Electronic Fuel Injection
Electronic Fuel Injection
                  TOT PROGRAM
         PROJECT BASED TRANING MANUAL ON
PREPARED BY
AUTOMOTIVE DEPARTMENT
August 16
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Contents
1.1 Introduction ............................................................................................................................... 3
1.2 Objective ................................................................................................................................... 3
1.3 SPECIFIC OBJECTIVES ......................................................................................................... 3
1.4 Special Service Tools ................................................................................................................ 4
1.5 Symptom Troubleshooting Guide Chart ................................................................................... 5
1.6 Sensors and Components Location ........................................................................................... 7
   1.6.1 ETC Description ............................................................................................................... 14
   1.6.2 MAP Description.............................................................................................................. 19
   1.6.3 ATS Description ............................................................................................................... 23
   1.6.4 For Turbocharged vehicles ( BOOST Description) ......................................................... 25
   1.6.5 Engine coolant temperature sensor Description ............................................................... 26
   1.6.6 Crankshaft position sensor Description............................................................................ 28
   1.6.7 Camshaft position sensor Description .............................................................................. 30
   1.6.8 Knock sensor description ................................................................................................. 32
   1.6.9 O2 Description ................................................................................................................. 34
   1.6.10 RAIL Description ........................................................................................................... 36
   1.6.11 APS Description ............................................................................................................. 38
1.7 GDI Description ...................................................................................................................... 40
1.8 PCSV Description ................................................................................................................... 42
1.9 CVVT Description .................................................................................................................. 43
1.10 For turbocharged vehicles (EWGT) Description .................................................................. 44
1.11 Turbocharged vehicles(RCV) Description ........................................................................... 47
1.12 Fuel pressure control valve Description ............................................................................... 49
1.13 Canister cloth valve Description ........................................................................................... 50
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1.1 Introduction
Because the field of automotive service is an ever-advancing and demanding profession, this institute
(Productivity improvement and center of excellency) has prepared this automotive training manual (ATM)
series it help its trainees to attain a higher degree of technical skills. Thus as you progress through this
training use this Electronic fuel injection system and related materials to their fullest for your advancement
and improve your and your customer satisfaction.
1.2 Objective
The aim of this training manual is to teach the basic construction, control, operation, and troubleshooting of
the Electronic fuel injection (EFI) system. Also after this training the trainee should have a full
understanding of the following, they should also be able to perform related inspections and repair based on
this understanding when appropriate workshop manual is used.
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Fuel Pump Locking Ring Remover                      Removal and installation of the fuel
(09310-B9100)                                       pump locking ring
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                                                                                            • Low compression
                        1. Test the battery
                                                                                            • Intake air leaks
                        2. Check the fuel pressure
                                                                                              Slipped or broken
                        3. Check the ignition circuit                                       • timing belt
Unable to start
(Incomplete                Troubleshooting the immobilizer system                             Contaminated
combustion)             4. (In case of immobilizer lamp flashing)                           • fuel
                                                                                            • DTC
• Low compression
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                                                                                            Contaminated
                    4. Check the ignition circuit                                         • fuel
Poor driving           Check the long term fuel trim and short term fuel trim (Refer to     Weak ignition
(Surge)             6. CUSTOMER DATASTREAM)                                               • spark
                    1. Check the fuel pressure
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11. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]   13. Rail Pressure Sensor (RPS)
12. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2]   20. Injector
14. Accelerator Position Sensor (APS) 15. Fuel Tank Pressure Sensor (FTPS)
16. Fuel Level Sender (FLS) 17. Ambient Temperature Sensor (ATS)
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18. A/C Pressure Transducer (APT) 21. Purge Control Solenoid Valve (PCSV)
24. Electric Waste Gate Actuator (EWGA) 25. RCV Control Solenoid Valve
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26. Fuel Pressure Control Valve 27. Canister Close Valve (CCV)
31. Data Link Connector (DLC) [16-Pin] 32. Multi-Purpose Check Connector [20-Pin]
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Schematic Diagram
Fail-Safe Mode
                 Item                             Fail-Safe
              ETC Motor                  Throttle valve stuck at 7°
                                   TPS 1 fault                  ECM looks at TPS2
                                   TPS 2 fault                  ECM looks at TPS1
                 TPS              TPS 1,2 fault               Throttle valve stuck at 7°
                                  APS 1 fault                   ECM looks at APS 2
                                  APS 2 fault                   ECM looks at APS 1
                 APS              APS 1,2 fault                   Engine idle state
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When throttle value is stuck at 7°, engine speed is limited at below 1,500rpm and vehicle speed at
maximum 40 ~ 50 km/h (25 ~ 31 mph)
Specification
[Throttle Position Sensor (TPS)]
                                                              Output Voltage (V)
          Throttle angle(°)                           TPS1                              TPS2
                  0                                    0.50                              4.50
                  10                                   0.96                              4.05
                  20                                   1.41                              3.59
                  30                                   1.87                              3.14
                  40                                   2.32                              2.68
                  50                                   2.78                              2.23
                  60                                   3.23                              1.77
                  70                                   3.69                              1.32
                  80                                   4.14                              0.86
                  90                                   4.60                              0.41
                  98                                   4.65                              0.35
                C.T (0)                                0.50                              4.50
             W.O.T (86)                                4.41                              0.59
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Circuit Diagram
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Inspection
Throttle Position Sensor (TPS)
1. Connect the GDS on the Data Link Connector (DLC).
     Start the engine and measure the output voltage of TPS 1 and 2 at C.T. and W.O.T.
3.
4. Remove the installation bolts, and then remove the ETC module (A) from the engine.
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Installation
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sides of the sensor respectively, this sensor can output analog signal by using the silicon variation
proportional to pressure change.
Specification
                     Pressure
                [kPa (kgf/cm?, psi)]                                Output Voltage (V)
                  32.5 (0.33, 4.71)                                          0.5
                 284 (2.90, 41.19)                                           4.5
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Signal Waveform
Circuit Diagram
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Specification
                 Temperature
           °C                  °F               Resistance (k?)
           -40                 -40               40.93 ~ 48.35
           -20                 -4                13.89 ~ 16.03
            0                  32                  5.38 ~ 6.09
            10                 50                  3.48 ~ 3.90
            20                 68                  2.31 ~ 2.57
            40                 104                 1.08 ~ 1.21
            50                 122                 1.56 ~ 1.74
            60                 140                 0.54 ~ 0.62
            80                 176                 0.29 ~ 0.34
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Specification
                Temperature[°C(°F)]                   Resistance (k?)
                      -40(-40)                          841.2~1019.3
                      -20(-4)                           263.8~306.5
                       0(32)                             92.4~102.8
                      10(50)                              57.0~62.2
                      20(68)                              36.2~38.8
                      40(104)                             15.3~16.7
                      50(122)                             10.3~11.4
                      60(140)                              7.1~8.0
                      80(176)                              3.5~4.0
Circuit Diagram
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Circuit Diagram
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Specification
                        Temperature
                  °C                  °F                      Resistance (k?)
                  -40                 -40                          48.14
                  -20                 -4                       14.13 ~ 16.83
                  0                   32                            5.79
                  20                  68                        2.31 ~ 2.59
                  40                  104                           1.15
                  60                  140                           0.59
                  80                  176                           0.32
Circuit Diagram
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Specification
                            Item                                    Specification
                     Coil Resistance (?)                       774 ~ 946 [20°C (68°F)]
Waveform
This example shows a typical Crankshaft Position Sensor (CkPS) and Camshaft Position Sensor
(CMPS) waveform at idle. The PCM controls the injection and ignition timing by using these
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signals. Generally CkPS signal is used to detect the piston's position and CMPS signal is used to
detect the Top Dead Center of each cylinder.
Circuit Diagram
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Circuit Diagram
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Circuit Diagram
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1.6.9 O2 Description
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed both upstream
and downstream of the Manifold Catalytic Converter. The sensor output voltage varies in
accordance with the air/fuel ratio.
The sensor must be hot in order to operate normally. To keep it hot, the sensor has a heater
which is controlled by the ECM via a duty cycle signal. When the exhaust gas temperature is
lower than the specified value, the heater warms the sensor tip.
Specification
HO2S [Bank 1/Sensor 1] (Linear type)
                           Item                                            Specification
                  Heater Resistance (?)                               2.4 ~ 4.0 [20°C(68°F)]
                           Item                                            Specification
                  Heater Resistance (?)                              Approx. 9.0 [20°C(68°F)]
                           Item                                            Specification
                  Heater Resistance (?)                              Approx. 9.0 [20°C(68°F)]
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Circuit Diagram
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Specification
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Signal Waveform
Circuit Diagram
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Inspection
1. Connect the GDS on the Data Link Connector (DLC).
     Measure the output voltage of the RPS at idle and various engine speed.
                            Condition                                      Output Voltage (V)
                              Idle                                              Approx. 1.2
                            1,500 rpm                                            2.2 ~ 2.5
2.                          6,300 rpm                                           Approx. 3.0
Specification
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Circuit Diagram
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Specification
                                 Item                                         Specification
                         Coil Resistance (?)                              1.5 ± 0.075 [20°C(68
Signal Waveform
The three waveforms below are taken from the #1 and #4 injectors. The top waveform is from the
high side (feed side) of the #1 and #4 injectors, while the middle waveform is from the low side
(ground side) of the #1 injector and the bottom waveform is from the low side of the #4
injector.The middle waveform is the same as the top waveform because there is no ground for the
circuit. With no current flowing in the circuit, the #1 injector is not energized and fuel does not
flow. The bottom waveform shows that ground is supplied and there is a voltage drop across the
#4 injector. With current flowing in the circuit, the #4 injector is energized and fuel flows.
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                       Electronic fuel injection system
Circuit Diagram
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Specification
                           Item                                          Specification
                    Coil Resistance (?)                            22.0 ~ 26.0 [20°C(68°F)]
Circuit Diagram
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Specification
                          Item                                                 Specification
                   Coil Resistance (?)                                    6.9 ~ 7.9 [20°C(68°F)]
Circuit Diagram
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Specification
[EWGA Position Sensor]
                                                                                     Range of Rod
                                                                                         [mm],
                   Position                 Output Voltage[V] Operating Angle[°]       reference
Mechanical Close end stop Position (MCP)           4.8                  0                    0
Electrical Close end stop Position (ECP)           4.2                  12                   1.8
Electrical Open end stop Position (EOP)            1                    79                   16
Mechanical Open end stop Position (MOP)            0.5                  90                   18
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[EWGA DC Motor]
                         Item                         Specification
                  Coil Resistance (?)          1.44 ~ 1.96 [21°C(69.8°F)
Signal Waveform
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Circuit Diagram
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Specification
                        Item                              Specification
                  Coil Resistance(?)                 28.3 ~ 31.1 [20°C(68°F)]
Circuit Diagram
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Specification
                              Item                                        Specification
                       Coil Resistance (?)                              0.5 [20°C(68°F)
Signal Waveform
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Circuit Diagram
Specification
                          Item                                                   Specification
                   Coil Resistance (?)                                     19.8 ~ 21.8 [20°C(68°F)
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Circuit Diagram
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