ECU Repair Course Study Guide.pdf

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filat1985@gmail.com 21 Sep 2023
filat1985@gmail.com 21 Sep 2023
SUMMARY
INDEX
PRESENTATION.........................................................................................................................................3
OBJECTIVE OF THE SYSTEM..................................................................................................................... 4
DIGITAL CENTRAL..............................................................................................................................10
CENTRAL SIMULATOR.......................................................................................................................16
ANALYZE WAVE FORMS........................................................................................................................... 16
Analog DC Voltage Signals C Ç......................................................................................... 17
AC AC voltage signals........................................................................................................ 20
Frequency modulated signals............................................................................................ 21
Modulated pulse width signals.......................................................................................... 24
Serial data signals............................................................................................................... 27
INTERPRETING WAVE FORMS.......................................................................................... 27
TESTING OF COMPONENTS.............................................................................................. 30
4 Zener diode or rectifier.................................................................................................... 31
8 Voltage Regulator............................................................................................................. 32
5.1.1 - TEST OF RESISTORS:............................................................................................. 32
DIODES TEST...................................................................................................................... 36
Rectifier Diode Test............................................................................................................. 36
Test Bipolar Transistors (NPN, PNP).................................................................................38
PROCESSOR TEST............................................................................................................. 39
EPROM TEST............................................................................................................................................. 42
TEST SOCKET 27C512........................................................................................................ 44
SOCKET FOR PLANTS BOSCH MP9.0..............................................................................46
5.1.4 EPROM REPROGRAMMING......................................................................................47
Bi-fuel socket for Delco control units................................................................................51
BANCADA CENTRAL TEST................................................................................................ 52
POWER TEST 12v and 5v................................................................................................... 52
Rework on SMD plates........................................................................................................ 56
SMD PLATE Rework............................................................................................................ 56
Types of SMD components................................................................................................ 56
SMD components rework station......................................................................................58
SMD desoldering................................................................................................................. 59
SMD welding - Step 1.......................................................................................................... 60
SMD welding - Step 2.......................................................................................................... 61
SMD welding - Step 3.......................................................................................................... 61
SMD welding - Step 4.......................................................................................................... 62
filat1985@gmail.com 21 Sep 2023
PRESENTATION
The management and command system for operating a vehicle
today is fully automated to achieve better performance, lower fuel
consumption and greater comfort for the driver.
This is possible thanks to the technologies of the embedded
electronics, used in the execution of this work routine.
We will see how these work routines are defined and how to find
possible defects.
Let's get to know the various electronic components and how they
act on the electronic device.
Component testing and replacement, welding techniques and
rework on printed circuit boards.
The methods presented are based on the ISO9001 and QS9000
standards for automotive quality, training professionals able to
perform services with quality assurance.
SUPPORT MATERIAL FOR STUDENTS AND REPAIR PROFESSIONALS IN ECU
MODULES!
RESPECT COPYRIGHT
NO PART OF THIS MANUAL MAY BE REPRODUCED IF WE ARE ANY MEANS USED WITHOUT THE
PERMISSION, IN WRITING, OF THE AUTHOR.
THE INFRINGEMENTS APPLY TO THE SANCTIONS PROVIDED FOR IN ARTICLES 102 TO 106 OF LAW
9.610 OF FEBRUARY 19, 1998.
filat1985@gmail.com 21 Sep 2023
OBJECTIVE OF THE SYSTEM
As we know, the main function of an electronic control module (ECU), it is to receive
and process the input signals as a reference to perform the fuel injection and emit
the appropriate spark for explosion in the cylinder, obeying the stoichiometric ratio. It
also performs secondary functions such as: Fan activation, slow ax control,
emission control etc.
With the current technological level, this Hardware has become very reliable
considering the strict work regimes.
The electronic circuits
have been designed with maximum security against
interference-resistant to high temperatures and long periods of work.
Despite all safety procedures, failure to production of sparks or fuel injection or even
secondary functions. Our job will be to analyze the source of the failure at the
Hardware level and fix it.
The operation of the
Electronic Control Unit ECU,
is shown
in the diagram below:
REGULATOR
5V VOLTAGE
12 V
PROCESSOR
sensors
MEMORY
ROM
MEMORY
RAM
ACTUATORS
4
filat1985@gmail.com 21 Sep 2023
SYSTEM CLASSIFICATION
The electronic injection system is constantly evolving as all current technology.
We are going to introduce the main commercial systems found in the domestic and
imported vehicles.
Systems are classified in several ways. These differences are present in natural
evolution and by different manufacturers such as Bosch - FIC - Magneti Marelli -
Siemens - Delphi - Mitsubishi - Hitashi etc.
In practice we find the following systems:
A - ANALOGUE COMMAND CENTER
Ex. Bosch Le-Jetronic
5

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