Basic Training Course
Basic Training Course
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The ECU must foresee to control the engine in any
state:
Cranking
Idle
«Normal»
Maximum revolutions (RPM limiter)
Acceleration/braking
Partial malfunctioning
…
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The ECU Operating System controls the engine
through:
Software
(control «strategies»)
Maps
(relationships between sensors’ and actuators’ signals)
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A bad engine management can result from:
Operating System
Solution: ECU replacement, recall campaign
(in case of «serious» problems)
Probability: Low
Cost: High
Software or Maps
Solution: Update of the «stock original file» of the ECU
(using the official «Diagnostic Tester» in a brand dealer)
Probability: High
Cost: Low
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The performances of an electronically-controlled
combustion engine (torque, power, fuel
consumption, emissions) can be modified by
modifying the maps of the stock original file
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Increase torque and power:
Cars, Motorbikes
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T
It is similar to force:
to apply torque to a body means w s
to accelerate its revolution
R
It is responsible for the
acceleration of a vehicle: F
R = Wheel Radius [m]
high T = high acceleration F = Force [N]
T = F x R = Torque [Nm]
w = Wheel angular velocity
[rad/s]
s = Vehicle speed [km/h]
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«Engine torque» is the torque which the engine
generates on the crankshaft
(responsible for the «drive» on the transmission)
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It depends on:
R1 T1
engine torque
(at the considered RPMs) w1 T2
selected gear w2
(gear ratio) st
R2
Ever greater than engine torque:
(Rwheel > Rcrankshaft G < 1)
G = Gear Ratio
𝑤2 𝑅1
However, there are mechanical losses 𝐺= =
𝑤1 𝑅2
(transmission, distribution, …) 𝐶2 = 𝐶1 𝐺
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Tw 3 main things:
𝐹 𝑇𝑤 𝑅
w a 𝑎= =
𝑚 𝑚
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It is the ratio between consumed energy and considered
time:
P=E/t
Measurement Units:
kW
Horsepower: HP, CV, PS, … (1 kW ≈ 1.36 HP)
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Related to vehicle speed:
to keep a vehicle at constant speed it is necessary to «spend»
power in order to contrast frictions and aerodynamic
resistance
So, if T is constant:
RPM P
RPM P
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g/km
3
2,72 CO
2,5 HC + NOx
Particolato
2
1,5
1
0,97
1
0,75
0,64
0,56
0,5 0,5
0,5 0,3
0,25
0,14
0,08
0,05 0,025 0,005
0
EURO 1 EURO 2 EURO 3 EURO 4 EURO 5
20
g/km
3
2,72 CO
2,5 HC + NOx
2,3
2,2
Particolato
2
1,5
0,97 1 1
1
0,5
0,5 0,35
0,18 0,135
0,005
0
EURO 1 EURO 2 EURO 3 EURO 4 EURO 5
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It is a chemical reaction involving precise quantities (weight) of:
Combustible (petrol, diesel, etc.)
Combustive agent (oxygen in the air)
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AFR (Air Fuel Ratio) = kg air / kg combustible
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The oxygen sensor (Lambda probe)
senses the percentage of oxygen
(O2) in the exhaust gases:
«Normal» sensors:
0.8 < λ < 1.6 → 11.8 < AFR < 23.5
«Wide-band» sensors:
0.7 < λ < ∞ → 10.3 < AFR < ∞
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«Normal» (4 wire) and «wide-band» (6 wire) sensors
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Single sensor: upstream of the catalytic converter
Double sensor: one upstream, one downstream of the catalyst
(more accurate carburetion, efficiency control over the catalyst)
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It reduces emissions of the 3 main pollutants (HC, CO, NOx)
Three types:
Reduction (NOx)
Oxidation or Two-way (HC, CO)
Oxidation-reduction or Three-way (HC, CO, NOx)
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Spark ignition
(control of spark advance)
Control parameter:
Air quantity
(a petrol engine always runs near to the A: Intake C: Power
stoichiometric ratio) B: Compression D: Exhaust
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The cylinder is filled with air, or mixture
in case of indirect injection
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The piston’s return to the TDC
compresses the mixture,
increasing its P and T
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The high T and P cause the
burning mixture to expand in
the cylinder
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The piston returns to
the TDC expelling the
exhaust gases through
the exhaust valves
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Air Intake
MAF
Filter manifold
m [kg] T [°C] %
tacc
ECU Engine
T [°C]
λ T [°C] λ
Exhaust
λ2 CAT λ1
manifold
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It supplies the correct fuel amount to create the
optimal air/petrol mixture
Evolution:
Carburetor
Forced mechanical injection
Indirect electronic injection
Direct electronic injection
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1) Closed throttle valve 2) Open throttle valve
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System initially used in planes and racing cars
because simple and reliable
Coil
Combustible
Nozzle filter
Valve spring
Piston
Fuel spray
ECU-controlled engines:
Closed Loop:
The ECU corrects the injection in order to maintain λ = 1
Open Loop:
The ECU increases the injection in order to maintain λ < 1
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MAF/
Engine λ Exhaust
MAP
Injection ECU
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MAF/
Engine λ Exhaust
MAP
Injection ECU
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Air Intake
MAF
Filter manifold
MAP
Air Intake
Filter manifold
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Limits intake airflow
Connected to the
accelerator pedal by wire
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Limits intake airflow
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Mass Air Flow sensor
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It senses air pressure in the intake
manifold (Manifold Absolute
Pressure)
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Inside the intake duct (IAT)
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It senses atmospheric pressure
(Absolute Pressure Sensor)
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Roots, Lysholm screws, scroll-type, …
Turbine Compressor
wheel wheel
Shaft
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Compressor
wheel Exhaust
snail
Intake
snail
Turbine
Shaft wheel
Variable vanes
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Wastegate:
gives vent to the excess
pressure of the exhaust
gases
Pop-off:
gives vent to the excess
pressure of the compressed
air at the intake
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Ignites the air-fuel mixture with proper
advance
Evolution:
Distributor
Distributor with variable advance
Electronic ignition timing
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Compression ignition
Control parameter:
fuel quantity A: Intake C: Power
(a Diesel engine always runs lean) B: Compression D: Exhaust
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The cylinder fills with air
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The return of the piston
to the TDC compresses
the air, increasing P and T
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High temperature ignites the
mixture, causing its expansion
in the cylinder
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After expansion, the
piston returns to the
TDC expelling the
exhaust gases through
the valve
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1. Air filter 11. Turbo pressure sensor
2. MAF (Manifold Absolute Pressure) 12. Engine
sensor 13. Electro-pneumatic turbo pressure
3. Turbocharger (high-pressure stage) regulation valve (exchange between
4. Turbocharger (low-pressure stage) high- and low-pressure stages)
5. High-pressure stage supercharging 14. Electro-pneumatic turbo pressure
pressure regulation valve regulation valve (wastegate) (high-
pressure stage)
6. IAT (Intake Air Temperature) sensor
15. Catalytic converter
7. Intercooler
16. FAP (anti-particulate filter)
8. Electronic throttle valve
17. Muffler (silencer)
9. EGR (Exhaust Gas Recirculation)
valve 18. ECU (Engine Control Unit)
10. EGR gas heat sink
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It injects the correct amount of Diesel at the end of the
compression stroke
Evolution:
Mechanical pump
Pump injector (unit injector)
Common Rail
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1. ECU (Engine Control Unit) 9. EGR control
2. MIL (Malfunction Indicator Lamp) 10.Injector
3. Glow-plug check lamp 11.Glow-plug
4. MAF (Mass Air Flow) sensor 12.Glow-plug relay
5. Turbocharger with wastegate 13.Engine RPM sensor
valve 14.ECT (Engine Coolant Temperature)
6. Turbocharger charge pressure sensor
control electrovalve 15.Mechanical pump
7. MAP (Manifold Absolute Pressure) 16.Accelerator pedal sensor
sensor
17.CAN Bus
8. EGR (Exhaust Gas Recirculation)
18.OBD-II connector
valve
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Simple electrovalve
Cheap
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«Hybrid», it internally generates
the high pressure (about 2000
Bar)
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1. High-pressure fuel circuit 10.Fuel filter and temperature sensor
2. Low-pressure fuel circuit 11.High pressure fuel return circuit
3. Fuel filters cooler
4. Throw pump 12.Fuel pressure regulator
5. Fuel level 13.Injectors
6. Connection of the low pressure
fuel return circuit
7. Connection of the low pressure
fuel feeding circuit
8. Connection of the high pressure
fuel feeding circuit
9. Connection of air bleeding
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1. Fuel tank 10.Fuel pressure regulator
2. Electrical fuel pump (low-pressure 11.High-pressure accumulator (Rail)
circuit) 12.Fuel pressure sensor
3. Fuel filter 13.Injectors
4. Fuel heater 14.Fuel pressure limiter valve
5. Pre-charge fuel tank 15.Vent valve
6. Fuel temperature sensor
7. Mechanical wheels pre-charge
pump
8. Electrical fuel pump (high
pressure circuit)
9. Fuel dosage valve
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Simple electrovalve
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MAP
Air Intake
COMP Intercooler
filter manifold
Intercooler:
it cools down air after the compressor
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Essential on Diesel engines:
↑ torque since low revolutions
↑ power at high revolutions
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Exhaust Intake
snail snail
Turbine Compressor
wheel wheel
Shaft
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Compressor
wheel Exhaust
snail
Intake
snail
Turbine
Shaft wheel
Variable vanes
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Wastegate:
gives vent to the excess
pressure of the exhaust
gases
Pop-off:
not used in Diesel engines
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Diesel engine Vs. Petrol engine:
it is more efficient (- 30 % fuel consumption)
it generates less HC, CO, and CO2, but more NOx and
particulate
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Particulate reduction through filtering
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Diesel engine evolution increased the
compression ratio:
T particulate NOx
Main problems:
EGR locks close: much O2, much NOx, few
particulate, more torque than normal
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AdBlue tank
DOC + DPF
AdBlue injection N2 + H2O
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NOx reduction through Selective Catalytic Reduction
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The performances of an ECU controlled
engine (torque, power, fuel, emissions)
can be tuned just modifying the stock
original file
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Reading the stock original
file of the Engine Control
Unit (ECU)
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INDEX Updated FUNCTIONS Updated MAPS
for engine for engine
management SW management
File size: 8 kB – 4 MB
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It is the «brain» that controls the
engine
Managed systems:
Sensors
Injection system
Ignition system (petrol)
Air system (+ turbo if turbocharged)
Emission reduction systems
…
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In an external Flash memory chip
(most common case, or in an EPROM chip for old ECUs)
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1. Microcontroller
It executes calculation
(it «employs» only numbers)
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2. Flash («EPROM»)
Engine data memory
Security:
VIN (Vehicle Identification Number)
Key codes
Immobilizer
Diagnostic Trouble Codes (DTC) (opt.)
Configuration:
Mileage (opt.)
Wheel size supported list
Injectors codification (opt. for Diesel)
Speed limiter (opt.)
Serial flash counters (opt.)
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4. External connectors
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2 - J1850 Bus + 10 - J1850 Bus -
4 - Chassis Ground 14 - CAN Low
5 - Signal Ground 15 - L Line
6 - CAN High 16 - Battery Power
7 - K Line
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5. Microcontroller communication
interface
It can be called:
Relating to:
version of the electrical circuit
(Micro, memories , «optional» components)
version of the Operating System
For Bosch:
0 281 xxx xxx = Diesel
0 261 xxx xxx = Petrol
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It identifies:
version of the updated functions for Micro’s OS
version of the maps for engine management
111
Bosch
10%
4%
4% Siemens
16%
Delphi Lucas
66%
Magneti Marelli
112
Diesel: EDC x e.g.: EDC 16U31
EDC = Electronic Diesel Control
V = Distributor injection pump (Verteiler Einspritzpumpe) (e.g. EDC 15V)
P = Pump-nozzle (Pumpe-düse) (e.g. EDC 15P)
U = Pump-nozzle (e.g. EDC 16U, EDC 17U)
C = Common Rail with 1 MB external Flash chip (e.g. EDC 16C)
CP = Common Rail with 2 MB external Flash chip (e.g. EDC 16CP, EDC 17CP)
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Siemens (Diesel): P x e.g.: PPD 1.5
PD = Pump injector (Pumpe-düse)
CR = Common Rail
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Old EPROM chips had low reliability
115
Checksum verification during cluster switch-on
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There are 3 possibilities:
Diagnostic port
(e.g. KESSv2)
Microcontroller communication
interface
(e.g. K-TAG)
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Always possible using
«Original Files Request»
from Alientech Data Bank
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It is the software to use to
manage Alientech tools:
KESSv2
K-TAG
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It is a serial flasher through diagnostic port
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Cables included in the standard offer:
OBD-II standard cable
Universal cable (with «OBD-I» plug for the Fiat/Alfa/Lancia group)
K4 cable
Options:
Diagnostic «OBD-I» cables (e.g. BMW, Mercedes, Porsche, …)
Specific cables for trucks and tractors
Tricore plug-in
(it transforms KESSv2 in a cloning device for Bosch «Series 17» ECUs)
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BMW Series 1 E88 118i 2000 16V 143 CV:
Connection: OBD-II cable
BMW Series 3 E36 318 1900 16V 116 CV:
Connection : Universal or BMW «OBD-I» cable
Alfa Romeo 145 II 1400 16V TS 103 CV:
Connection : Universal or OBD-II cable
Note: Forbidden reading, Flashing enabled using the blue cable
Renault Megane III 1900 cc 8V dCi 130 CV:
Connection : OBD-II cable
Note: Injector coding, Engine temperature, Electronic key card
VW Jetta V 1900 8V TDi 105 CV:
Connection : OBD-II cable
Note: Flash counters
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BMW MS 52-MS 54:
Connection : OBD-II cable
Note: File cutting required (2 flash chips, Utility menu)
Fiat Grande Punto 1300cc 16V MJet 75 CV CAN:
Connection : OBD-II cable
Note: Forbidden reading, File cutting required (Micro + Flash, Utility menu)
Fiat Grande Punto 1300cc 16V MJet 75 CV K_Line:
Connection : OBD-II cable
Note: Forbidden reading, File cutting required (Micro + Flash, Utility menu)
Fiat Punto II 1200 16V 80 CV:
Connection : On desk using K4 cable
Note: «Hybrid» ECU
Bosch ME7.9.10 (Fiat 500 II etc.)
Connection : On desk using K4 cable
Note: Bootloader ST10Fxxx (Extras menu)
Bosch EDC17 BMW
Connection : On desk using the Tricore plug-in
Note: Bootloader Tricore (Extras menu)
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It is a reader/programmer directly interfaced
with the microcontroller
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Two ways to communicate with an ECU:
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CHIP-TUNING SOFTWARE EVOLUTION
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Software integrated in a special 8 GB USB flash drive
It can store:
Original files
Modified files
Driver files (maps positions)
Checksum algorithms
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Each time ECM Titanium is started, if the PC is
connected to Internet, the software will search
for available updates
174
Two kinds of updates:
Automatic
Manual
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Automatic updates download:
New ECM Titanium SW version
New ECM Upgrade SW version
(software for the updates)
New Drivers list
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The database contains all the files loaded (ORI) and
modified (MOD) to date using ECM Titanium and
stored in the internal 8 GB memory
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When a new stock original file is loaded, ECM
Titanium asks if the user wants to save it in the
integrated personal Database
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Saving files in the Database, when a stock
original file already stored is opened ECM
Titanium warns the user that the Database
already contains a file similar to the loaded one
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When a new modified file is created, ECM
Titanium asks the user if he wants to save it in
the integrated personal Database
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What is a Driver?
It contains the positions of the maps in the loaded
stock original file
It groups the maps into categories
(Air, Injection, Turbo, Spark advance…)
It contains the number of the proper Checksum
algorithm
(it is useful only if the flashing tool does not automatically
correct Checksum)
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When you open a stock original file with ECM
Titanium, the SW automatically searches for the
proper Driver
Four possibilities:
Driver file to be downloaded
Driver file already downloaded
Driver file update available
Driver file not found → Driver request
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If the driver is not available it is possible to use
«Drivers Request»
from the Alientech Data Bank
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Checksum is an algorithm for the validation of
the modified file for the ECU
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Checksum correction using ECM Titanium is
possible only if the proper Checksum family has
already been downloaded
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The software allows to view and modify files using
different windows, useful for different purposes:
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If the loaded stock original
file is not associated to a
driver, it is only possible
to use the views:
2D graphics
Hexadecimal
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