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Samand
Injection System Presentation
1
Samand
Table of Contents...
• General Information
• Fuel Supply Function
• Air Supply Function
• Ignition Function
• Injection Function
• Petrol Vapour Recycling Function
• Driver's Information Function
• Schematic Diagram
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Samand
General Information…
1. Foreword:
Application: this injection-ignition operating principle applies to various engines.
The application may lead to slight installation variations.
This injection controls the engine's injection and ignition using, in particular, the inlet air
pressure and engine speed information.
Features:
• “Sequential” injection (4 electromechanical injectors).
• Programmed injector opening time (cartographic map).
• Integral electronic ignition (twin static).
• Cartographic advance.
• Management of engine cooling.
The SAGEM S2000 , BOSCH MP7.3 and BOSCH ME7.4.4 injection systems is used to
fulfil the following standards.
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Samand
General Information…
2. Presentation:
Petrol injection system may be broken
down into 3 sections:
•
•
•
The electrical system built round an
electronic control unit (ECU) witch
controls the different actuators on the
basis of the information received from
sensors.
A fuel system witch provides the
pressure and feeds the fuel to the
injectors.
An air system witch carries out filtering
and mixing of the intake air.
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General Information…
3. Precautions when working on the fuel system:
•
The fuel system referred to in this book is defined as the external mounted fuel pump, fuel filter, the
fuel injectors (fuel rail/inlet manifold assembly) pressure regulator and all the fuel lines between these
components. All these contain fuel which will be under pressure while the engine is running, and/or
while the ignition is switched on. The pressure will remain for some time after the ignition has been
switched off, and must be relieved in a controlled fashion when any of these components are
disturbed for servicing work. 1 Disconnect the battery negative terminal. 2 Place a container beneath
the connection/union to be disconnected, and have a large rag ready to soak up any escaping fuel
not being caught by the container. 3 Slowly loosen the connection or union nut to avoid a sudden
release of pressure, and wrap the rag around the connection, to catch any fuel spray. Once the
pressure is released, disconnect the fuel line. Plug the pipe ends, to minimise fuel loss and prevent
the entry of dirt into the fuel system. The fuel tank has no drain plug. When work on the fuel system
requires the tank to be drained, this can be done with a separate tank draining unit via the fuel filler
pipe. Important. Scrupulous cleanliness is of the utmost importance when working on the fuel
system. Prevent dirt, etc. from entering the fuel tank and fuel lines. Warning. Emptying the fuel tank
involves partial dismantling of the car's fuel system. The following points must therefore be observed
in connection with this work:
- Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapour is
available, be sure to use it.
- Wear suitable gloves. Prolonged contact with fuel may give rise to skin irritation or dermatitis.
- Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by
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short-circuits and when connecting and disconnecting leads, etc, in electrical circuits/.
- No smoking anywhere in the vicinity.
Samand
Fuel Supply Function…
1. System overview:
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5
2
1
10 11
3
6
9
8
9
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•
•
•
•
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( 1 ) Fuel filler.
( 2 ) Fuel tank.
( 3 ) Fuel gauge sender unit (level).
( 4 ) Fuel pump.
( 5 ) Fuel filter.
( 6 ) Fuel feed pipe.
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•
•
•
•
•
( 7 ) Inlet manifold.
( 8 ) Pressure regulator.
( 9 ) Injectors.
(10) Fuel return pipe.
(11) Fuel drain.
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Fuel Supply Function…
2. Fuel tank:
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21
•
•
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(21) Screws and retaining clamps.
(22) Fuel tank.
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Fuel Supply Function…
3. Fuel pump:
•
•
The fuel is fed through the petrol pump witch draws the fuel from the tank.
It may be submerged in the tank.
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Fuel Supply Function…
4. Fuel filter:
•
The fuel filter is mounted in the pressure line between the fuel pump and the fuel
injection manifold at the front right-hand side to the fuel tank. The purpose of the filter is
to strain out impurities and other foreign matter in the fuel and so prevent clogging of the
injectors. The filter contains a paper element and after it a strainer to catch any paper
fragments that may have worked loose. A support locates the filter element in the
housing, which is made of metal. It is essential that the fuel flow is in the direction as 9
shown on the filter body. Its filtering surface is around 3000 cm2.
Samand
Fuel Supply Function…
5. Fuel pressure regulator:
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The pressure regulator is mounted on the end of the intake manifold/fuel supply line assembly.
The pressure regulator maintains a constant ratio between the fuel pressure and the pressure
in the air induction pipe. This ensures that the amount of fuel injected is determined
exclusively by the opening duration of the electromagnetic injectors. The pressure regular is a
diaphragm-controlled overflow valve set for 2.5 bar. It consists of a metal housing divided into
two chambers by a press-fitted diaphragm. In one of the chambers a spiral spring presses
against the diaphragm while fuel flows through the other chamber. If the pre-set pressure is
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exceeded a valve controlled by the diaphragm exposes an opening to the return line through
which superfluous fuel can flow back to the fuel tank.
Samand
Fuel Supply Function…
6. Injector:
•
•
The injectors are concealed within the fuel supply line and fed from the side. The fuel
injectors are electromagnetic pintle valves, which spray atomised fuel into the
combustion chambers under the control of the engine management system ECU. There
are four injectors, one per cylinder.
Each injector is mounted at an angle that allows it to spray fuel directly onto the back 11
of
the inlet valve.
Samand
Air Supply Function…
1. System overview:
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7
2
5
6
4
1
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( 1 ) Air intake.
( 2 ) Air filter.
( 3 ) Air chamber.
( 4 ) Intake air pipe.
•
•
•
( 5 ) Throttle body.
( 6 ) Idle control step motor.
( 7 ) Intake air thermistor.
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Air Supply Function…
2. Air filter:
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•
( 4 ) Filter element.
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Air Supply Function…
3. Inlet manifold:
Fuel Tank
• Total capacity Approx.
• Fuel remaining when fuel reserve warning lamp lights up Approx.
• Minimum octane rating
• Spark plugs type
• Idle speed
• Fuel pump type
• Pressure regulator
70 Litres
7 Litres
95 Ron unleaded
FC 52 LS Gap -.0.8
850 ± 50 rpm
Electric, in tank 14
3, bars
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Air Supply Function…
3. Inlet manifold:
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3
2
1
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( 1 ) Inlet manifold and fuel supply line.
( 2 ) Injectors.
( 3 ) Regulator.
The inlet manifold is of plastic construction. The fuel supply line which carries the
injectors is built into the inlet manifold.
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Air Supply Function…
3. Inlet manifold:
Gallery fuel
A
Injector
•
•
The fuel injection manifold is mounted on the cylinder head. It is used to secure the
injectors and the petrol pressure regulator, when slaved to engine load.
Schrader valve (A) is used on the recent systems to drop the pressure in the system
and for the pressure and fuel delivery testing.
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Air Supply Function…
4. Idle control step motor:
•
This motor is mounted on the throttle housing and is electronically controlled by the
ECU. It governs the flow of air from the throttle valve so as to:
- Provide additional air when starting from cold
- Control idling speed according to engine load and temperature
- Improve transient phases (return to idle).
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Air Supply Function…
5. Catalytic converter:
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The catalytic converter uses a chemical principle, catalysis, to reduce the pollution
content in the exhaust gases.
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Samand
Ignition Function…
1. DEPHIA:
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DEPHIA (=detection of phase integrated in the ignition system)
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In order to drive separately the injectors, the ECU needs to know witch cylinder is in
compression phase. The strategy DEPHIA is used to obtain this information. This
strategy consists of using a signal coming from the ignition coll.
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Ignition Function…
2. Twin static ignition:
•
•
Twin static ignition systems comprise two coils with two high-voltage outputs fitted in a
single unit.
One of the two sparks is produced in the cylinder at the end of the exhaust cycle.
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Injection Function…
1. Synoptic Diagram:
1261: Accelerator pedal position sensor.
1120: Knock sensor.
1313: Engine speed sensor.
1020: Alternator.
1620: Vehicle speed sensor.
8007: Pressostat.
4020: Engine coolant thermal switch.
4005: Coolant temperature sensor.
1350: Upstream oxygen sensor.
1351: Downstream oxygen sensor.
BM34: Engine fuse board with 34 fuse(s).
1211: Fuel gauge pump.
1312: Induction air pressure sensor.
BSI1: Built-in systems interface.
1320: Engine management control unit.
1262: Motorised butterfly.
7001: Power steering fluid pressure switch.
C001: Diagnostic connector.
1135: Ignition coil.
1215: Purge canister solenoid valve.
1331: Injector cylinder no.1.
1332: Injector cylinder no.2.
1333: Injector cylinder no.3.
1334: Injector cylinder no.4.
1630: Automatic transmission control unit.
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Injection Function…
2. Throttle housing:
3
2
4
1
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( 1 ) Injection potentiometer.
( 2 ) Throttle housing heating resistor.
( 3 ) Idle control step motor.
( 4 ) Inlet air thermistor.
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Injection Function…
3. Inlet manifold pressure sensor:
•
•
The intake manifold pressure sensor continuously measures the pressure inside the
intake manifold. It is of the Piezo-electric pre-selections type (pressure-controlled
sensor).
Supplied at 5 volts by the ECU the sensor sends back a voltage which is in proportion
to the measured pressure. This information allows the control unit to adapt the injected
flow to the various lead conditions of the engine and to the difference of altitude. This
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information is also used for charging the ignition advance.
Samand
Injection Function…
4. Throttle Potentiometer:
•
•
It informs the control unit of the position of the throttle butterfly. This information is used
for recognition of the foot off full throttle and transition positions for the acceleration,
overrun and injection cut-off strategies.
It is supplied with 5 V by the control unit and returns to the control unit a voltage varying
with the position of the throttle butterfly. It also provides emergency operation if the 24
manifold pressure sensor fails. It is not adjustable.
Samand
Injection Function…
5. Accelerator Pedal Sensor:
•
This sensor tells the ECU when the driver wishes to accelerate (accelerator pedal
position).
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Injection Function…
6. Motorized Butterfly:
On vehicles fitted with this device, the throttle is no longer controlled directly by a cable from
the accelerator pedal, but by an electric motor and gears.
The ECU opens the throttle on the basis of several parameters.
• Driver action (accelerator pedal sensor)
• Requirements of other systems (automatic transmission, air conditioning, cruse control,
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etc.).
Samand
Injection Function…
7. Inlet air thermistor:
•
•
This thermistor, located on the throttle housing, informs the ECU of the temperature of
the intake air.
It's electrical resistance is of the NTC type.
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Injection Function…
8. Throttle housing heating resistor:
•
It is of the PTC (positive temperature coefficient) type. Mounted in the throttle housing,
its purpose is to prevent icing.
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Injection Function…
9. Engine Speed Sensor:
•
•
The engine speed and position information is supplies by an inductive sensor mounted
on the clutch housing.
This sensor detects a toothed wheel from witch two teeth (A) have been removed in
order to determined the crankshaft position.
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Injection Function…
10. Engine Coolant Temperature Sensor:
•
Located on the water outlet housing, the engine water temperature sensor informs the
ECU of the engine temperature status by measuring the coolant temperature.
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Injection Function…
11. Mixture Regulation Oxygen Sensor:
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Fitted upstream of the catalytic converter, the oxygen sensor (O2 or lambda)
continuously measures the exhaust gas oxygen content. The ECU calculates the actual
mixture and corrects the injection time.
A built-in heating element accelerates sensor warm-up time.
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Injection Function…
12. Knock Sensor:
•
A piezo-electric sensor, located on the engine block, informs the ECU of engine preignition by means of an electrical signal.
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Injection Function…
13. Vehicle Speed Sensor:
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A sensor on the gearbox output informs the ECU of the vehicle speed. This information
is used to improve vehicle low speed drive ability.
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Injection Function…
14. Multifunction double relay:
•
The dual relay allows an electrical feed to the ECU, ignition coil, fuel pump, injectors,
idle control step motor, purge canister solenoid valve and the throttle housing heating
resistor.
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Injection Function…
15. Inertia switch:
•
This is a safety switch which disconnects fuel in accident.
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Injection Function…
16. Power Steering Pressure Switch:
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•
A pressure switch is located on the power steering hydraulic high pressure circuit.
It informs the ECU if a pressure threshold is exceeded.
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Injection Function…
17. Electronic Control Unit (ECU):
The ECU uses the information from the different sensors and using the program and
mappings in its memory, it actuates the following:
• Double relays (power supply to petrol pump, etc.)
• Injectors
• Ignition coil
• Canister purge solenoid valve
• Idle actuator
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Petrol Vapour Recycling Function…
1. Canister:
•
Fitted to the fuel tank vent, the canister traps escaping fuel vapours.
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Petrol Vapour Recycling Function…
2. Canister Purge Solenoid valve:
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Controlled by the ECU, the canister purge solenoid valve is used to draw the vapours in
the canister into the engine, based on the engine operating conditions.
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Samand
Driver's Information Function…
1. Diagnosis Light and European On-board Diagnosis (EOBD):
•
•
The ECU has an on-board diagnosis system witch alerts the driver in case of an
electrical or emission control systems fault (EOBD). It memorizes the faulty functions.
The ECU uses a back-up strategy in order to run the engine if certain parts of the
system should fail.
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Schematic Diagram…
1. Bosch ME7.4.4:
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Samand
Schematic Diagram…
2. Sagem S2000:
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IKCO
Samand
… The End
Questions ?
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