF sensor, even though it has more accuracy but sensor tip can be easily damaged by foreign materials resulting in fuel system problems. Sensor reliability is increased using Siemens MAF sensor but accuracy can be lower than Boschs. When you install MAF sensor you must be careful to installation direction. Other sensors or actuators are no differences except individual ignition system which is newly adopted. Direction : Explain CKP sensor and MAF sensor here. Others dont have any change. MAF for 1.6 liter MAP for 1.4 liter

8 RLFS Fuel System 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 discussion 3. Required materials - Workshop manual - EMS and Troubleshooting book 4. 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 it 5. Time to complete : 15 minutes 6. Reference : - Workshop manual - EMS and Troubleshooting book [Notice] [Caution] Available VehicleXD, LC, FC, MC Filter Interval 60,000 KM (Depends on the region) Advantage : Because of the circulation of fuel from fuel tank to heated fuel delivery pipe, conventional return type fuel system compared to RLFS which fuel is regulated in fuel pump module inside of fuel tank can produce much more evaporated high temperature gas. Reducing circulating fuel line as shown in the picture, RLFS maintains lower fuel temperature and reduces evaporative gas by 25 ~ 30%. Main items consist of RLFS are fuel pump module including fuel filter and fuel pressure regulator submerged in fuel tank.

9 Fuel Pump Module Disassembling 1. Application : - MC 1.6 or Objectives - Understanding how to disassemble fuel pump module - Understanding how to replace fuel filter - Checking fuel system related items 3. Required materials - 1 set of fuel pump module - 1 set of fuel filter 4. Procedure - Write down your procedure 5. Time to complete : 15 minutes 6. Reference : [Notice] [Caution] Procedure : 1. Descrewed two bolts hidden in rear seat 2. Disconnect fuel pump connector 3. Carefully open fuel tank cap and take out the fuel pump module 4. Disassemble one by one carefully and replace fuel filter

10 Fuel Pump Circuit 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 voltage 3. Required materials - Multi meter - Hi-scan pro 4. Procedure - 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 minutes 6. Reference : - MC ETM [Notice] [Caution] (V) Ig. On0B+ 0 B+ Starting B+ 0 B+ B+ 0 Running0B+ 0 Battery Main Relay F/Pump Relay PCM Fuel Cut Switch Fuel Pump : When Ig on, only 1.5 ~ 2 seconds fuel pump goes on condition Real measuring is around for B+ and 0 for 0.8 ~ 0.9V

11 Fuel Pressure Measuring 1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Measuring fuel pressure - Understanding how to use fuel pressure measuring adaptor 3. Required materials - Fuel pressure gauge - 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 result 5. Time to complete : 20 minutes 6. Reference : - Workshop manual [Notice] [Caution] Fuel Pressure(kg/ ) Ig. On Starting3.5 Sudden Acceleration3.5

12 Fuel Pump Current Consumption 1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Understanding fuel pump current consumption 3. Required materials - Amp Meter - Hi-scan pro or other oscilloscope - General tools - MC ETM 4. Procedure - Prepare oscilloscope - Set this to power line to fuel pump - Measure current consumption during fuel pump operation - Write down on the table 5. Time to complete : 15 minutes 6. Reference : - Hi-scan pro optional manual [Notice] [Caution] Current (A) Maximum11.2 Average4.5 Minimum3.5

13 Parts Location 1. Application : - MC 1.6 or Objectives - Understanding each parts location - Understanding how to disconnect each connectors 3. Required materials 4. Procedure - Check sensors or actuators location - Check engine room junction box - Disconnect each parts one by one - Write down correspond parts name to the picture 5. Time to complete : 15 minutes 6. Reference : - [Notice] [Caution] 1. PCM 2. MAF Sensor 5. TP Sensor 6. ECT Sensor 7. CMP Sensor 8. CKP Sensor 9. Frt. Oxygen Sensor 11. Knock Sensor 12. Vehicle Speed Sensor 14. ISA 15. PCSV 16. OCV 17. Ignition Coil

14 Drive Belt Installation & Adjustment 1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Understanding drive belt components - Understanding drive belt tension adjustment mechanism - Understanding how to replace drive belt - Understanding how to inspect it 3. Required materials - 1 unit of MC 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 - Disassemble all drive belts - Inspect these - Reassemble correctly - Write down the procedure 5. Time to complete : 30 minutes 6. Reference : - Workshop manual [Notice] [Caution] There are 3 belts in drive belt. A is for power steering. B is for A/Con compressor and C is for alternator. Belt B and C can be confused when you reinstall so make your own mark to distinguish. Belt C is a little longer than belt B. Above pictures show each mechanical adjuster which are similar to beta 2.0 liter engine.

15 Timing Belt Installation 1. Application : - MC 1.6 CVVT 2. Objectives - Understanding how to align timing belt system - 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 minutes 6. Reference : - Workshop manual [Notice] [Caution] Procedure : In case of timing chain side, each one has unique mark on that. Every 4 times of crankshaft rotation can align timing chain to timing mark on CVVT module because of the different gear ratio between crankshaft and camshaft timing chain sprocket.

16 Timing Belt Inspection 1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Understanding timing belt alignment - Understanding belt tension 3. 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. Time to complete : 30 minutes 6. Reference : - Workshop manual [Notice] [Caution] Belt Tension TIMING BELT INCREASED IN THICKENESS PART NAMEPART NUMBER TIMING BELTPREVIOUSNEW To reduce timi ng belt noise problem in Alpha series engine, thickness of this is changed as shown in the picture. Even MC is already installed with new one, when you have the same noise problem in timing belt, check the thickness for your reference. One belt tension method in Alpha series engine is using the bolt position shown in the picture. If you give 4.5kg-m of force to timing belt to tensioner side, timing belt will reach to the near half of bolt center if it is in good condition. Another method to check correct tension is using sonic type tensioner gauge. For more details, refer to the relevant TSB.

17 Compression-1 1. Application : - MC 1.6 or 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 necessary, oil the cylinder and measure it again - Write down the result 5. Time to complete : 20 minutes 6. Reference : MC EM-9 [Notice] [Caution] Not to touch spark plug when it is hot No.1No.2No.3No.4 Dry (Kg/ ) 12.5 ~13 Oil (Kg/ ) 13.5~14.2 Good/BadGood Compression test result can be different by tools and conditions. Rationality check for 4 cylinder is useful.

18 Compression-2 1. Application : - MC 1.6 or 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 - Compare each cylinders output voltage - If necessary, take out one spark plug, and test it again - Write down the result 5. Time to complete : 15 minutes 6. Reference : - - Hi-Scan Pro optional manual [Notice] [Caution] No.1No.2No.3No.4 Voltage (V) Good/BadBadGood Test is done after removing No.1 spark plug. Amp meter setting is 10mV/A so 1.5 V means 150A current consumption by start motor for that cylinder.

19 Bearing Selection & Measuring 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 bearing 3. Required materials - Engine block with main moving parts - General tools - Torque wrench - plastic gauge 4. 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 minutes 6. Reference : - Workshop manual EM [Notice] [Caution] Con-Rod Bearing Con rod bearing oil clearance is ~0.040mm. Also bearing has 5 selection with difference size. Con Rod itself has 3 type A, B and C by its size. Size mark is stamped on the side of con rod cap. Main Bearing Main bearing oil clearance is ~ 0.036mm. Bearing color is divided with 5. Actual measuring shows 0.025mm in plastic gauge scale. Cylinder Bore Cylinder bore size is stamped on the bottom face of cylinder block to no.4 cylinder side. It has 3 size mark a, b and C by its size. In case of 1.6 liter b type size becomes ~ 76.52mm

20 Vacuum (Negative) Pressure Measuring 1. Application : - MC 1.6 or Objectives - Understanding vacuum pressure measuring - Understanding leakage checking 3. Required materials - PV350 with adapter - Hi-scan pro 4. Procedure - Connect adapter between vacuum line - Connect 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 minutes 6. Reference : - Hi-scan pro optional manual [Notice] [Caution] ConditionPressure (cmHg) Idling-35 ~ -37 Sudden Acceleration-35 to +26 Sudden Deceleration+6 to -45 then -35 Idle WOT to Deceleration (Full Vacuum) Using PV350 which is one of hi-scan pro optional items, you can measure vacuum pressure. When leakage happens the pressure in surge tank will goes to near ambient but if it is good condition in combustion, it will show specific value. Refer to vacuum pressure result as a tool to diagnosis

21 Current Measuring 1. Application : - MC 1.6 or Objectives - Understanding each components current measuring such as - Starter Motor - Charging Current - Dark Current 3. Required materials - AMP meter - Hi-scan pro - 1 unit of MC 4. Procedure - Set AMP meter with hi-scan pro - Measure each components current consumption - Write down the result 5. Time to complete : 15 minutes 6. Reference : - Hi-scan pro optional manual [Notice] - In case of charging current, measure this form alternation Positive side in 5 minutes after vehicle starting. [Caution] ItemsCurrent(A) Dark Current (Ig. Off)0 Starter Motor (Cranking)150 ~ 170 Charging Current (Alternator) In 5 minutes after starting 28~32

22 Micro 570 Analyzer The Micro 570 analyzer provides the ability to test the charging and starting, including the battery, starter and alternator. Caution : Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when working with batteries. Function Battery Test - Out of Vehicle Test - In Vehicle Test Starter Test Charging Test

23 key Pad Function The Micro 570 button on the key pad provides the following functions : Use the arrow buttons to scroll to main menu. Press the Enter button to make selection Press Menu button to view the last test result and set the time The tester will ask if the battery is connected IN VEHICLE or OUT OF VEHICLE. Make your selection by pressing the arrow buttons: then press ENTER button.

24 Battery Test

25 Battery Test Result ResultRemedy Good batteryNo action is required. Good recharge Battery is in a good state. Recharge the battery and use. Charge & Retest Battery is not charged properly. Charge and test the battery again (Failure to charge the battery fully may read incorrect measurement value) Replace battery Replace battery and recheck the charging system.(Improper connection between battery and vehicle cables may cause REPLACE BATTERY, retest the battery after removing cable and connecting the tester to the battery terminal directly prior to replacing the battery) Bad cell-replace Charge and retest the battery. And than, test results may cause REPLACE BATTERY, replace battery and recheck the charging system.

26 Starter and Charging System ResultRemedy Cranking voltage normal System shows a normal starter draw Cranking voltage low Cranking voltage is lower than normal level. Check the battery and retest Charge battery The state of battery charge is too low to test. Check the battery and retest. Replace battery Replace battery. If the vehicle is not started though the battery condition of Good and fully charged is displayed. Check wiring for open circuit, battery cable connection, starter and repair or replace as necessary. If the engine does crank, check fuel system. As soon as you finish battery, move on to charging system following the direction shown on the screen. Please refer to proper workshop manual section. As for the test result on starter and charging system, refer to bellow chart.

27 battery Tester Utilization 1. Application : - MC 1.6 or Objectives - Utilization of battery tester 3. Required materials - Micro 570 tester - 1 unit of battery - 1 unit of MC 4. Procedure - Referring to workshop manual - Test battery with battery tester both out of battery and in vehicle - Test Starting and Charging one by one after finishing battery test - Write down the result 5. Time to complete : 15 minutes 6. Reference : - Workshop manual - Micro 570 user manual [Notice] [Caution] ItemsResult(on the Screen) BatteryGood / Bad StarterGood / Bad ChargingGood / Bad

28 Starting Circuit 1. Application : - MC 1.6 CVVT or 1.4 Non CVVT 2. Objectives - Understanding starting operation circuit - Measuring each points voltage 3. Required materials - Multi meter - 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 minutes 6. Reference : - MC ETM [Notice] [Caution] (V) Ig. On Starting12 0

29 Cooling Fan Control Logic APT sensor is used instead of triple switch. In case of 1.4 liter engine, it has only one cooling fan unlike 1.6 liter which has 2 cooling fans.

30 Hi-Speed Control Hi-Speed On (V)000120

31 Low-Speed On (V) Low Speed Control

32 Alpha II Engine Management System In case of Alpha 2 engines ECM, it is mounted in engine room compartment as mentioned before. To measure barometric pressure, small ventilation hole which is shown on top of the PCM is used. For perfect waterproof, never disassemble or make any damage to this. CCV which is for evap. monitoring checking for NAS is located near canister.

33 M7.9.8 ECU M7.9.1 ECU ECM Comparison There are several differences between M7.9.1 used in alpha engine and M7.9.8 for MC. Except something which are already described before, there are some more in connectors. In case of M7.9.1 which has 121 pins, only 81 pins is used for engine control. Left 40 pins are for transmission control purpose. But in M7.9.8 with 151 pins, there isnt any assignment for ECM or TCM purpose. Like M7.9.1, M7.9.8 is also divided with two but pin designation is totally different. Can protocol is another big changes. No. 12 and No. 27 in A side are assigned for communication. If you measure the resistance between No.12 and No. 27, you will have around 120. No.12 is for Can high, and No.27 is for Can Low. Can high signal moves from 2.5 to 3.5 voltage after ignition on but Can low signal shows from 2.5 to 1.5 volt. Detail waveform will be followed later.

34 Input and Output M/TInput VariableECU PIN NO. With OBD-II With ABSABS SignalK 64 Without ABSWheel Speed Sensor K 79, K 58 (K 64 open) Without OBD-II With ABS Vehicle Speed Sensor K 64 Without ABSK 64 AutoInput VariablePCM PIN NO. With OBD-II With ABSABS SignalK 20 Without ABSWheel Speed SensorA 60, A 45 Without OBD-II With ABS Vehicle Speed Sensor K 20 Without ABSK 20 Frt. Right side WSS Vehicle sensor signal recognition is a little different. When ABS or OBD system are applied to the vehicle, wheel speed sensor is used for vehicle speed instead of VSS. This wheel sensor is also used for misfiring detection like typical acceleration. The VSS which is mounted on T/M housing is for only clusters vehicle speed information purpose. Signal input lines are also quite different by vehicle specification. Refer to above table for input pin assignment. Direction : Make them understand for vehicle speed signal recognition.

35 Pin Taking Out 1. Application : - MC 1.6 or Objectives - Understanding how to take out a pin from the connector 3. Required materials - Components connectors - Small sharp pin (needle) 4. Procedure - Choose 3 more connectors for each group and take one or two more pins out from that connect 5. Time to complete : 15 minutes 6. Reference : Workshop manual FL10 ~FL14 [Notice] [Caution] Procedure : Since MCs ECM is in engine room side and it is waterproof, each pins to PCM side is secured so tightly. It means it has a lot of difficulty to take one of these pins out for replacement. Very thin and sharp SST is necessary to do this. To adjust any terminal pin problems, you must make ignition off first and fully understand how to make correct inspection and repair procedure. When a tester in used to check for continuity, or to measure voltage, always insert tester probe from wire harness side.

36 ECM Pin Assignment 1. Application : - MC 1.6 CVVT with A/T 2. Objectives - Understanding each pin assignment 3. Required materials - MC ETM - Multi meter 4. Procedure - Find out each assigned function pins in each connector - Measure voltage at ig on and idling - Write down the result 5. Time to complete : 30 minutes 6. Reference : [Notice] [Caution] Assigned FunctionPin. No. Ig. On (V) Idling (V) GNDK(1,2,3,8,9,31,38,51,73)O0 Power K6 A56 12 Relay Control A9 A MAP S(1.4 Only)K Sensor Reference (V)A43, A5855 Injector ControlA36,A48,A50,A TPS SignalK ~0.9 CMP SensorK ~12 O2 Sensor UpK ~0.8 O2 Sensor DownK ~0.8 (K)(A)

37 MFI Circuit (V) Ig. off Ig.On

38 Inductive and Hall Effect Inductive type sensor which is generally used in CKP sensor generates AC voltage and do not need an external power supply. As each sensing tooth moves by the sensor, an AC voltage of signal is induced. Each tooth produces one pulse signal. A sensing tooth rotates faster there more pulses are generated. One critical point with this sensor is the distance between the sensor and the sensing tooth. The further apart they are, the weaker the signal. Sensor wires are twisted and shielded to prevent electrical interference from disturbing the signal. In case of MC, CKP signal shows -3 ~ -9V at idle with sign waveforms. Hall Effect

39 CKP & CMP Sensor Function : ECM calculates engine rpm by using CKP sensor which is used by inductive type to controls the injection timing, ignition timing, misfiring, and variable valve timing with CVVT. CMP is a hall IC type sensor and signals to ECM for determining the TDC point with CKP sensor. Related DTC : P0016, P0335, P0336, P0337, P0338, P0339, P0340, P0341, P0342, P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] CKPPCM Pin No.Description 1C Signal High 2C Signal Low CMPPCM Pin No.Description 1Main RelayB+ 2C Signal 3C Ground

40 Synchronizing Check 1. Application : - MC 1.6 CVVT 2. Objectives - Measuring CKP and CMP synchronizing waveform 3. Required materials - Hi-Scan Pro 4. Procedure Synchronizing - Use Hi-scan pro oscilloscope function - With manual scope, measure CKP and CMP synchronizing waveform Synchronizing related Current Data - Capture with flight record function - Choose specified items - Analyzing whether it show any data during starting 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution] Syncro.State(CKP/CMP) is for ECMs logical thinking related on Synchronizing. On means it doesnt have any problem in synchronizing. It is quite useful when you have starting problem. Camshaft position is for set point of CVVT. Initially it shows -8 deg. Right side picture will be changed. Item Ig. On (V) Idling (V) CKP2.53-2~10 CMP0.090~12 Signal Output Voltage

41 Synchronizing Reference Signal Starting Point This signal is captured by road tech device. Unfortunately any T-connector is not available until now. When start motor is rotating, CKP signal from CKP sensor is coming to ECM. When first both CKP and CMP signals come to ECM, injection starts and ignition follows. As you seen in this picture CMP signal acquisition is a little different because of target wheel shape. This is only for 1.6 with CVVT. In case of 1.4 liter dowel pin type target wheel is still used. Synchronizing 1Synchronizing 2

42 VSS Sensor Function : VSS is one of the essential components which ECM utilizes to calculate vehicle speed when it is moving especially with A/T. It is also used for shift pattern decision and shift timing controlling. Unlike conventional VSS, this VSS installed in MC is only used for cluster operation. When ignition key goes on position ECM automatically detects VSS signal from relevant sensors such as WSS or VSS. In case without any OBD2 regulation (EOBD) and ABS system, VSS sensor is used for both ECM and cluster. If not, VSS in MC is only used for cluster operation. Related DTC : P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] VSSPCM Pin No.Description 1Ground 2IG 1B+ 3C Signal WSS 1C Signal + WSS 2C Signal -

43 VSS Waveform 1. Application : - MC 1.4 or 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 driving 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution] Vehicle speed value which is shown through hi-scan pro current data is from WSS. Even you disconnect VSS sensor connector in T/M side, it doesnt give any effect to this. Only cluster operation in VSS information is affected. One of the main changes in MC is VSS signal acquisition. Signal from VSS is the same as conventional one with hall IC effect. The signal which is shown in this slide is not from VSS. It is from WSS used in OBD 2 regulation. Just for your reference, compare with conventional one.

44 VSS Waveform Explain VSS signal acquisition with whether it has ABS system or not and whether it is equipped with OBD 2 or not. You can not be inter changeable between WSS for only OBD 2 which sensor type is analogue and WSS only for ABS which sensor type is digital.

45 VSS Waveform VSS signal for engine ECM is from WSS which is mounted on front right side. When you make D shifting on circled condition, analog time signal goes to engine ECM and it is converted there into digital one.

46 Zirconia Principle and Lamda control Zirconia type oxygen sensor is used. It is made of zirconia (zirconium dioxide), platinum electrode, and a heater. This oxygen sensor generates a voltage signal based on the amount of air in exhaust compared to the atmospheric oxygen. The zirconia element has one side exposed to the exhaust stream, the other side is connected to atmosphere by wires. Each side has a platinum electrode attached to zirconia dioxide element. The platinum electrodes conducted the voltage generated. Contamination or corrosion of the platinum electrodes or zirconia dioxide elements will reduce the voltage signal output. When exhaust oxygen content is high, oxygen sensor voltage is low. When exhaust oxygen content is low, voltage output is high. The greater difference in oxygen content between the exhaust stream and atmosphere, the higher the voltage signal. From the oxygen content, the ECM can determine whether the air fuel ratio is rich or lean and adjust the fuel mixture accordingly. A rich mixture consumes nearly all oxygen, so the voltage signal is high in the range of 0.6 ~ 1 V. A lean mixture has more available oxygen after combustion than a rich mixture, so the voltage signal is low in the range of 0.4 ~0.1V. At the stoichiometric air fuel ratio (14.7:1), voltage output is nearly 0.45V.

47 Oxygen Sensor Related DTC : P0031,P0032, P0036, P0037, P0038, P0135, P0141 for Heater failure P0130~P0134, P0136~P0140 for Oxygen sensor failure P0171 ~P0172 for Fuel Trim failure P0420 Catalyst System Efficiency failure P2096, P2097, P2232 Post Catalyst failure (Rear Oxygen Sensor) 1. Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] Frt. O2 Sensor PCM Pin No.Description 1C01-2 (31)Sensor Gnd 2C01-1 (35)Signal 3C01-2 (34)Heater control 4Main RelayB+

48 Oxygen Sensor Waveform 1. Application : - MC 1.6 CVVT 2. Objectives - Measuring Frt. and Rr. Oxygen 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 oscilloscope function - With manual scope, measure Frt. and Rr. heater control waveform - Analyzing 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution] Since oxygen sensor related DTCs are so various. Understanding its function and DTC are important. Explain here why rear oxygen sensor is used. What is different comparing with front oxygen sensor. Rear oxygen sensor is the rear side of catalytic converter to check the proper operation of catalyst. Oxygen density after the catalytic converter has to be within specific range around 0.5V when there is no acceleration or deceleration. If the oxygen density changes in accordance with front oxygen sensor, it means the poor performance of catalytic converter.

49 Oxygen Sensor Current Data 1. Application : - MC 1.6 or Objectives - Understanding oxygen sensor related items - Understanding heater controlling - Understanding fuel trim 3. Required materials - Multi meter - Hi-scan Pro 4. 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 minutes 6. Reference : - ETM - Workshop manual [Notice] [Caution] Heater Resistance ItemsIdle Function A/F Closed Loopon Open or Close loop Frt. O2 Sensor0.12~0.79A/F feedback S/T Fuel Trim Fuel correction Long Term – Idle Fuel Adaptation Long Term – P/Load-0.7 Fuel Adaptation Injection (ms) Injection Duration AFS (kg/h) AFS volumn Current Data Analyzing Frt. :8.6 Rr. :9.4

50 What is Short Term ? Caused Condition Intake air leakage Incorrect fuel pressure to low Injector valve defective or coked Engine temperature sensor defective PCSV defective or leaking AFS defective Clogged or damaged catalytic converter Contaminated fuel Combustion altered by mechanical failure such as : - Spark plugs, - Compression - Intake and Exhaust valve - CVVT system Function : There are two different fuel trim values that affect final injection duration and can be observed by the technician through hi-scan pros current data, short fuel trim (Short F/T), and long term fuel trim (Long term Idle or Long term P/Load). Short term F/T is a temporary addition or subtraction to the basic injection duration following by oxygen sensors feedback. Long term F/T is part of the basic injection duration calculation and it is stored in the ECMs memory. As short term is based on the oxygen sensors feed back, it only functions in closed loop. It responds rapidly to changes in the oxygen sensor. If short term is varying close to 0%, little or no correction is needed. When short term percentage is positive, the ECM has added fuel by increasing the duration. A negative percentage means the ECM has subtracted fuel by decreasing the injection duration. The short term value is temporary and not stored when the ignition key is turned off. Also short term is used to modify the long term f/T. When the short term remains higher or lower longer than expected, the ECM will add or subtract this value to the long term F/T. Short Term Fuel Trim

51 Short Term Fuel Trim 1. Application : - MC 1.6 or Objectives - 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 group 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution] When positive short term shows like 15.6%, it means the fuel trim in system is too learn condition. Next injection time will be affected by this condition resulting in extending its duration. If you meet this condition check air leakage or ignition failure etc. Oxygen sensor shows now uneven because of the fuel trim problem. Without any problem in A/F ration, it will show even signal but in case the system goes wrong way, it will show uneven like the signal from the left. When you check oxygen sensor signal increase engine rpm to 1500 ~1800 for better signal achievement.

52 Long Term Fuel Trim What is Long Term ? Function : Long term F/T is stored in ECM memory and it is not erased when the ignition key is turned off because it is part of the basic injection duration calculation. It affects injection duration both closed loop and open loop. The ECM uses the short term F/T to modify the long term F/T. It does not react rapidly to sudden changes, it only changes when the ECM decides to use the short term F/T value to modify the long term F/T. Like the short term F/T, when long term is at 0% there has been no modification to the basic injection duration. A positive percentage means the ECM is adding fuel; a negative percentage, subtracting fuel. Long term is used to control injection duration over the entire range of engine operation. It is divided into two ; Long term Idle and Long term part load by engine load. Long term idle is monitored under less than 920 rpm and 24 kg/h of air amount. Add or subtract control is used at this range since the inhaled air amount is relatively small. Unlike long term idle, Long term P/load is monitored over 30 ~ 75% of engine load and 40 ~200kg/h of air amount. Multiple correction control is utilized with this. FR A-area Limits (multiplicative Correction Air Mass Flow>30.4 kg/h rl>30% Coolant Temperature

53 Those items which are showing from the right are related with fuel trim checking. Whenever you have any problem in fuel trim please carefully check those items. Flight record function in hi-scan pro is quite useful with driving test. Using hi-scan pros record function, you can record oxygen sensor signal as a duty one. If the engine condition on which is near to stoichiometric then duty signal will show flat and stable. If it is not it will show fluctuated like the signal on the left. 1. Application : - MC 1.6 or Objectives - Understanding long 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 group 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution] Long Term Fuel Trim

54 Oxygen Sensor Response Checking 1. Application : - MC 1.6 or Objectives - Measuring Frt. oxygen sensor waveform at 1,800 rpm - Analyzing its response time from 0.3 to 0.6 and 0.6 to 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 minutes 6. Reference : - [Notice] [Caution] Response Time : 50 ms Response checking method can be a alternative to diagonis oxygen sensor. To measure the response time from low to high(0.3 to 0.6V), set the hi-scan pro with oscilloscope function and analyze its time. Response Time : 110 ms In case of response time result, it doesnt have any specification. Only comparing the test result can be used. To increase your experience, measure its response time and compare with others. Normally high to low response time is taking a little longer than that of low to high.

55 WOT Test with TPS 1. Application : - MC 1.4 or Objectives - Understanding oxygen sensor waveform with TP signal - Measuring response time from lean to rich 3. Required materials - Hi-scan pro 4. Procedure - Use Hi-scan pro oscilloscope function - Increase engine rpm to Make fuel cut condition releasing accelerator pedal - Depress Accelerator pedal to WOT - With manual scope, measure the response time from lean to rich 5. Time to complete : 15 minutes 6. Reference : [Notice] [Caution] Procedure : To check Oxygen sensors response time with TP Sensor, first make fuel cut condition. Increase engine rpm to approximately 4000, then suddenly deceleration so that fuel system goes to fuel cut. When engine rpm reaches to near 2000, depress the accelerator pedal to WOT. When it comes to oxygen sensors view, when you make fuel cut, then it should turn to be lean. When you make WOT on the other hand, it goes up to rich. Using this kind of test method, you can measure correct response time from lean to rich in oxygen sensor. General response time shows 200m/S ~ 300m/s in MC.

56 WOT Test with TPS 270m/s 530m/s During fuel cut condition oxygen sensor for both up and down should be near to 0V. If you make WOT from this fuel cut, oxygen sensor will signal to near 1 voltage. Comparing with TPS rising up time and oxygen sensors, you can check o2 sensor response time too. Fuel Cut

57 MAF Sensor Function : MAF sensor converts the air amount drawn into the engine into a voltage signal output to ECM. The ECM needs to know air volume to calculate engine load. This is necessary to determine how much fuel to inject, when to ignite the cylinder and when shift the transmission. Siemens hot film type air flow sensor is used in MC. At idle it shows nearly 1V with 8.2kg/h of amount air volume. Related DTC : P0068, P0100, P0101, P0102, P0103, (P0112 & P0113 for IATS) 1. Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] MAFPCM Pin No.Description 1C01-1 8Ground 2Main RelayB+ 3C MAF Signal 4GNDGround 5C IATS Signal

58 MAF Sensor Waveform 1. Application : - MC 1.6 CVVT 2. Objectives - Measuring MAF waveform 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure sensor waveform of MAF with TPS from idle to WOT - Analyzing current data 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution] At idle condition the voltage output of MAF shows around 1V. In terms of MAF with air flow rate, it nears more or less about 8kg/h. When you have any fuel system related problems or something else check this value carefully and refer to this with troubled vehicle. ItemIdleWOT MAF(V) 13.5 Air(kg/h) TPS(V) Signal Output Voltage MAF TPS

59 MAF Sensor Simulation 1. Application : - MC Objectives - Understanding sensor simulation - Understanding related items 3. Required materials - Hi-scan pro 4. Procedure - Use Hi-scan pro simulation function - Analyzing related current data - Discuss the result with group member 5. Time to complete : 15 minutes 6. Reference : [Notice] [Caution] Item1.5V2.0VSymptom Injector Duration5.70Injection extended Ignition Timing6.80Increased S/T Fuel Trim-250Negative controlling ISA Duty29.50Increased Engine Speed7200Increased Discuss the result : When you make simulation with 1.5 V (Normal voltage output at idle show around 1.0), ECM becomes cheated with this fake signal. Even though the inhaled air volume is the same as before, injection duration can be extended resulting in short term negative controlling because of this rich condition. If you have the same problem in field case, it doesnt have any DTC related with MAF but you can possibly have short term related DTC first. Of course if your vehicle has some function in rationality checking, it will have any DTC. To check MAFs performance or correct controlling, simulation will be useful device. Additionally you can check control wiring too.

60 MAP Sensor In MAP sensor, there is a silicon chip, diaphragm mounted inside a reference chamber. On one side of the chip is a reference pressure. The reference pressure is either a perfect vacuum or calibrated one depending on the application. On the other side is the pressure to be measured. The diaphragm changes the resistance with the changes in pressure. This change in resistance alters the voltage signal. The ECM interprets the voltage signal as pressure and any change in voltage signal means there was a change in pressure. Below shows A/D converters function which is located inside of the ECM. A/D Converter and Fault Detecting

61 MAP Sensor Function : Intake manifold pressure is a directly related to engine load. The ECM needs to know intake manifold pressure to calculate how much is coming to cylinders. At ignition on conditions it shows ambient pressure of nearly 4.3V(100kPa) but when engine is running it shows around 1.4 V (35kPa). When it has some faults, this signal is replaced with TPS and engine rpm Related DTC : P0106, P0107, P0108, (P0112&P0113 for IAT Sensor) 1. Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] MAPPCM Pin No.Description 1C Map signal 2C Reference(5V) 3C IAT signal 4C01-1 8Ground

62 MAP Sensor Waveform When you make ig on. then ECM recognizes ambient pressure with MAP input. With normal value it shows around 4.2~4.3V. Using this, you can check MAP sensor failure. Set hi-scan pro current data and choose MAP sensor related items. Make ig. on condition and check the out put voltage whether it reaches around 4.2V or not. Item Ig.On (V) Idle (V) MAP TPS0.3 Signal Output Voltage MAP TPS 1. Application : - MC Objectives - Measuring MAP waveform 3. 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 data 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution]

63 MAP Sensor Simulation 1. Application : - MC Objectives - Understanding sensor simulation - Understanding related items 3. Required materials - Hi-scan pro 4. Procedure - Use Hi-scan pro simulation function - Analyzing related current data - Discuss the result with group member 5. Time to complete : 15 minutes 6. Reference : [Notice] [Caution] Item1.5V2.0VSymptom Injector Duration5.70Injection extended Ignition Timing6.80Increased S/T Fuel Trim-250Negative controlling ISA Duty29.50Increased Engine Speed7200Increased Discuss the result : When you make simulation with 1.5 V (Normal voltage output at idle show around 1.0), ECM becomes cheated with this fake signal. Even though the inhaled air volume is the same as before, injection duration can be extended resulting in short term negative controlling because of this rich condition. If you have the same problem in field case, it doesnt have any DTC related with MAF but you can possibly have short term related DTC first. Of course if your vehicle has some function in rationality checking, it will have any DTC. To check MAPs performance or correct controlling, simulation will be useful device. Additionally you can check control wiring too.

64 TP Sensor Function : TPS is mounted on the throttle body and converts the throttle valve angle into an electrical signal using variable resistor (Potentiometer). As the throttle opens, the output signal voltage increases. ECM uses this signal information to know engine mode (idle or WOT), A/F correction, Power increase correction and fuel cut control etc. Normal voltage range is form 0.2 to 4.8V. At idle in MC it shows 0.3V. P0068 is rationality check (NAS) between MAF and TPS through calculated engine load. Related DTC : P0068, P0121, P0122, P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM find each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] TPSPCM Pin No.Description 1C Signal 2C Reference(5V) 3C Ground

65 TP Sensor Idle Status on means now engine controlling is under idle. Even it doesnt any idle switch ECM detects idle condition logically. WOT starts around 3.9V. Adapted throttle shows in wrong way because of the software problem. Check this later. In normal value it shows around 10%. TPsIg. OnWOT Output (V) Signal Output Voltage 1. Application : - MC 1.6 CVVT 2. Objectives - Measuring TP Sensor waveform 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure sensor waveform with TPS from idle to WOT - Analyzing current data 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution]

66 TP Sensor Simulation Item0.6V1VSymptom Injector Duration2.62.7The same as before Ignition Timing40.542Fully advanced S/T Fuel Trim4.82.7Positive controlling ISA Duty4145Increased Engine Speed Increased Discuss the result : As mentioned before in MAF simulation result, simulation is a good alternative to check several things together. First, you can check control wiring. Since making simulation means supplying signals to ECM not from sensor side but from hi-scan pro side. Another advantage of simulation is you can create the same condition when vehicle is faced. When you conduct TPS simulation as shown in the table, mainly ignition timing is advanced by changing supply voltage. From this reason, engine rpm and ISA open duty goes up. Since TPS 0.6V means it is not idle condition anymore. If Engine is not under idle condition, ECM is focusing on increasing torque. 1. Application : - MC Objectives - Understanding sensor simulation - Understanding related items 3. Required materials - Hi-scan pro 4. Procedure - Use Hi-scan pro simulation function - Analyzing related current data - Discuss the result with group member 5. Time to complete : 15 minutes 6. Reference : [Notice] [Caution ]

67 Knock Sensor Function : Knocking is a phenomenon characterized by undesirable vibration and noise that can cause engine damage. Knock sensor is mounted on the cylinder block and senses engine knocking. A knocking vibration from the cylinder block is applied as pressure to the piezoelectric element. ECM controls the ignition timing based on the amplitude and frequency of the knock sensor signal. For example, when knocking is detected, the ignition timing is retarded to prevent it. Related DTC : P0326, P0327, P0328, P1550, P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] KnockPCM Pin No.Description 1CO1-2 30Signal high 2C Signal Low

68 Knocking Control MBT (minimum spark advance for the best torque) is the ignition timing to generate maximum torque, and is positioned just adjacent to the ignition timing to generate knocking. So ignition timing shall be set a little away from knock generation range. Without knock control, ignition timing will be set at retarded point from maximum torque generating point in order to ensure required allowance, and then lower torque will be generated. On the other hand, ignition point may be set close to knocking range effectively raising engine output using knock sensor. Knocking generates high frequency (5-10khz) vibration in cylinder, which vibrates knock sensor located on cylinder block outer wall at the same frequency. As knock sensor output signal contains various frequency components, band pass filter filters the signal, which in turn will be used to determine knocking. Knocking occurs only during combustion period in the relevant cylinder, and therefore decided only within knocking judgment period in order to avoid faulty detection due to noise. ECU retards ignition timing when knock is detected and slowly advances the timing after no knock has been generated for a certain period of time, in the form of feedback control Maximum Retard Limit : 12˚ When knocking is detected : Initially retard 3˚and increase step by step with 0.75

69 Knock Sensor When Knocking happens it shows DTC and mainly ignition timing is retarded. 1 degree of ignition is nearly equal to 50 rpm. It means ignition timing retard means lack of power. When severe knocking happens in some case, piston or other moving parts can be severely damaged. Those chosen items are related with knock sensor. If knocking happens, ignition timing is retarded to certain range. Comparing normal condition with failures you can easily recognize its controlling. 1. Application : - MC 1.4 or Objectives - Understanding Knocking control 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro dual display function - Analyzing current data with DTC 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution]

70 NTC Resistor The ECM needs to adjust a variety of systems based on temperatures. It is critical for proper operation of these systems that the engine reach operating temperature and the temperature is accurately signaled to the ECM. For example, for the proper amount of fuel to be injected the ECM must know the correct engine temperature. Temperature sensors measure engine coolant temperature (ECT Sensor), intake air temperature (IAT Sensor) and oil temperature (OT Sensor) in CVVT system. In case of Job's Alpha 2 engine, it doesnt have any OT Sensor. Typically NTC type sensor is used. When resistance is increased, output voltage goes down as a result. No. 3 Pin for IAT The IAT sensor which is assembled together with AFS in 1.6 liter and with MAP in 1.4 liter Alpha 2 engine, detects the temperature of the incoming air stream. The IAT sensor is used for detecting ambient temperature on a cold start and intake air temperature as the engine heats up the incoming air. When it has any failure ECM is switched from its faulty value to ECT sensors as a limphome function.

71 IAT Sensor 1. Application : - MC 1.6 CVVT or MC Objectives - Measuring sensor output voltage - Measuring 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 items 5. Time to complete : 20 minutes 6. Reference : - [Notice] [Caution] IAT sensor is assembled with MAF sensor. When IAT value show too hot temperature, injection volume is limited resulting in lean condition. But with normal operation it doesnt make any big affect to engine control. When disconnection problem happens, both MAF and IAT value goes to fail together. IAT Output (V) k Signal Output Voltage 1.6 CVVT1.4 DOHC

72 ECT Sensor Function : The ECT sensor responds to change in engine coolant temperature. This sensor is critical to many ECM functions such as fuel injection, ignition timing, variable valve timing, transmission shifting etc. It always checks to see if the engine is operating temperature and reports its result to the ECM. Related DTC : P0117, P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] ECTPCM Pin No.Description 1C Signal 2ClusterTemp. Gauge 3C Ground

73 ECT value can easily be checked through hi-scan pro. With cold temperature, injection time is increased to compensate the wall film. If this sensor doesnt compensate this fuel shortage at cold temp. starting can be delayed or you can possibly have hard starting problem. ECT Output (V) k Signal Output Voltage ECT Sensor 1. Application : - MC 1.6 CVVT 2. Objectives - Measuring sensor output voltage - Measuring 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 items 5. Time to complete : 20 minutes 6. Reference : - [Notice] [Caution]

74 ECT Sensor Simulation Item1V2V3VSymptom Temp.( ) Injection Duration (m/s) Ignition Timing (BTDC) S/T Fuel Trim (%) ISA Duty (%) Engine Speed ,040 Discuss the result : When fake ECT value goes to ECM, it is cheated by fake temperature. Generally when temperature is low then injection duration is increased to compensate wall film condition. Wall film is such a technical usages which injected fuel sticks to intake runner or cylinder head surface because of cold temperature of fuel. When the temperature is cold then, also the weight of fuel is increased so as not easy to move. In case of ignition timing, it is also advanced for that reason so that engine rpm goes abnormally up. 1. Application : - MC Objectives - Understanding sensor simulation - Understanding related items 3. Required materials - Hi-scan pro 4. Procedure - Use Hi-scan pro simulation function at 90 more degree in ETS. - Analyzing related current data - Discuss the result with group member 5. Time to complete : 15 minutes 6. Reference : [Notice] [Caution]

75 Basic RPM & Rationality Check Above graph shows internal map of ignition timing and basic idle rpm controlling by ECM. When Temperature is low, ignition timing is advanced resulting in engine rpm increasing. If you have 1 degree of ignition timing advance, it is nearly the same of 50 rpm increasing. For A/F ration, when it is located in cold range it becomes to be rich condition. Left graph show rationality checking in OBD 2 system. After you drive some distance and check ECT output value, if there is any specific difference between target and real it will detect ECT failure. A/F ratio Ignition Area Basic Idle RPM Coolant Temp. A/F ratio Ignition TimingRPM

76 Ignition Coil Inspection 1. Application : - MC 1.6 CVVT 2. Objectives - Understanding individual ignition system with cigar type coil 3. Required materials - Multi meter - General tools 4. Procedure - Take out ignition system carefully - Measure coil resistance - Measure supplying voltage and control line voltage at Ig. On - Write down the result 5. Time to complete : 20 minutes 6. Reference : - [Notice] [Caution] Be careful not to touch spark plugs at hot temperature Coil / Connector No.1No.2No.3No.4 Voltage / Good/Bad (Ig. On) GGGGGGGG Coil () 0.9 Good/BadGGGG

77 Ignition Coil Test 1. Application : - MC 1.6 or Objectives - Understanding how to inspect ignition system - Understanding spark test - Understanding power balance test with hi-scan pro 3. Required materials - General tools - Spark Tester - Hi-scan pro 4. 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 rpm 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 minutes 6. Reference : - [Notice] [Caution] Coil1234 Good Bad GGGG Spark Test Cylin der 1234 Drop rpm Good Bad Goo d Power Balance Test

78 Primary Coil Waveform 1. Application : - MC 1.6 and Objectives - Measure the primary coil waveform 3. Required materials - Hi-scan pro 4. Procedure - Set Hi-scan pro to the vehicle - Using oscilloscope function, measure the primary coil 5. Time to complete : 15 minutes 6. Reference : - [Notice] [Caution] Primary Coil/Cylinder At Idle (Voltage/ms) 1234 Ignition off (V) 14 Maximum (V) 198 Ignition on (V) 0000 Duration (ms) 1.76

79 Ignition coil Current Consumption 1. Application : - MC 1.6 or Objectives - Understanding current consumption by ignition coil - Understanding how to use AMP meter 3. Required materials - Hi-scan pro - Amp meter - T connector 4. 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 result 5. Time to complete : 15 minutes 6. Reference : - Hi-scan pro optional manual [Notice] [Caution] Primary Coil No.1No.2No.3No.4 Current (A) Good/BadGGGG

80 Ignition Controlling Ignition Time/Cylinder1234 At Idle (BTDC) (BTDC)41 1. Application : - MC 1.6 or Objectives - Understanding ignition current data 3. Required materials - MC 1.6 or 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 result 5. Time to complete : 15 minutes 6. Reference : - Workshop manual [Notice] [Caution]

81 Spark Plug Inspection 1. Application : - MC 1.6 or Objectives - Understanding how to check spark plug 3. Required materials - General tools - Additional spark plug - Torque Wrench - Multi meter - Thickness gauge 4. 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 resistance - Measure each clearness - Writhe down the result 5. Time to complete : 15 minutes 6. Reference : - Workshop manual [Notice] [Caution] Spark PlugNo.1No.2No.3No.4 Condition k Gap(mm)1.1 TypeBKR5ES-11( ) RC10YC4( ) Good/BadGood

82 Injector Function : Electronically controlled fuel injector is a solenoid valve which supplies exactly calculated amount of fuel to engine for optimum combustion under various engine load and speed. To meet air fuel ratio required in system. ECM regulates fuel injection quantity as controlling injector solenoid operating duration referring air flow to cylinders and output signals from oxygen sensor. For this precise control, quick response of solenoid is required. Related DTC : P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] Injecto r No.1 PCM Pin No.Description 1Main RelayB+ 2C No.1 control

83 Injector Test Application : - MC 1.6 or Objectives - Understanding injector checking methods - Understanding injectors line to line voltage measuring - Understanding injectors resistance 3. Required materials - Multi meter - 1 unit of MC 4. 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 minutes 6. Reference : - Workshop manual [Notice] [Caution] Injector / Connector No.1No.2No.3No.4 Voltage / Good/Bad (Ig. On) GGGGGGGG Injector () 14.1 Good/BadGGGG

84 1. Application : - MC 1.6 or Objectives - Understanding injector checking methods - Understanding injectors operation - Understanding how to check injector leakage 3. Required materials - 1 unit of MC - 1 unit of stethoscope - General tools 4. Procedure Leakage checking - Remove fuel delivery 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 operation Write down the result 5. Time to complete : 15 minutes 6. Reference : - [Notice] [Caution] Leakage/Cylinder1234 Good/BadGGGG Injector Test - 2 Sound/Cylinder1234 Good/BadGGGG Operation Sound Leakage Test

85 1. Application : - MC 1.6 or Objectives - Understanding injectors checking methods - Understanding injectors operation - Understanding how to use vacuum pump - Understanding hi-scan pros actuation test 3. Required materials - 1 unit of test injector - vacuum pump - hi-scan pro - extension wire for shorting injector to battery 4. 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 injectors operation sound 5. Time to complete : 15 minutes 6. Reference : - [Notice] [Caution] Leakage/Cylinder1234 Good/BadGGGG Injector Test - 3 Actuation/Cylinder1234 Good/BadGGGG Actuation Test with Hi-scan Pro Leakage Test

86 Injector Test Application : - MC 1.6 or 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 result 3. Required materials - Hi-scan pro - 1 unit of MC 4. 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 result 5. Time to complete : 15 minutes 6. Reference : - [Notice] [Caution] Cylinder1234 Drop rpm 560 Good Bad Good

87 Injector Test - 5 Duration/Cylinder1234 At Idle(ms)2.8 2,000 (ms)2.5 Fuel Cut rpm6,500 Re starting rpm1, Application : - MC 1.6 or Objectives - Understanding injectors current data 3. Required materials - MC 1.6 or 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 result 5. Time to complete : 15 minutes 6. Reference : - Workshop manual [Notice] [Caution]

88 Injector Waveform 1. Application :] - MC 1.6 or Objectives - Understanding how to measure injector waveform - Analyze its signal 3. Required materials - Hi-scan pro with oscilloscope - 1 unit of MC - T-Connector 4. Procedure - Operate hi-scan pro with oscilloscope function - Measure injectors waveform from control line to ECM - Analyze its signal - Write down its result 5. Time to complete : 15 minutes 6. Reference : - [Notice] [Caution] Condition/Cylinder At Idle after warm up 1234 Injection off (V) 13.6 Injection On (mV) -800 Peak Voltage (V) 70.4 Duration(ms)3.2

89 Injector Current Consumption 1. Application : - MC 1.6 or Objectives - Understanding injectors current consumption 3. 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 AMP meter Injector 12 V supply line - measure current consumption at idle 5. Time to complete : 15 minutes 6. Reference : - Hi-scan pro optional manual [Notice] [Caution] Idle/Cylinder1234 Current(A) a b (ms) Duration(ms)2.8 ab

90 CVVT System CAMSHAFT-SPROCKET CAMSHAFT-EXHAUST CAMSHAFT-INTAKE CVVT BELT-TIMING CHAIN SPROCKET CHAIN-TIMING Retard Advance Rotating Direction of Engine Driving conditionIntake V/V TimingWhy ? At low loadRetardStable combustion At high load & high speedRetardImproved performance At high load & low speedAdvanceImproved Torque At middle conditionAdvanceIncrease fuel consumption PIN STOPPER ROTOR VANEHOUSING

91 CVVT Operation P D ROTOR VANE HOUSING VANE Advance Retard P D P EX BDCTDCBDC Ignition IN V/Lift C/Angle EX BDCTDCBDC Ignition IN V/Lift C/Angle EX BDCTDCBDC Ignition IN V/Lift Retard Advance Advance Hold

92 OCV Function : Different from the existing fixed cam phase angle type, CVVT is the device which varies cam phase angle continuously to be optimum. It operates by engine oil pressure. OCV controls the amount and direction of oil delivered to CVVT module by oil valve which is connected to a solenoid. If there is 3 more degree differences between target angle and real then it goes to limphome function and sets DTC of P0011 or P0012 Related DTC : P0011, P0012, P0075, P0076 OCVPCM Pin No.Description 1C OCV control 2Main RelayB+ 1. Application : - MC Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution]

93 OCV Control 1. Application : - MC 1.6 CVVT 2. Objectives - Measuring OCV Duty waveform 3. Required materials - Hi-Scan Pro - MC ETM 4. Procedure - Use Hi-scan pro oscilloscope function - With manual scope, measure the OCV control line duty - If necessary, write down signal characteristic 5. Time to complete : 15 minutes 6. Reference : - [Notice] [Caution] OCV is controlled by ECM with PWM but the duty is so various depending on engine load. Maximum advance of intake cam timing is set around 1800 ~ 2500rpm range. Of course you cannot say that rpm range as fixed range because ocv is not controlled only rpm factor. It is controlled mainly by engine load (Air inhaled volume / rpm) Cvvt status on means it doesnt have any failure. When it has any problem, it will show limp-home which all cvvt activation is prohibited. Calculated oil temp. is kind of reference value from ECT sensor. In case of Alpha engine with cvvt system, it doesnt have any oil temperature sensor.

94 CVVT Practice Application : - MC 1.6 CVVT 2. Objectives - Understanding basic inspection methods 3. Required materials - General scan tool - Air gun with compressor - Assembled CVVT module with intake camshaft 4. Procedure - Refer to workshop manual, check and test each CVVT related items such as - Timing Chain Alignment - Auto Tensioner - Oil Filter clogging - CVVT module rotation etc 5. Time to complete : 40 minutes 6. Reference : [Notice] [Caution] Air Test Oil Filter Clogging Check Auto Tensioner Check Timing Chain Align Check

95 CVVT Practice Application : - MC 1.6 CVVT 2. Objectives - Understanding how CVVT operates with current data - Understanding OCV controlling by engine rpm - Understanding CVVT status 3. Required materials - Hi-Scan Pro 4. 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 it 5. Time to complete : 15 minutes 6. Reference : - Workshop manual - CVVT system training guide book [Notice] [Caution] Item/rpmIdle Camshaft Position CVVT Duty (%,Open) Adaptation Angle #1124.1

96 CVVT Practice Application : - MC 1.6 CVVT 2. Objectives - Understanding OCV checking methods 3. Required materials - Multi meter - Power extension cable 4. Procedure Test 1 - Disconnect OCV connector - Measure resistance - Write down it - Check each connectors voltage - Write down the result Test 2 - Warm up the 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 minutes 6. Reference : - Workshop manual - CVVT system training guide book [Notice] [Caution] Test 1 Test 2 Symptom : When you supply direct power to OCV at idle condition, regardless of ECMs intension, it will go on advanced in intake valve timing. This additionally inhaled air will make engine fluctuated at idle. If you have this kind of fluctuation at idle simply disconnect OCV whether it is recovered or no. 1. Resistance : Voltage output - No.1 Pin to GND : 3.2V - No.2 Pin to GND : 13.2V

97 CVVT Practice - 4 Advanced in Valve Timing. Approximately 30 degree. Since Each CKP tooth becomes 6 degree in CKP angle.

98 ISA Function : The ISA is designed to maintain a steady desired idle speed. Idle airflow is adjusted through the idle air actuator in order to maintain the desired idle speed under various load conditions. Load conditions vary due to numerous factors, such as engine temperature, air conditioning, electrical load and power steering etc. Two coil type of ISA is used. At idle condition control duty for open coil shows around 25 ~ 28%. When there is a 100 more or less rpm difference between target and real then ECM sets P0506 or P0507 DTC. Related DTC : P0506, P0507, P1505 ~ P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM write down each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] ISAPCM Pin No.Description 1C01-2 6Open control 2Main RelayB+ 3C Close control

99 ISA Waveform Main function of ISA controlling is sustaining engines perfect idle running. These days fuel consumption concern is quite big issue in customers. To meet need demand it is inevitable to make lower idle rpm. In case of MC idle rpm is around 650rpm using CVVT method and fine controlling. At idle condition ISA opening duty shows around 26% without any electrical load. ISAIdleWOT Duty (%) Signal Output Voltage 1. Application : - MC Objectives - Measuring ISA waveform 3. 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 data 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution]

100 PCSV Function : The purge solenoid is a pneumatic device that meters the air and fuel vapor flow to the purge port. In a sense, the purge solenoid is comparable to a fuel injector, because the metered purge flow follows the same slope and offset characteristics. However, the purge solenoid normally runs whit a duty cycle at a fixed frequency because the opening response is significantly slower than a fuel injector. The normal frequencies for the purge solenoid are between 8 to 20 Hz. Related DTC : P0444, P0458, P0459, P0496, P Application : - MC 1.4 or Objectives - Understanding circuit diagram - Understanding each pin assignment 3. Required materials - MC ETM 4. Procedure - Using MC ETM find each pin description - Write down sensor function - Write down Related DTC and failure symptoms 5. Time to complete : 15 minutes 6. Reference : - MC ETM - MC Workshop manual [Notice] [Caution] PCSVPCM Pin No.Description 1Main RelayB+ 2C01-2 8PCSV control

101 PCSV Waveform PCSVIdle3000 Duty (%) 0~ Signal Output Voltage 1. Application : - MC Objectives - Measuring ISA waveform 3. 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 data 5. Time to complete : 20 minutes 6. Reference : [Notice] [Caution] When engine load is increased, generally purge goes on condition. Resistance at normal temperature shows : 16 ohmn. When you disconnect connector and measure the voltage output of control line it will show 3.5 V. In case it has some abnormal controlling such as normal opening, fuel trim will be changed and idle control will be destroyed because of the additional air and fuel gas.

102 ISA & PCVS Purge phase becomes the maximum 100% when engine load is applied.

103 Immobilizer - Smartra Function : Smartra immobilizer system is applied to MC. ECM has a responsibility to control the immobilizer function instead of ICM. Also current data and key coding methods are totally different. Immobilizer related DTC in Smartra is shown in Engine section.

104 In current data, you can see key teaching status. Teaching section is for general key teaching. Pin code is needed when you conduct it. Password teaching is for limp home. This password which has 4 digits is only used for limp home. When you lost it, then you can virgin through neutral mode. There is one section allocated in hi-scan pro operation, Immobilizer. Here you can make key coding, password teaching and immobilizer neutral. Pin code should be strictly controlled. Whenever you lost yours, contact TSC to find it. Pin code is kind of combination from VIN. Hi-scan Pro Operation 1. Application : - MC 1.6 or Objectives - Understanding current data - Understanding actuation function - Understanding MC Immo. System - Utilizing hi-scan pro operation 3. Required materials - Hi-Scan Pro 4. Procedure - Use Hi-scan pro current data function - If necessary, use flight record function for better practice - Discuss the result with your group 5. Time to complete : 120 minutes 6. Reference : [Notice] [Caution ]

105 Immobilizer Wake up Communication between Transponder and ECM via Smartra