Automotive Engineering

Mechanical Engineering Department

Sana’a University
by
Eng. Hani Anis Shagder

1 Automotive Engineering
 Introduc
.tion
Automotive engineering is a branch of mechanical engineering which involves
the design, manufacturing, testing and maintenance of automotive vehicles. It
.encompasses elements from mechanical and electrical to software and safety
Automotive Engineering covers the elements that are involved in creating an
automobile such as design, develop, fabricate, test and manufacturing,
distribution and sales of various types of automobile or automobile systems
and components. It is a specialist branch of mechanical engineering that looks
into automotive engines, transmission, braking systems, comfort and safety,
among others. Besides cars and motorcycles, automotive engineers also work
.with other land vehicles such as lorries, trucks, buses and trains

Eng. Hani Anis Shagder 2 Automotive Engineering

 Sana’a university Mechanical engineering department
Automotive parts and systems can be organized
:into ten major categories
.Body and frame—support and enclose the vehicle •
.Engine—provides dependable, efficient power for the vehicle •
Transmission system—is developed for transmitting the power from the engine to the wheels of the vehicle •
.Drive train systems—transfer power from the engine to the drive wheels •
……Engine Managements—monitor and control various vehicle systems ECM, TCM, BODY CONTROL •
.Fuel system—provides a combustible air-fuel mixture to power the engine •
Electrical system—generates and/or distributes the power needed to operate the vehicle’s electrical and •
.electronic components
Cooling and lubrication systems—prevent engine damage and wear by regulating engine operating •
.temperature and reducing friction between internal engine parts
Exhaust and emission control systems—quiet engine noise and reduce toxic substances emitted by the •
.vehicle
.Suspension, steering, and brake systems—support and control the vehicle •
.Accessory and safety systems—increase occupant comfort, safety, security, and convenience •
3
Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university
Engine management Mechanical engineering department
systems
Contents
.Introduction -1
Engine control structures and function blocks -2
.Hardware structures -1
.Software structures -2
.EC function blocks -3
Engine control and diagnosis -3
.On the control of gasoline engines -1
.On the control of diesel engines -2
.Engine Control Unit Pin Out -4
.ECU connected components -5
On-Board Diagnostics -6
CANBUS -7
Common causes of ECU failure -8
4
Automotive Engineering Eng. Hani Anis Shagder
 Engine management
Mechanical engineering department
Sana’a university
systems
Modern engine management systems allow powertrain designers to maintain
the critical balance between performance, fuel economy, and emissions. As
government regulations concerning emissions and fuel economy become
more demanding, the need for advanced fuel delivery technologies and
operational strategies that can meet these exacting standards becomes
.greater
A modern engine needs a system to manage the complex collection of inputs
and outputs and correctly interpret the ways they relate to each other. This
course is about the sophisticated systems that have been developed to
control the supply of air and fuel, and to control the exact moment at which
.this mixture is ignited
Incorrect application of any of these three inputs (air/fuel/ignition) can lead to
unsatisfactory performance, poor fuel economy, and/or excessive exhaust
.emissions
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 Sana’a university
Engine management Mechanical engineering department
systems
Enhancements in fuel economy and emission reductions are two active areas
of engine research. Advanced engine control techniques are engaged
because of the strict emission regulations and demand for higher fuel
economy. It is of great importance to design the power train components in
order to improve the fuel efficiency and reduce emissions while fulfilling
drivability and ride comfort issues. Control has always been a part of engine
design and it is one of the most complex problems in the application.
Automobile engines effectively encompass the spirit of mechatronic systems
with their abundant application of electronics, sensors, actuators and
microprocessor based control systems to provide improved performance, fuel
economy and emission levels. The classical approach of engine-control tasks
is accomplished by means of a mechanical approach, but now it is being
replaced by electronic control systems. In such systems, engine performance
such as power, torque, fuel-consumption and emission level, is significantly
affected by the control strategies followed in the engine management system
(EMS). The modern spark ignition engines are generally equipped with an EMS
6
whose taskTechnology
Modern Automotive is to provide the desired output
Eng. Hani from the engine and it plays an
Anis Shagder
 Engine management Mechanical engineering department
Sana’a university
systems
It controls the operations such as ignition, air- to-fuel ratio, idle speed and
complex variable valve timing, etc., in order to reduce the emissions and
improve the average fuel economy. Compared with ordinary embedded
systems, it requires more stringent demands on reliability, resource sharing
and cost efficiency. Engine management system (EMS) usually consists of
various sensors to monitor the real-time operating conditions of the engine
and actuators to control injector, spark plug, throttle, etc. The control signal
sent to different actuators is accomplished by means of the EMS control
system, which is comprised of a large number of control modules (control
loops) in its architecture. In addition to optimizing performance and ensuring
compliance with environmental regulations, the ECU enhances vehicle safety
and reliability. By integrating with other vehicle control systems, the ECU can
provide crucial data that influences overall vehicle dynamics. For example, in
the event of sudden braking, the ECU may communicate with the anti-lock
braking system (ABS) to prevent wheel lock-up, ensuring stable braking
performance. This level of integration helps create a cohesive driving
.experience
M where all systems work
odern Automotive Technology inAnisharmony
Eng. Hani Shagder 7
 Engine management Mechanical engineering department
Sana’a university
systems
The ECU’s role also extends to adaptive features that improve the
overall driving experience. For example, many modern ECUs utilize
machine learning algorithms that allow them to learn from driver
behavior and adapt to individual driving styles. This capability
means that over time, the ECU can optimize performance based on
how a driver typically accelerates, brakes, and maneuvers,
.resulting in a more personalized driving experience
Furthermore, the ECU is integral to vehicle diagnostics. It
constantly monitors the health of the engine and associated
systems, running self-checks to identify potential issues before they
become serious problems. When a fault is detected, the ECU can
trigger warning lights on the dashboard and store diagnostic
trouble codes (DTCs), which mechanics can access for
troubleshooting. This proactive approach to vehicle maintenance 8
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 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and
function blocks
Engine Control Hardware and -
Software
ECUs and PCMs typically consist of a -
microcontroller, memory (RAM, ROM,
.EEPROM), and input/output interfaces
Software for ECUs and PCMs is often -
written in low-level languages (C, Assembly)
for efficient execution and direct hardware
.control
ECU and PCM software includes complex -
control algorithms, lookup tables, and
diagnostics to manage engine operation and
.detect faults
Calibration data and parameters are stored -
in non-volatile
Modern memory and can beEng.
Automotive Technology updated
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 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and
function blocks
Hardware structure -1
The figure illustrates the
schematic representation of the
control system architecture of an
internal combustion engine. It
:includes
.microcontroller -
.memory (RAM, ROM, PROM) -
input interfaces -
output interfaces -
. Quad Driver Module -
.Pulse Width Modulation)PWM(-
primary backup control )FBC(-
.system 10
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 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
Microcontroller Unit (MCU) -
It contains the central processing unit (CPU) and has an own control unit for
the execution of instructions from the program memory, and a logic unit (ALU)
to handle arithmetic and logic operations. The CPU performs the flow control
with address management and a command decoder. Processing happens in
.one cycle (10 ns for 100MHz) towards the external memory
.Memories
Microprocessors operate with nonvolatile and volatile memories. Random
access memories (RAM) are write/read volatile memories and part of the
microprocessor as main memory. Their content is lost if the voltage is
switched off. Read-only memories (ROM) are nonvolatile. They store all
programs and data that will not change and are retained even in the absence
of a voltage. ROM’s contain usually program code for control functions and
constant data, programmed by the manufacturer. If programmed by the user,
programmable read-only memories (PROM) are applied. Some types of read-
.Modern
onlyAutomotive
memoriesTechnology can be erased and reprogrammed
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 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
Erasable read-only memories (EPROM) are
erased with UV-radiation and newly
programmed. Electrical erasable read-only
memories (EEPROM) can be electrically
erased and reprogrammed in the ECU with
a separate device. An advantage is that
each line of memory can be individually
rewritten. A next development are Flash
EPROM’s. They allow the erasure, or
flashing of complete memory storage by
electrical pulses and reprogramming, by
using a programming device. If the flash
memory is part of the ECU, flashing can be
applied on-board. Therefore, flash
memories have become standard as they
12
allow the modification of nonvolatile
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 Engine management Mechanical engineering department
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systems
Engine control structures and function blocks - 1- Hardware structure
-:Input interface
The input modules provide a link
between external sensors or switches
and the microprocessor. They receive
the analog, binary or digital input
signals and transmit them to the
microprocessor. The electrical analog
input signals may be filtered, are
converted to a uniform voltage, and
pass a multiplexer, hold element and
an analog-to-digital converter (ADC).
Digital inputs are acquired word-wise.
For incremental sensor inputs the
number of signal changes is
processed by counting circuits. A bus
interface allows the communication
with other electronic control units
(e.g. by CAN-bus), as for the 13
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automatic transmission, and chassis Eng. Hani Anis Shagder
 Sana’a university Mechanical engineering department
Engine control module
An engine control unit (ECU) consists of a central processing unit (CPU) or
microcontroller, memory (RAM, ROM, and EPROM), an input interface to
process signals from sensors, and an output interface to control actuators. It
also includes a power supply circuit for stable operation, and communication
.interfaces like the CAN bus for networking with other vehicle systems

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Automotive Engineering Eng. Hani Anis Shagder
 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
-:Input interface
:Analog-to-Digital Converter (A/D -converter or ADC) -
translate the continuous analog signals from the engine's various sensors into a digital
format that the ECU's central microprocessor can read, process, and use to make real-time
.operational decisions
:Oscillator -
Generates a precise and stable clock signal that provides the timing for all operations within
.the ECU
:Digital Buffer -
it primarily functions as an interface to provide signal isolation, enhance current capacity,
.and ensure signal integrity between different components
:Input Amplifier -
the input amplifier is vital for transforming raw, low-level, and potentially noisy sensor data
into clean, robust, and usable digital information that the ECU's main processor needs to
.make real-time decisions and control engine functions like fuel injection and ignition timing
:Power Supply Driver Chip -
is responsible for converting the vehicle's battery voltage into various stable, regulated
voltages required by the ECU's internal components (microcontroller, memory, sensors,
communication modules) and the actuators
Modern Automotive Technology Eng. HaniitAnis Shagder the power supply driver chip serves 15
controls. as
 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
-:Output interface
The output interface serves as a link to the actuators and relays. Based on the
drivers’ and sensors’ inputs the microcomputer calculates the manipulated
variables to the engine. The low-level signal outputs of the microprocessor are
amplified by the driver stages to the level required by the various actuators.
Usually the drivers may supply enough power for the actuators. In the case of
large currents as for the radiator fan the driver may switch a relay. Special
power drivers are required for an inductive ignition system. Based on the
calculated ignition time the ignition driver stage cuts the ignition coil to
generate the high voltage for the spark plugs. The injected fuel quantity
depends on the opening duration of the fuel injector and the fuel pressure.
The microprocessor delivers a digital signal for the beginning and duration of
the injection. In the case of high-pressure common-rail direct injection system
the injection duration is very small. A special application specific circuit (ASIC)
therefore generates a dynamic triggering signal to the DC/DC converter in the
16
ECU to generate a booster voltage
Modern Automotive Technology
of, Anis
Eng. Hani e.g. 65 V, which results in a boost
Shagder
 Sana’a university Mechanical engineering department
Engine control module

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 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
Output interface:- A special application specific circuit (ASIC) therefore
generates a dynamic triggering signal to the DC/DC converter in the ECU to
generate a booster voltage of, e.g. 65 V, which results in a boost current peak
followed by a holding current to drive the fuel injectors. Solenoid drivers for
proportional acting electromagnetic actuators are controlled with a high
frequent pulse-width-modulated (PWM) voltage. The PWM signal is, e.g.
generated with a special ASIC. An H-bridge with diodes allows boost voltages
for fast field changes in both directions. The position of the electrical throttle
is manipulated via an H-bridge to allow a controlled DC motor speed and
.position change in both directions
:primary backup control system )FBC( -
The Flash IC (Integrated Circuit) in an Engine Control Unit (ECU) serves as the
primary non-volatile memory component, responsible for storing the engine's
core operational software, firmware, and calibration data. This information is
.retained even when the vehicle's power is turned off
18
Modern Automotive Technology Eng. Hani Anis Shagder
 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
:primary backup control system )FBC( -
:This feature activates when
.The voltage of computer drops below 9 volts -1
.There is a (PROM) failure -2
.There is a (CPU) failure -3
Power Supply Circuit -
This circuit provides the necessary voltage and current to the ECU and its
.components, ensuring reliable operation
Sensors -
Oxygen Sensors: Measure oxygen levels in the exhaust to optimize the -
.air-fuel mixture
.Mass Airflow Sensors: Gauge the amount of air entering the engine -
.Throttle Position Sensors: Monitor the position of the throttle pedal -
.Temperature Sensors: Track engine coolant and air intake temperatures-
19
Modern Automotive Technology Eng. Hani Anis Shagder
 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
Actuators -
These
components
receive
commands from
the MCU to
perform actions,
:such as
Fuel Injectors: -
Control the
amount of fuel
injected into the
combustion
.chamber
Ignition Coils: -
Manage the
timing of spark
.plug activation 20
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Idle Air Control - Eng. Hani Anis Shagder
 Engine management Mechanical engineering department
Sana’a university
systems
Engine control structures and function blocks - 1- Hardware structure
Communication Interfaces -
CAN Bus Interface: Facilitates -1
communication between the ECU and
other vehicle control units, enabling
.coordinated actions
K-Line Interface: Primarily found in -2
older vehicles, this interface enables
communication for diagnostic purposes,
allowing external diagnostic tools to
connect and retrieve trouble codes and
.monitor real-time data
Diagnostic Port: Allows external -3
diagnostic tools to connect for
troubleshooting and programming,
providing access to both K-Line and CAN
21
.Modern
bus Automotive
systems in compatible vehicles
Technology Eng. Hani Anis Shagder
 Sana’a university Engine control module Mechanical engineering department
Engine control structures and function blocks - 2- Software structure
The software structure of an electronic control unit for engines is highly
.complex
It is hierarchically and modularly organized and must comply with strong real-
time
requirements. The engine control has to be seen in connection with the
overall powertrain control of the vehicle. Figure 5.1.4 shows a schematic
where the engine control itself is part of the powertrain management and
vehicle motion control. The powertrain management includes also the
transmission (automatic or manual shifted gear) and possibly electrical drives
(e.g. starter/generator for hybrid drives). The vehicle
motion control comprises the powertrain and the chassis in form of traction
control
electronic stability control (ESC), adaptive cruise control (ACC). In this ,)TCS(
way software function blocks are defined which can be treated as closed units
with defined interfaces. These function software blocks may be partially
integrated in the engine ECU, like
Modern Automotive Technology [Link] and
Hani Anis ACC, or implemented in other
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 Sana’a university Engine control module Mechanical engineering department

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Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university Engine control module Mechanical engineering department
Engine control structures and function blocks - 2- Software structure
The basis software serves in lower levels to organize the data flow from the
input components to the microcomputer and to the output components. This
includes
the reading of sensor data or set points via the analog, digital and binary
inputs
or sending command signals to the various driver stages, as well as
communication
and component diagnosis tasks. Therefore the basis software is hardware-
,oriented
.ECU specific and independent on the application programs of the ECU
The application software operates in higher levels, and executes the engine
control
and some vehicle control functions. It receives the input values via the basis
software functions of the input components and sends the control outputs to
the basis
software ofTechnology
Modern Automotive the output components. The
Eng. Hani application software is in principle 24
Anis Shagder
 Engine management Mechanical engineering department
Sana’a university
systems

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Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university Engine control module Mechanical engineering department

Engine control structures and function

blocks - 2- Software structure
For the development of the software
special tools are applied. They can be
divided in function development tools,
software implementation tools and
calibration tools. The software
implementation is performed either with
manual programming or by automatic
code generation. The software function
development begins for example by using
MATLAB/ Simulink and transfer to
language C with a precompiler. The C-
program is then turned into machine
code with special compilers. This
procedure is, e.g. realized with the
industrial software systems and Eng. Hani Anis Shagder
Automotive Engineering 26
 Sana’a university Mechanical engineering department
Software structure
CONTROLLE
R DESIGN
The injection
time is a
function of
the fuel mass
density speed
according to
equation (1)

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Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university Mechanical engineering department
Software structure
CONTROLLER DESIGN
Most of the parameters
in equation (1) are
constant. The
parameters that are
dependent on the
current state of the
engine are: manifold
absolute pressure,
,intake air temperature
and volumetric
efficiency (Ev).
Equations (2), (3), and
illustrate how the )4(
volumetric efficiency
are calculated by
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Eng. Hani Anis Shagder
:Modern
the ECMAutomotive Technology
 Engine management Mechanical engineering department
Sana’a university
systems

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Modern Automotive Technology Eng. Hani Anis Shagder
 Engine management Mechanical engineering department
Sana’a university
systems

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Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university Mechanical engineering department
Engine control module

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Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university Engine control module Mechanical engineering department

- Engine control structures and function blocks

EC function blocks -3
The overall control of internal combustion engines consists of discrete-event
or
crank-angle or time dependent control functions. After turning the ignition key
the
ECU has to be started. It passes through different discrete ECU-states, like
,booting
initializing the controllers, testing of hardware and software and the engine
starting
program as shown in the following Figure, block I. The start command then
lets the starter turn and starts the engine according to a special starting
program. Hence, the ECU follows a certain boot-up program and thereby goes
through different discrete states. The engine operation also distinguishes
different discrete engine states, block II. For starting, a cold-start and warm-
start phase has to be distinguished. This is followed by a warming-up phase.
Also for idling
Modern Automotive speed control, a cold
Technology orAnis
Eng. Hani warm
Shagderstate has to be provided. After 32
 Sana’a university Engine control module Mechanical engineering department

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- Engine control structures and function blocks

EC function blocks -3
The transition from one state to another depends on conditions, which are for
example the ambient and the coolant or oil temperature. Other discrete-
events are the shifting of gears, the regeneration of catalysts or particulate
.filters or the limp-home mode, and finally the shut-off of the engine
The main control functions of combustion engines are either crank-angle
dependent or time dependent, block III. According to the batch process
characteristic of the combustion the injection and ignition control depend
on the crank-angle position and are therefore based on the pulses of the
crankshaft tooth wheel sensor. Other control functions depend only on
time, like the air flow and EGR flow control, emission (lambda) control, fuel
supply control and coolant control. Torque control is with regard to injection
and ignition crank-angle dependent and with regard to air and EGR flow
.depends on continuous-time
of all functions of the electronic control unit program are 50%
.Modern
related to
Automotive reducing exhaust Eng.
Technology gas Haniemissions
Anis Shagder 34
 Sana’a university Engine control module Mechanical engineering department

EC function blocks -3
The arrangement of the discrete states of the ECU and the engine and the
continuous
control and diagnosis functions in the previous figure, shows a hierarchical
structure
within the functions of the ECU. After the boot-up program of the ECU and the
starting command through the starting key the cold- or warm-start program
comes action. The main input is then the driver’s accelerator pedal and after
idling, the various engine control functions start to operate. The engine passes
through the warming up phase and the control functions obtain mainly
temperature dependent correcting values and set points. Also gear shifting
and exhaust after-treatment influence, e.g. Set points of control functions.
Therefore these discrete engine states are one level above the continuous
control functions. The diagnosis functions can be seen for signal processing as
parallel to the control functions but have with regard to a safe driving function
of the automobile a
lower levelTechnology
Modern Automotive significance, becauseEng.
they only
Hani Anis indicate and store faults and do no
Shagder 35
 Sana’a university Mechanical engineering department
Example2:- Block diagram of the control functions of the
Fig. 4 shows the three subsystems of the engine control system : admission,
.EMS
injection, and ignition. which control air mass, fuel mass, and electric spark
.timing, respectively

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Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university Engine control module Mechanical engineering department

Basics of Control Theory in Engine Management

The use of mathematical methods that constantly or discretely modify engine operating
parameters to achieve desired performance characteristics is known as control theory,
this is in the context of engine management. The ECU regulates solenoids, relays, and
.DC motors to adjust the flow of fluid through the subsystem and open or close valves
Feedback Control: This refers to a system in which the output determines the
control action. The engine's output parameters, including speed, torque, and emissions,
are measured by the ECU, which then modifies the input parameters until the engine's
.output parameter equals the required reference value
Feed-Forward Control: This predicts changes by computing control actions
before the actual change in output, based on quantifiable disturbances such as throttle
.position
PID Controllers: One kind of feedback control is the PID controller. Because of their
ease of use and efficiency, proportional-integral-derivative controllers are frequently
employed in engine management and other applications involving the control of
electromechanical actuators. To calculate the control action, they use error terms that
are generated from the discrepancy between the measured output and the intended set
.point
Model-Based Control: Complex engine control techniques can compute control 37
.Modern
actionsAutomotive anticipate engine behaviorEng.
and Technology Hani Anis
using Shagder
mathematical models of the engine
 Sana’a university Mechanical engineering department
.Example3:- Block diagram of the control functions of the EMS

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Modern Automotive Technology Eng. Hani Anis Shagder
 Sana’a university Mechanical engineering department
.Block diagram of the control functions of the EMS
The gas pedal input serves as the main reference for the entire controller. The
reference engine speed, measured in Revolutions Per Minute (RPM), is
computed from the gas pedal and used as reference input to the RPM
Proportional-Integral (PI) controller, which evaluates the error between the
reference engine speed and the actual engine speed, and computes the
throttle valve value based on the well-known PI control algorithm. The throttle
valve value is used as the reference input to the throttle PI controller, which
sends Pulse-Width Modulation (PWM) commands to the physical throttle valve,
with feedback signal from the Throttle Position Sensor (TPS). The advance
ignition controller takes as input the engine speed in RPM and pre-stored
maps, and computes the spark advance. The dwell time controller takes as
input the engine speed, voltage of the alternator and the engine coolant
temperature, and computes the dwell time. The injection time is computed
based on the density of air inside the engine intake. The final injection time is
adjusted based on the current engine state and the volumetric efficiency. This
adjustment increases the injection time during acceleration and decreases the
39
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injection time, or cuts Eng. Hani Anis Shagder
 Sana’a university Engine control System Mechanical engineering department

Engine control and diagnosis -

The (ECU) has the task to control, optimize and supervise all relevant
functions of an internal combustion engine (ICE). At first glance this
:comprises
torque generation according to the drivers accelerator pedal •
low fuel consumption •
low exhaust emissions and low noise (compliance with legislation) •
.good driving behavior •
With regard to the general assembly of internal combustion engines the
control functions
:can be dedicated to following engine subsystems or engine parts
Intake system (air system) .1
Injection system .2
Fuel supply .3
Combustion and crankshaft drive .4
Lubrication .5
Exhaust gas system .6
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 Sana’a university Engine Control System Mechanical engineering department

Engine control and diagnosis -

A part of the subsystems is basically controlled mechanically, as for
example, the
inlet and outlet valve timing and lift through the camshaft for four-stroke
,engines
the fuel pressure and oil pressure with overpressure relief valves and the
coolant
.temperature with thermostatic expansion valves
Many other important variables are controlled electronically like the air
flow, fuel flow, combustion, torque, speed and exhaust gas treatment.
However, also the camshaft can be controlled electronically in the case of
variable valve trains (VVT) and the fuel pressure for common rail direct
injection systems, as well as the oil pressure. Therefore electrically
commanded actuators are required which operate with electrical, pneumatic
or hydraulic auxiliary energy, and sensors at the engine with electrical
.outputs
The optimization of the thermodynamic,
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fluid dynamic and mechanical design
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Eng. Hani Anis Shagder
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Engine control and diagnosis -

The electronic control unit (ECU) controls
.the start. - idle. - warm-up -
normal operation. - Acceleration. --
.deceleration
The increase of control functions is demonstrated by the size of programs and
data of the digital microcomputer based system. Within the last 15 years the
clock frequency of
the microprocessors has increased from 12 to 250 MHz, the data bus width
from 8 bit
to 32 bit, program storage from 32 Kbyte to 20 Mbyte, the computing time
from about
to 400 millions instructions per second (MIPS), and the calibration labels 10
from
.about 2500 to 50000
This development was mainly influenced by the increase of variabilities to
optimize
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 Sana’a university Engine Control System Mechanical engineering department
Engine control and diagnosis -
The following Figure shows a simplified signal flow diagram for gasoline
engines. The engine control system has to be designed for 6–8 main
manipulated variables and 5–8
measured output variables, leading to a complex nonlinear multiple-input
multiple output
system. Because several output variables cannot be measured in mass
production vehicles, like the torque and some emissions, as they are too
costly or may not be robust enough, some output variables of the engine are
controlled by feedforward structures, also called open-loop structures.
This requires that the driver‘s pedal position, several influencing variables like
the engine speed, air mass flow, air temperature and pressure, oil and coolant
temperature have to measured and feedforward control actions on the main
manipulated variables have to be specified. In the case of gasoline engines
feedback control or closed-loop control is used for λ- control and knock
control. Diesel engines use charging pressure, air mass flow rate and
overspeed feedback control, Both engine types have idling speed and coolant 45
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Eng. Hani Anis Shagder
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Engine control and diagnosis -
The closed loop structures compensate also not measured disturbances, but
their controllers must be precisely and robustly adapted to the engines
nonlinear dynamic behavior. All the control functions depend strongly on the
load and speed and on the operating state such as starting phase, warm-
up, normal state, idling, overrun and
.shutdown
On the control of gasoline engines -
The figure illustrates the main components of a direct injection gasoline
engine with its actuators and sensors. To generate a certain torque at the
crankshaft the gasoline engines require a very specific air-fuel mixture. For an
optimal combustion they need a close to stoichiometric mixture of air and fuel
in the range 0.8 < λ < 1.4 and because of the mostly applied three-way
catalyst the air/fuel ratio must be precisely in the range of 0.98 < λ < 1.02.
Therefore the air is usually throttled for part-load by a throttle valve so that
the cylinders suck the air from the manifold with sub-atmospheric pressure.
The air mass (air charge) taken in by the cylinders determines together with48
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Engine control and diagnosis -
However, the conventional load control of the engine by an upstream throttle
generates charging losses in contrast to diesel engines. The control unit
(ECU) commands the electrical actuated throttle valve depending on the
drivers accelerator pedal position and adjusts the injected fuel quantity with
the fuel injection system by feedforward control. The fuel is injected either in
the intake manifold upstream the inlet valves (port injection) using a low-
pressure pump (4–6 bar) or directly into the combustion chamber with
controlled high-pressure fuel pumps (120–200 bar). The injection into the
intake manifold during the induction stroke of the cylinders may consist of
several injection pulses (multi-point injection) and is applied for a
conventional homogeneous combustion. The ECU converts the accelerator
pedal position into a desired calculated torque value. By using various
correction functions the air charge and the corresponding fuel injection mass
per cylinder and an optimal ignition angle relative to the top dead center of
the crankshaft are calculated and the manipulated variables throttle valve
angle, fuel injection angle and duration and the ignition coil activation are set
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Engine control and diagnosis -
The injected fuel mass is corrected by a (cascaded) lambda feedback
controller with measurements of λ in the exhaust system before and after the
catalyst in order to reach a stoichiometric combustion for an optimal
conversion of CO, HC and NO in the three-way catalyst. The direct injection in
x

the cylinders has as additional manipulation the high pressure in the fuel rail
and allows different types of combustion. At lower engine speed
and torque a stratified cylinder charge can be reached, where in one zone a
combustible
air/fuel mixture cloud is generated and transferred to the spark plug. The
other zone contains excess air and residual exhaust gases. The zones are
controlled by a turbulence flap in the manifold. Thus, the throttle valve can be
opened, avoiding throttling and charging losses, resulting in better efficiency.
The fuel is injected during compression. However, the lean combustion
generates larger NOx concentrations and because of the excess air a three
way catalyst cannot be used. Therefore NOx is reduced by exhaust gas
recirculation (EGR), manipulated by an EGR-valve and a NOx accumulator- 51
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Engine control and diagnosis -
Hence, this two-mode (also three-mode) combustion requires precise control
functions for several variables and operates by using universal (broadband)
lambda sensors with variable set points for the air/fuel ratio. A Nox sensor
may also be used. In addition knock feedback control corrects the ignition
angle by using one or two knock sensors at the crankcase in order to prevent
.knocking combustion, which can lead to engine damages
Based on these main control tasks Fig. 1.3.5 shows a control-oriented block
structure
for a gasoline engine. The overall functions of the engine control system are
frequently
summarized by the term electronic engine management. The individual
feedforward
and feedback control functions show a hierarchical structure which consists of
higher level and lower level control functions. The higher level control
functions can be grouped in control subsystems or modules for torque control,
injection and air/fuel control, ignition control, knock control, air charge, and 52
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Engine control and diagnosis -
Figure 1.3.5 shows seven main actuators which manipulate the air
flow, the injection mass and angle, rail pressure, ignition time,
camshaft phase, and recirculated exhaust gas flow. Some control
functions change for different operating conditions like cold start,
.warming-up phase and normal operation, idling, and shut-off
The control of automatic transmissions with torque converters and
planetary gears or double-clutch transmissions with spur gears is
mostly realized in a special electronic control unit attached to the
transmission housing. The speed of the engine results together
with the power consuming load, here the transmission and the
.vehicle

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On the control of diesel engines 1.3.2 -
The main components of a diesel engine with turbocharger are shown in Fig.
.1.3.6
The air for diesel engines is sucked into the cylinders with slightly lower than
atmospheric pressure, if no turbochargers are used and the torque is
manipulated by the injected fuel mass. However, most of the modern diesel
engines have turbochargers
to increase the torque and the power. The air charge then depends on the
charging
pressure, which is controlled by the charging pressure controller, e.g. )boost(
by changing the wastegate position or the position of a variable geometry
turbocharger
At low load, the diesel engine operates with large excess air, i.e. with .)VGT(
large
air/fuel ratio expressed by the excess-air factor λ. Only at high loads, λ comes
closer
to 1. If it gets too small, the diesel engine starts smoking. The relative high 55
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On the control of diesel engines 1.3.2 -
In order to lower the combustion temperature and the NO concentration, the
x

exhaust gases can be recirculated to the intake on cost of the fuel efficiency.
Modern diesel engines have either a common rail or a unit pump injection
system with pressures until 2200 bar. The ECU commands the injected fuel
mass into the cylinders according to the drivers accelerator pedal position. In
order to influence the burning process with regard to optimized fuel
consumption, NOx and soot formation and the generated noise multiple
injections are applied, with pre-, main-and after-injection pulses. The air mass
flow rate in the intake system is indirectly controlled by the EGR valve
(passenger car diesels mainly). Because the fresh gas mixture taken in by the
cylinders is about constant for a certain operating point, an increasing EGR
flow rate m˙ results in a reduction of the air flow rate m˙ . This means that
egr air

the ratio m˙ /m˙ is changed. The control variable of the closed air mass
egr air

control loop is the measured mass flow rate and its reference value is
. calculated from the desired reference excess air factor λ ref

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On the control of diesel engines 1.3.2 -
A further feedback control is the charging
pressure control loop, which manipulates
either a wastegate for fixed geometry
turbochargers or the guide vanes of
turbochargers with variable geometry (VGT).
.Both closed control loops are strongly coupled
Diesel engines require a speed controller for
the maximum speed in order to limit the
speed by reducing the fuel mass. Otherwise
the engine could be damaged by over
speeding. This is because a load control by
intake throttling is missing. Speed control is
also applied for idling, but not during the
normal operating range for diesel engines in
vehicles. The exhaust after-treatment has the
task of reducing HC, CO, NOx and particulates. 58
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An engine control unit (ECU) pinout -4

is a cross-reference of each pin on the ECU connector and its specific function, such as power,
ground, sensor inputs, or output controls for components like fuel injectors and ignition coils. To
find a specific pinout, you need to use the ECU's part number or the vehicle's
VIN to look up the correct wiring diagram, often found in repair manuals or
.specialized online services
How to find and use an ECU pinout
Identify the ECU: The first step is to find the specific ECU (or ECM) for your
.vehicle and note its part number
Search for the diagram: Use a search engine to find the pinout diagram by
searching the ECU part number followed by "pinout". You can also use
specialized automotive repair websites and enter the vehicle's VIN for the
.most accurate results
Use special programs:- There are some special programs that collected
OBD2 pinouts of all popular car manufacturers on one page. All pinouts are
presented with pictures and visual schemes
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 Engine
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An engine control unit (ECU) pinout -4

Analyze the diagram: The pinout will show a table or diagram that lists
:each pin by number and describes its function. This includes
Power and Ground: Pins for constant battery power and system -
.grounds
Sensor Inputs: Connections for sensors that provide data to the ECU, -
.such as throttle position, oxygen sensors, and crankshaft position
Output Controls: Pins that control actuators like fuel injectors, ignition -
.coils, and relays for the fuel pump and fans
Follow wiring best practices: When making any connections, follow the -
vehicle's wiring diagram and use proper splicing techniques. The diagram will
.show which wires are joined and where to install fuses for safety

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Engine control module

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ECU connected components -5

- Input (sensors):- The ECU relies on
sensors to gather data. Examples
include oxygen sensors, mass airflow
sensors, throttle position sensors, and
crankshaft/camshaft position sensors.
Sensors are used to convert engine
operating conditions like temperature,
rpm, throttle position, and other
parameters into electrical signals
which the ECM constantly monitors.
Electronic circuits built into the ECM
sense some circuits, (like the electrical
load circuit) for proper operation. With
this data, the ECM has sufficient
information to run the programs that
operate the
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 Sana’a university Mechanical engineering department
Engine control module
ECU connected components -5
Output (Actuators): These are the components the ECU controls -
to adjust the engine. Examples include fuel injectors, ignition coils,
.and idle air control valves
Output commands are sent from the microprocessor inside the ECM
to
the various output driver transistors. The output drivers then turn on
or off, causing the actuator (output) device to turn on or off.
Types of output actuators are:
• Solenoids - Fuel Injectors, Vacuum Switching Valves (VSV).
• Relays - Circuit Opening Relay.
• Transistors - Igniter.
• Lights - Malfunction Indicator Light (MIL).
• Motors - Electronic Throttle Control Motor.
• Heater(s) - Oxygen and Air/Fuel Ratio sensor heaters.
• Clutch - Electronic Throttle Control.
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Engine control module
ECU connected -5
components
An engine harness
functions as the vehicle's
electrical backbone,
transmitting power and
control signals between the
engine control unit (ECU) and
various engine components
like sensors and actuators. It
organizes wires into a
protected, durable system,
ensuring reliable operation
by preventing short circuits,
signal interference, and
damage from the harsh
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engine environment of heat,
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Engine Control

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Engine Control

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Engine Control

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-:On-Board Diagnostics -6
Diagnostic Link
-:Connectors
The Diagnostic Link
Connector (DLC) provides
a way to communicate
with the ECM and
simplifies many diagnostic
procedures. Three types
of DLCs have been used,
and some years will have
all three. OBD II
regulations require a
standard DLC for
vehicles, and it is referred
.to as DLC3
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-:On-Board Diagnostics -6
On-Board Diagnostics:-
On Board Diagnostics (OBD) monitor the engine’s systems and components and
report failures through Diagnostic Trouble Codes (DTC). The state of California has been instrumental in
setting emission standards. For this reason, systems have appeared on California vehicles before
appearing on vehicles and engines sold in other states. Today federal and state standards may vary, but
the equipment and monitoring systems are essentially the same.
OBD Objectives:- The primary objective of OBD systems is to reduce vehicle and engine emissions
and the possibility of further damaging emission components by detecting and reporting a malfunction.
To meet that objective:
• The operator or driver is alerted of
a malfunction in the emission control
System by the Malfunction Indicator
Lamp (MIL).
• All vehicles or engines are certified to
meet or exceed emission standards.
OBD systems are designed to monitor
and report malfunctions when emission
output will exceed mandated standards.

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CANBUS -7
CANBUS or CAN bus – Controller Area Network bus
An automotive serial bus system developed to satisfy the following requirements : Network
multiple microcontrollers with 1 pair of wires. Allow microcontrollers communicate with each
other. High speed, real-time communication. Provide noise immunity in an electrically noisy
environment. Low cost

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Common causes of ECU failure -8

1- Water damage: Moisture can corrode the internal components, especially
as seals degrade over time.
2- Electrical issues:
- Power surges can overload the circuits.
- Electrical shorts, either internal to the ECU or in the wiring, can cause
damage.
- Poor grounding can also lead to problems.
3- Overheating: Excessive heat, often from being too close to engine parts,
can cause the ECU to malfunction.
4- Wear and tear: Over many years, the components inside the ECU can
simply wear out and fail.
5- Vibration: Constant vibration from the vehicle can cause internal solder joints and
components to become loose.
6- Faulty components: Issues with other components, such as a failing Variable Valve Timing
(VVT) motor, can sometimes cause a circuit in the ECU to blow.
80
7- Incorrect
Modern jump-starting: Jump-starting
Automotive Technology a car
Eng. Hani incorrectly
Anis Shagder can also damage the ECU.
 How to diagnose a faulty ECU with no
Sana’a university Mechanical engineering department

communication
Diagnosing a faulty Electronic Control Unit (ECU) when there is no
communication can be challenging but manageable with a systematic
approach and the right tools. Here’s a practical guide to help you through the
:process
.Check the power source. 2- Check the ground -1
.Check the Connection. 4- Visual Inspection -3
.Resistance Checks. 6- Bench Setup: If possible -5
.Check the Internal Components. 8- Use External Modules -7
:Common Issues
ECU Failure: Internal faults such as damaged circuits, faulty
.microcontrollers, or corrupted firmware can lead to communication failure
Wiring Issues: Faulty wiring harnesses, damaged connectors, or poor
.ground connections can disrupt signal transmission to and from the ECU
Network Issues: Problems within the vehicle’s communication network (CAN
bus) can prevent the ECU from establishing communication with other
.Modern
modulesAutomotiveand diagnostic tools
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:ECU Replacement and Re-Programming

ECU programming is a process that involves modifying the settings within the Engine
Control Unit (ECU) to improve a vehicle’s power, fuel efficiency, and overall performance. By
adjusting certain parameters, technicians can unlock the full potential of the engine, often
enhancing its performance beyond the factory settings. This service is popular among car
enthusiasts and drivers who want to get the most out of their vehicles.
Replacement: If all diagnostic efforts point to a faulty ECU with no communication, consider
replacing the ECU with a new or refurbished unit.
Re-Programming: Ensure the replacement ECU is compatible with your vehicle model and
requires re-programming or re-initialization to match the vehicle’s specifications.
What is an ECU flash?
ECU ReFlashing, in general terms, is a method of erasing the ECU's program code
(instructions) and reprogramming the vehicles ECU's Flash Memory with altered program code,
thereby changing how the ECU will respond to inputs.

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