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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
hal.meb@outlook.com 31 Jan 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.
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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 12 V
5V VOLTAGE

PROCESSOR

sensors ACTUATORS

MEMORY MEMORY
ROM RAM

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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

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B – 8 bits DIGITAL ELECTRONIC CONTROL PANEL

Ex.

IAW 1G7
IAW 1AVB

Ford FIC
Bosch 1.5.4

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C – 16 Bits DIGITAL ELECTRONIC CONTROL COMMAND

Ex.

IAW 4AF Bosch ME 7.5.10

Renault Delphi Multec

Today we already find vehicles equipped with ECU with information processing
capacity of 32 and 64 bits.
The electronic control centers, have different conceptions, according to the internal
design of each Manufacturer.

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Internal Assembly of the Control Center

ANALOG CENTER

Bosch Le Jetronic

Common Defects
Cold solder in several points of the exchange (mainly in the Drives of the Coil,
Injectors and Temperature Sensor).

injector
drive
Coil
Drive

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Central EZK

MAP Sensor - Inside EZK

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DIGITAL CENTRAL

Internal assembly of the 8 bits digital control panel

In this example we illustrate an 8 bits digital exchange. In these exchanges we can

highlight the nozzle drivers, coil driver and Ram and Rom memories.
The design configurations and specific components change from manufacturer to
manufacturer, but we can understand how the signals are processed internally in
the Hardware.

coil driver
5v regulator

nozzle
driver

Rom RAM Crystal Stepper

Memory memory Motor
driver
Processor

Internal assembly of the 16 bits digital control center

In this example, we show a more advanced 16 bits switch. Note that in this case the
nozzle drivers are combined with other drivers and components within a single chip.
As well as coil drivers with other drivers. These chips are called Mult-Drivers. The
Ram and Rom memories are inside the processor.

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Driver Coil Driver

Probe

Cold Start
Mult -Driver's Multi -Driver
Nozzle, Engine Pump
Footstep,
Canister

Processor with memory

Rom and Ram internal

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DATASHEET

The datasheet is the description of the electronic component, it

contains all technical specifications, such as:

•Function of each pin;

•Work tension;
•Maximum voltage;
•Maximum current;
•Block diagram (Internal electrical schematic of the component)

Example Below is part of the datasheet for the L 298 N component,

which controls the stepper motor of IAWG6 / G7 systems.

We can find the Datasheet of the components on any search engine by typing the
code of the same.

L 298 N - Stepper Motor;

Pin Description
1 Monitors the current of Coil A
2 – 3 Controls coil A (pin 2 and 20 of the control panel)
4 Vs
5 – 7 Command input for coil A
6 – 11 Enables the activation of coil A or B
8 Grounding
9 Component power
10 – 12 Command input for coil B
13 – 14 Controls coil B (pin 21 and 3 of the control panel)
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Block Diagram of L 298 N

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TEST EQUIPMENT
Mult-Test or Multimeter

There are many equipments, simple and sophisticated to perform analysis of

components and electronic circuits. For this training we will use only common
equipment.

• To measure the voltage and resistance of components in a system, it is

recommended to use a high impedance multimeter (10 KW / Volt
minimum), which includes a voltage scale of 0 - 20 V and a scale of Ohm
low (0 - 200) and high (0 - 20 K).

• There are analog (1) and digital (2) multimeters within a wide range of
prices and specifications. Since the instrument will be used in the harsh
workshop environment, the purchase of a shockproof one will be a good
investment, which will justify the extra expense.

• In addition to the normal scales in volts, Ws and milliamps, certain

characteristics such as, for example, the ability to read Capacitances (uF)
frequencies (Hz) and operating cycles (%) will also be useful.

2
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OSCILLOSCOPE

Indispensable equipment for testing in electronic centrals.

The oscilloscope helps us to find the problem quickly and easily. Often the problem
has not registered an error code (DTC) in the corresponding ECU, the DTC, which
can be read with a code reader. Generally, a DTC is recorded when there is a broken
cable or a cable is short-circuited to a positive or negative source. But when a
detector or mechanism has stopped working at some intermediate position, there is
no error recorded. In this case, like when you need to find the reason that caused an
error to be recorded - the automotive oscilloscope is your most important instrument
required.

With the increase in sensors, actuators and wiring diagrams in modern automobiles,
the oscilloscope is an instrument that diagnoses irregularities faster and easier.
Let's see the waveforms found in the different points of the ECU Let's study the
meaning of each one.
For configuration and setup (setup) of the Oscilloscope we recommend
consult the AutoLeap Oscilloscope Handout .

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3.1 CENTRAL SIMULATOR

The ECU Electronic Control Unit, in order to function and thus allow the tests and
diagnostics, needs several signals at the input, provided by the sensors, as well as
12v power at other several points (line 15 and line 30).
To create this situation that allows the ECU to work on the workbench, there is the
equipment that simulates all the existing signals in the Automobile.

ANALYZE WAVE FORMS

Each oscilloscope waveform contains one or more of the following parameters:
Amplitude - voltage (V)
•

The signal voltage at a given time Frequency -

Cycles per second (Hz)
•

The time between signal points

• Pulse width - duty cycle (%)
The period during which the signal is on - expressed as a percentage (%) over the
total
• Shape - peaks, curves, serrations, etc. The global "image" of the
signal

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Waveform parameters - 1

• Pattern - repeated shapes. The repetition pattern of the overall shape

of the signal.
• The oscilloscope shows all these parameters on a single screen and
the comparison of the wave forms presented in the ECU Module to be
tested with those illustrated here allows to evaluate the status of each
circuit and its components. The line of an anomalous circuit or
component is usually very different from the line of one under
satisfactory conditions, which facilitates the identification of
malfunctions.
• The five parameters listed above can be categorized as follows form:

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4.1.1 Analog DC Voltage Signals

Coolant temperature sensor - 2

Intake air temperature sensor - 3

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Throttle throttle position sensor - 4

Oxygen sensor - 5

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Airflow volume sensor - 6

Air flow measurement sensor - 7

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AC voltage signals

Knock sensor - 8

Motor speed sensor - inductive type - 9

Frequency modulated signals

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Rotation Sensor - Inductive Type - 10

Phase sensor - inductive type -11

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Vehicle speed sensor - inductive type - 12

Rotation and position Hall effect sensors - 13

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Optical Rotation and Position Sensors - 14

Absolute pressure sensor in the manifold - digital type - 15

Modulated pulse width signals

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Injectors - 16

Idling air control devices - 17

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Primary ignition coil circuits - 18

Purge valve for fuel vapor emissions - 19

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Exhaust gas recirculation valves – 20

Serial data signals

• Serial data signals are generated by the engine control module (ECU) (21).
• Observing the pulse width, pattern and frequency, short pulses can be
counted in groups and interpreted as a fault code (in this case 1223).
• The amplitude and shape remain constant and the pattern is repeated until
the code of malfunction to be cleared.

Data communication waveform - fault code - 21

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INTERPRETING WAVE FORMS

Typical waveforms - 22 and 23

• Oscilloscope waveform patterns can vary immensely and depend on

many factors. So, whenever the waveform appears to you to be incorrect
when compared to the "typical" waveform that appears in the pin data
table to be analyzed, consider the following points before making a
diagnosis or replacing components.
Voltage

• Typical waveforms indicate the approximate position of the waveform

relative to the "zero grid", but this can vary depending on the system
being tested and can be positioned anywhere within the "range"zero
"approximate.
• The overall amplitude or height of the pattern (the voltage) depends on
the operating voltage of the circuit.
• In the case of direct current (DC) circuits, this depends on the voltage
that is switched; for example, the voltage of the idle speed control device
is constant and does not change with the engine speed.
• In the case of alternating current (AC) circuits, this will depend on the
speed of the signal generator; for example, the output voltage of an
inductive RPM sensor (CKP) increases with the speed of the motor.
• Therefore, if the oscilloscope pattern is too high (or the top is missing),
increase the voltage scale to obtain the desired display. If the pattern is
too low, reduce the voltage scale.
• Some circuits with solenoids may exhibit spikes when the circuit is turned
off. This voltage is generated by the component and can normally be
ignored.

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Some circuits that have a typical square-type wave may experience a voltage drop at
the end of the switching period. This is typical of some systems and can usually be
ignored, as it is not an indicator in itself malfunction.
Frequency
The total width of the pattern (the frequency) depends on the operating speed of the
circuit.
• The typical waveforms illustrated are obtained with the oscilloscope's
timescale adjusted to allow detailed observation. In direct current (DC)
circuits, the time scale will depend on the speed at which the circuit is
switched;
• In the case of alternating current (AC) circuits, the time scale depends on
the speed of the signal generator; for example, the frequency of an
inductive speed sensor increases with the motor speed.
• If the oscilloscope pattern is too compressed, decrease the time scale
to obtain the desired view. If the pattern is too expanded, increase the
time scale.
• An inverted pattern indicates that the system to be tested has its
component connected with the polarity opposite to the typical waveform
shown and can normally be ignored, as it is not a malfunction indicator
by itself.
Digital Waveform - 22 Analog waveform - 23

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TESTING OF COMPONENTS

As we have already seen, the first analysis is the detailed visual inspection of the
conditions of the printed circuit board, connectors, component positioning, components
with overheating characteristics, etc. In case of removing any component, do not forget
to write down or photograph the original position of the component. In the sequence
we will see the components to be tested:

4
5 6
3 7
3
2

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The vast majority of defects found in Control Centers (ECU), is the “cold solder” or
interrupted conductive track.

Cause - Several factors can cause bad contact in terminal welds or breakage of
tracks: 1-Time action 2-Oxidation 3-External short circuit 4-Over load, due to lack
of grounding of external components.

It is made - Lack of grounding of some sensors, actuators not operating, Central does
not work.
Solution - First check the cause. Redo the weld or rebuild the track with capped wire.

The components shown in the photo above, have their physical appearances
(encapsulation), very different in the different models of ECUs, according to the
manufacturer but the internal characteristics of operation are the same. We can check
each type of component and its characteristics, with the help of the Datasheet of the
manufacturer of the component under test.

1- Drivers
Components such as Transistors and FETs, used to amplify and transform processed
digital signals into power signals for triggering the injector nozzle, coil, solenoids, etc.
Check the internal characteristics in the Datasheet. The Coil Driver is generally shorted
when the Coil is damaged. The Driver consists of an individual Power Transistor in
Integrated Circuit with several internal components, Mult-Driver.
2 - Transistors
Low power transistors used for switching and communication of processed digital
signals.
3 - Electrolytic capacitor
Used to filter the input voltage before the voltage regulator and after the voltage
regulator. It consists of two dielectrics and an acidic substance internally, which can
leak over time, causing corrosion and short circuits in the board.
4 - Zener diode or rectifier
The rectifier diode allows the passage of the electric current only in a sense. The zener
diode protects the system against over voltage.

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5 - Processor
As with a Desk Top Computer, it is the heart of the ECU. Contains a internal software
with the system's work routine. To check its operation, consult the Datasheet to find the
power terminals + 5v, Earth, and with the help of the oscilloscope, check the Clock
signal.
EEprom
Serial Eprom package SOIC08 contains information like code immobilizer, engine,
Airbag etc. It can be reprogrammed via Scanner.
Eprom
It can be found in DIP, PLCC, PSOP or internally in the processor in Hybrid ECUs.
Contains information about the engine's operating parameters: advance, injection time,
temperature etc. Programming can only be done by changing the Chip or using special
equipment.
Voltage Regulator
Adjusts the 5v working voltage of the ECU.
Connector
Connects the ECU to supply voltage, earth, sensors and actuators. It presents defects
of bad contact, oxidation.
5.1.1 - TEST OF RESISTORS:

Electric resistors are electronic components, whose purpose is to offer opposition to

the passage of electric current through its material. This opposition is called "Electrical
Resistance".
Electrical resistance

Unit Oh M Ω
kilo Ohm k Ω = 10³
Mega Ohm M Ω = 10 6

Resistors can be Fixed or Variable.

Fixed: They are resistors whose electrical resistance cannot be changed (they have
two terminals)

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Variables: They are those whose electrical resistance can be changed through an axis
or course (Rheostat, Potentiometer).
Resistors are identified by a color code, where each color and its position in the
resistor body represents a value or a factor multiplicative.

Color 1st 2nd Multiplicative Factor Tolerance

black 0 0 X1 ---
Brown 1 1 X10 1%
Red 2 2 X100 2,00%
Orange 3 3 X1,000 --
Yellow 4 4 X10,000 --
Green 5 5 X100,000 --
Blue 6 6 X1,000,000 --
Violet 7 7 --- --
Grey 8 8 --- --
White 9 9 --- --
Golden - - X0.01 5%
Silver - - X0.1 10%
No color - - --- 20%

SMD RESISTOR

SMD resistors are 1/3 the size of conventional resistors. They are soldered on the
underside of the board by the side of the tracks, taking up much less space. They have
the value marked on the body with 3 numbers, the 3rd digit being the number of
zeros. Ex: 102 means 1,000 Ω = 1K Ω.TESTING OF ELECTRYLIC CAPACITORS

Symbols that represent electrolytic capacitors:

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Real look
These capacitors are used specifically in filtering power supplies, low frequency
oscillating circuits, low signal coupling frequency and time circuit (timer).
There are two types of electrolytics: Those that have a metallic body
(similar to the common ones) and those with an epoxy body, similar to the diodes.
Some have the characteristics indicated by a letter (working voltage) and a number
(value in mF). Ex: 22/16 See below:

To do the tests of the electrolytic capacitors, it is first necessary to know their value in
Microfarade in order to be able to position the selector switch in the correct scale

SCALE VALUES IN MICROFARADE

X1 OR X10 330 Mf at 10,000 mF
X 1K 0.05 Mf at 220 mF

Also note that the electrolytic capacitor has polarity (+ and -) the working voltage value
is also found in the capacitor.
In your tests it is not necessary to see its polarity or the working voltage, only the
capacitance value to position the selector switch on the correct scale.
• Take a capacitor whose value is between 330mF to 10,000mF.
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• Position the selector switch on the X10 scale.

• Place the test leads on the capacitor terminals and keep the multimeter test
leads fixed to the capacitor terminals and note that the multimeter's pointer
has shifted and returned to the resting point.
• Change the multimeter's test leads at the capacitor terminals, that is, invert
the cables; black cable in place of red and red in place of black. Note that
the pointer will move and return to the rest position. This occurs when the
capacitor is fine.

Start with the smallest scale (X1) and measure in both directions. Increase
the scale until you find one that the pointer deflects and returns. The larger
the capacitor, the smaller the required scale. This test is only for the charge
and discharge of the capacitor. See below:

If the pointer does not deflect or deflect just a little, the capacitor is open or exhausted.
If the pointer deflects and does not return, the capacitor is in short.
See below:

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DIODES TEST
We find it in several common and SMD packages.

There are several types of Diode such as Rectifier, Zener, LED, Varicap etc. let's look
at just two types most used in ECUs.

Rectifier Diode
It has the characteristic of allowing the passage of electric current in a single sense.

Zener Diode
It has the characteristic of allowing the current to flow inversely, when it exceeds the
zener value.

Rectifier Diode Test

Use the largest scale (X10K or X1K) and measure the diode in both directions. The
pointer should only deflect in one direction. As the black tip is connected to the
positive of the batteries, the pointer will touch the black on the anode. If the pointer
deflects in both directions, the diode is in I enjoy . If the pointer does not deflect in
any direction, the diode is open . See below:

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Zener Diode Test

The test for Zener Diode is the same for rectifier diode, if we improve the test we can use
an adjustable voltage source and adjust for rupture voltage, the diode and check the
reverse current, finding the zener voltage.

TRANSISTORS TEST

The Transistor has the function of amplifying electric currents and switching loads
electrical. In the ECU, among other functions, it is mainly used as an output and switching
nozzle driver, coil etc.

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Test Bipolar Transistors (NPN, PNP)

A transistor for testing purposes is no more than two diodes connected in opposition,
the verification with the multimeter is performed according to the two PN junctions and
NP.
The measurement is carried out in the same way as on a normal PN diode.

The test is carried out on all joints.

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FET TRANSISTOR

A common defect in power transistors is a short one between collector and emitter,
or Dource and Drain that can be detected by these tests. Remember that certain
types, such as the Coil output, may have an internal diode between emitter and
collector and also internal resistance between base and emitter. But the short
mentioned is observed by the low resistance in both directions.

PROCESSOR TEST

Processors are also different depending on the manufacturer and the ECU model.
Major processor manufacturers are: Motorola, STMicroelectronics, NEC
Electróncs, Texas Instruments, SGS Tomson.

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The complete test of a Processor is performed with Hardware and advanced

software. In this stage of Cuso we will carry out the basic test of the processor's
operation in the circuit.
With the aid of the component's Datasheet, we will locate the terminals
Vss (land) V DD (+ 5v) and Clock. With the 12v supply properly connected, we
check with an oscilloscope or frequency meter, if the processor is generating the
clock frequency - frequency of the Cristal.

EARTH Frequency
Clock

+ 5v

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With the self-adaptive feature, the Processor performs the reading of the
sensors and rewrites the parameters at a speed 4 times greater than the engine
speed. When the sensor readings report values that are too high or too low at
random, far outside the characteristic parameters, the processor registers an error
and crashes its operation. For this ECU to return to normal operation, we have to
reset this processor, loading new software into its memory.

This procedure happens with all types of Electronic Command, such as Electronic
Panel, ABS Brake Central, Immobilizer etc.
Very common procedure in vehicle repair shops, is the exchange of the Vehicle
Dashboard or Injection Module, for a component removed from another vehicle
whose characteristics are different. For everything to work correctly, just copy the
software from the Panel or Module Processor and write to the Processor of the new
Module.
In the most recent Centrals, it is possible to do this work by interface OBD2 via
diagnostic connector or even through the Scanner. In other plants it is only
possible to reprogram the Processor with the help of special programmers.

Below are some Processor programmers:

MC68HC (7) 11

Supported devices:
MC68HC11A8 (AB95T), MC68HC11A8 (C96N), MC68HC11A8 (D26E), MC68HC11E20 (3E22B),
MC68HC11E9 (1B60R), MC68HC11E9 (D82R), MC68HC11E9 (E22B), MC68HC11HC (2D), MC68HC11E9 (E28B),
MC68HC11F1 (E87J), MC68HC11K1 (2D58N), MC68HC11K4 (1E62H), MC68HC11K4 (OE75J),
MC68HC11KA4 (1E59B), MC68HC11KS2 (0H95B), MC68HC11KS4 (0E57S), MC68HC11711 MC68HC711E9 (5C47M),
MC68HC711EA9 (0D46J), MC68HC711K4 (K59D), MC68HC711PH8 (0H30R), MC68S711E9 (5C47M), XC68HC711KS8 (1H96P
MC68HC11P2 (2E74J), XC68HC711P2 (1E53M).

MC68HC11PA8

Supported devices:
MC68HC11PA8, MC68HC11KA1, MC68HC11KA4, MC68HC11P2,
MC68HC705B16 / 32, MC68HC705X16 / 32, MC68HC05B6 / 8/16/32

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Supported devices:
MC68HC705B16, MC68HC705B32, MC68HC705X16,

TMS370
Supported devices: TMS370CX6X TMS370CX5X TMS370CX4X
TMS370CX3X TMS370CX0X TMS375C006 TMS374C003A TMS374C013A

NEC uPD17011GF
Supported devices: uPD17011GF
Tested on: NEC D17011GF E91, E93, E95

Programmer ST10Fx
Supported devices: ST10F168, ST10F276,
ST10F279, ST10F280

EPROM TEST

The models of eproms vary according to ecapsulations and sizes of memory

capacity, according to the scheme and table below.

- They are rewritable

DIP (Large) -Use the eraser to erase Start with 27C...

EPROM “NORMAL” - Only record

PLCC (Small)

- Start with 27C ...

FLASH -They are rewritable

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- Use the recorder to erase

- Start with 28F ...

DIP NORMAL PLCC PLCC FLASH

27C128 27C512 28F512
27C256 27C010 OR 228F010 OR
27C1001 * 28F1001 *
27C512
27C010 OR
27C1001 *

* 010 OR 1001 have the same parameters.

Example of an Eprom DIP Example of an Eprom PLCC

Eproms are distinguished from each other by their respective data storage
capabilities:

CLASSIFICATION CAPACITY FORMATS FOUND

27C128 16KB DIP only
27C256 32KB DIP only
27C512 64KB Both DIP and PLCC Both DIP
27C1001 (27C010) 128KB and PLCC

Eprom Test

The test is performed with the Eprom Reader and Recorder equipment.

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Adapters

This adapter socket is used to allow reading and writing PLCC type eproms on
equipment whose socket is DIP. Observe carefully which socket the particular Eprom
PLCC should be fitted in (27C010 or 27C512).

TEST SOCKET 27C512

This socket is used to test a file that originally belongs to a PLCC 27C512. In case the eprom is a
27C010, we have the possibility to do the tests on a PLCC Flash 28F010 eprom. However, we do
not have this same device in the case of PLCC 27C512. In this case, we write the file to a 27C512
DIP and use the test adapter.

Example of a 27C512 test adapter

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TYPES OF FIXATION

The eproms are fixed to the Central Electronic board in three different ways: socket, solder
and mencal.
SOCKET: The eprom is fixed to the central board through a socket, varying only the type
of socket, according to the type of eprom used, DIP or PLCC.

Example of socketed eprom.

WELDING: The eprom is welded directly to the central plate, that is, it is fixed.

Example of welded eprom.

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MENCAL: The eprom is fixed to the central board using a special socket, developed
by the central manufacturer. These mencals are found in some Delco plants. There are
two types of mencals: MENCAL BLUE, which are small (to assist in the exchange of
this eprom, we developed the Delco Spacer), and the large mencals.

Mencal Blue example Delco Spacer Example Mencal example

Big
SOCKET FOR PLANTS BOSCH MP9.0

These plants are found in the Gol 1.0 8V until 1999 (from 2000 onwards it is already a
PLCC) and in the 1.6 8V Kombi. In both cases, the replacement eprom will be DIP

27C512. This socket will be fixed between the central and the new eprom and will be
fixed in the central.
Example of a socket for MP9.0 control panels

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PROGRAMMING ENVIRONMENT

EPROM: It's a memory. It works like a computer diskette. It has a file stored inside it
where the car's electronic and electronic information is located, as well as the
information from the sensors, its routines and maps.
FILE: It is a set of data transformed into binary or hexadecimal numbers represented
by letters and numbers.
BUFFER: It's the computer's memory. It is there that the file extracted from Eprom or the file
remapped by the program is stored.

PROGRAM: It is the tool used to change (remap) a file which has been transformed into a graphic
so that it can be viewed.

EPROM REPROGRAMMING

There is a lot of software to Edit and Reprogram the internal File of the
Eprom memory. In the next step of our Courses, we will learn how to use the most
advanced Reprogramming tool to date. Let's learn how to reprogram with Software
ECM2001 from AlienTech.
ECM 2001 is a new concept of remapping software for electronic injection. Enables
modifications to the file contained in the EPROM memory with more precision and
practicality, whether on engines Diesel or Gasoline , aspirated or turbo-compressors,
quickly loading the maps available in the driver (injection, point, pressure, turbo ...).

Plots all the data contained in an eprom in graphical form, generating

graphs in which the curves related to the mapping can be recognized and
shows the exact location of the injection, advance, rotation limiter, lick
probe etc. maps.

* It allows the visualization of maps of 8 bits, 8 bits / 128, 8 bits / 255, 16 bits IEEE,
16 bits IEEE / 32768,
16 bits Motorola and 16 bits Motorola / 32768;

Calculates and adjusts the cheksum automatically.

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3D Graphic Editor

2D Graphic Editor

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BI-FUELS

THE EPROMIX is a program for adding files. It generates a third file from the sum of two
others. How does it work:

First: You must choose (select) the first file by clicking on the button that contains the
drawing of a yellow folder referring to file one. When working as an original file and a
remapped file, it is advisable that file number one (first file) be the original. In the case
of two remaps, the order of the files is the same.

Second: You must repeat the same procedure as before, but now to choose file
number 2.

Third: In the field called “Sum”, you will click on the button with a yellow folder drawn
and choose where (in which directory) your new file (the third, coming from the sum of
the first two) will be saved.

Bedroom: On the right side of the program window (or in the “Eprom” menu) you
have the option to select which type of eprom will be used by the added file. That is,
when the original eprom of the vehicle you are converting is a DIP 27C256, a DIP
27C512 or a PLCC 27C512, in this field, you will always select the eprom "271001" .
When the vehicle's original eprom is a PLCC 27C010, in this field you will select the
eprom "27020" .

Fifth: After the previous four procedures, you must generate the added file by clicking
on the program button called “Generate”.
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Note that the size of the generated file corresponds to the type of eprom you selected
and that Cheksum is the sum of the Cheksum of the two first files.
Socket BI-MM28

This socket is used in vehicles that have DIP 27C256 or DIP 27C512 as the original
eprom. In the EPROMIX program, it must be selected in the kind of eprom a 271001 .
In the socket there is a “jumper” that serves to select the type of original eprom of the
vehicle. There is also a connector where you will connect a positive 12 volt supply
together with a common, on-off switch. This switch will switch between files, that is,
while the switch is off and the bi-fuel socket is not being powered

positively (12 volts), the socket will trigger file number one. The moment the key is
activated (on) and starts driving 12 volts to the socket, it will trigger file number two,
without having to turn the vehicle off.

Example of a BI-MM28 socket

Socket BI-PLCC 010

Its operating principle (12 volt supply and on-off switch) is the same as that of the
BI-MM28, however this socket is only for the PLCC 27C512 eprom, so it does not
have any jumper to select the type of eprom. In the EPROMIX program, it will also be
selected as the type of eprom to be 271001 .

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Socket BI-PLCC 020

Its working principle (12 volt power and on / off switch) is also the same as the
previous sockets, but this socket is only for the eprom PLCC 27C010 and also does
not have any “jumper” to select the type of eprom. However, in the EPROMIX
program, the type of eprom will be selected as 27020 .

Example of a BI-PLCC socketBi-fuel socket for Delco control units Its operating
principle (12 volt power and on / off switch) is also the same as the previous sockets,
however this socket does not use the EPROMIX program. Its two files are recorded
in different eproms, that is, the first file in one eprom and the second file in another
eprom, both using the eproms corresponding to the vehicle's original.

Example of a Bi-Fuel socket for Delco control units.

Original Vehicle Eprom Bi- Socket Fuel

Eprom to be used Software Screen

DIP 27C256 BI DIP MM28 DIP 27C1001 271 0 01

DIP 27C512 BI DIP MM28 DIP 27C1001 271 0 01
PLCC 27C512 BI PLCC 010 PLCC 27C010 271 0 01
PLCC 27C010 BI PLCC 020 PLCC 27C020 two 7 020
PLCC 28F512 BI PLCC 010 PLCC 28F010 271 0 01
PLCC 28F010 BI PLCC 020 PLCC 28F020 two 7 020
Central Delco (Mencal BI DELCO Two equal to original --------
BLUE)

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BANCADA CENTRAL TEST

POWER TEST 12v and 5v

Test 12v input and 5v voltage regulator.

We must connect the simulator to the ECU. Using the universal cable of the
simulator, we can connect the corresponding pins only to the sector of the Central
that we want to test at the moment.

With the aid of the vehicle's electrical

scheme to identify the pins,
connect all grounds and line
15 and line 30 of 12v supply

Check the 12v line following the

connector path until it reaches the
Regulator. input of the
1 - Zener diode shorted by battery
With the help of the Datasheet,
inversion or over voltage.
identify the 5v output pin, and check 2 - Broken trails
this voltage. All chips are powered 3 - Voltage regulator shorted.
by 5v. Identify this pin, and check 52
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FULL ECU TEST

By connecting all the input and output pins, we can carry out a complete test of the
ECU.

With the aid of the vehicle's

electrical scheme to identify the
pins, we connected the simulator
to the ECU.

1 - Select the Rotation

signal 2 - Connect line 30
(Battery)
3 - Connect line 15 (switch)

ECU WORKING:
Injection light comes on
Pump light turns on and
off. Turn on Ignition.
Pump indicator light
comes on again; Coil
indicator light flashes
Nozzle indicator light
flashes.

For Immobilized Centrals,

perform the reset or
connect an antenna with
key and Immobilizer
Central.

We can connect Scanner

and others
Reset equipment, encode
keys etc. Directly in the
ECU or through the
Simulator
With Multimeter and
Oscilloscope equipment,
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Connecting all input and output pins we can perform a complete test of the ECU,
considering an ECU in good working order we will have these readings.

With the aid of the vehicle's

electrical scheme to identify the
pins, we connected the simulator
to the ECU.

Sign on the said Coil Driver

When triggering
inductive
actuators, the
voltage return
stored in the coil,
generates this highest
peak of voltage.
The ECUSIMv8
Simulator has the
function of
activation with
the actuator
disconnected.
So we can visualize
the waveform without
this peak of reverse
voltage.

Signal coming from the Processor at the Coil Driver input.

The Nozzle Driver should also have a similar signal.

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Data Signal

The Universal Simulator Cable allows

free access to the other ECU pins,
thus allowing other sensors and
actuators to be connected directly to
the ECU.

SCANNER READINGS

With the Scanner we can analyze the signal processing of the sensors
carried out by the ECU.
1 - Connect the Scanner directly to the ECU through the pin of the K
communication line or through the Simulator.

2 - Enter Scanner Readings

3 - Vary the Simulator sensors and check the readings on the Scanner

With this procedure we check which function the ECU is not processing
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Rework on SMD plates

SMD PLATE Rework

SMD ("superficial monting device") components or surface mount components

have dominated electronic equipment in recent years. This is due to its small size
compared to conventional components. See below the comparison between the two
types of components used in the same function in two different devices:

Types of SMD components

Most SMD components are made of silicon (transistors, diodes, ICs) and soldered
on the side of the tracks, taking up much less space on a printed circuit board.
Thanks to these components it was possible to invent the cell phone, notebooks,
handheld computers, etc. Below is an example of some types of
SMD components:

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SMD resistors, capacitors and jumpers

The resistors are 1/3 the size of conventional resistors. They are soldered on the
underside of the board by the side of the tracks, taking up much less space. They
have the value marked on the body with 3 numbers, the 3rd digit being the
number of zeros. Ex: 102 means 1,000 Ω = 1 K. The jumpers (wires) come with
the indication 000 on the body and the capacitors do not come with the indicated
values. We can only know through a capacimeter. See below:

Electrolytics and SMD coils

The coils have an epoxy encapsulation similar to that of transistors and diodes.
There are two types of electrolytics: Those with a metallic body (similar to the
common ones) and those with an epoxy body, similar to diodes. Some have the
characteristics indicated by a letter (working voltage) and a number (pF value).
Ex: A225 = 2,200,000 pF = 2.2 µ F x 10 V (letter "A"). See below:

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SMD Semiconductors

Semiconductors comprise the transistors, diodes and ICs placed and soldered
alongside the tracks.
The transistors can come with 3 or 4 terminals, however the position of these
terminals varies according to the code. Such code is marked on the body by a
letter, number or sequence of them, but it does not correspond to the indication of
the same. For example. the BC808 transistor comes with a 5BS indication on the
body.
In the diodes the color of the cathode indicates its code, and some of them have
the encapsulation of 3 terminals equal to a transistor.
ICs have 2 or 4 rows of terminals. When there are 2 rows, the count starts with
the pin marked by a dot or to the right of a "half moon". When they have 4 rows,
the 1st pin is below the left of the code. The remaining pins are counted
counterclockwise. Below are some examples of SMD semiconductors:

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7.1 SMD components rework station

This is an excellent tool for removing and soldering SMD components from
printed circuit boards.

SMD desoldering

Turn on the blower and place an average amount of air and the temperature
between 300º and 380º appropriate to the CI and the printed circuit where the
operation is carried out.

Phenolite sheets are more sensitive to heat than fiberglass sheets. Therefore, for
phenolite, care must be taken (lower temperatures and desoldering as quickly as
possible) to avoid damaging the plate.

Then blow the air around the CI until it is completely released from the plate.
Then just clean with a brush and isopropyl alcohol.

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SMD CI welding

First of all, we observe if the CI to be placed is with the terminals perfectly

aligned. A slightly bent pin will make the operation very difficult. Use a magnifying
glass to assist you in this task. Please note below:

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SMD welding - Step 1

Place the CI on the board taking care to position it so that each pin is exactly on
its corresponding track. If necessary, use a increase.
Then keep a finger on the CI and apply solder to the first two pins on two opposite
sides so that it does not move out of position during welding. Watch bellow:

SMD welding - Step 2

Put some solder flux on the IC pins. Melt common solder in one corner of the CI
until it forms a solder ball. The welding should be done in a row of the CI at a
time. Look:

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SMD welding - Step 3

Stand the plate upright and carefully run the tip of the iron through the pins from
top to bottom, dragging the solder down. Add more flow if necessary.When the
solder reaches the bottom, place the plate horizontally again, apply a little more
flow and pull the solder out of the pins. If it is too difficult, remove the excess
solder with a solder suction. Repeat this operation on each row of pins on the CI.
See below:

SMD welding - Step 4

After welding, preferably check with a magnifying glass that two or more pins are
not shorted. If this has occurred, apply more flux and remove excess solder.
Finally, clean the plate around the IC with isopropyl alcohol. See below how the
CI was after the process:

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