Note: This Chapter deals only with systems that are directly related to the operation of the engine. Placement, the procedure for replacing control devices, the design of illuminators, the procedure for replacing lamps and other equipment are described in Chapter 12, and the principles of their functioning and the procedure for managing them are described in Chapter «Controls and methods of operation».
1. The composition of the electrical equipment of the engine includes components of ignition systems (petrol models), preheat (diesel models), charge and start, as well as an electronic engine management system.
2. The ignition system provides ignition of the air-fuel mixture supplied to the combustion chambers of the cylinders of gasoline engines. To form a spark of the required intensity, the 12-volt voltage of the on-board network is converted in the ignition coils into high voltage (up to 30 000 V). Its main working components are candles, coils and an ignition module. The distribution of the high voltage supply to the spark plugs is controlled by the engine control unit (ECM) - manual adjustment of the ignition timing is not performed, - if the required settings are violated, the failed components should be replaced.
3. On all gasoline engines covered in this manual, except for the Z16SE engine, 3 or 4 ignition coils (one per cylinder) combined into a single ignition module. The coils are placed in a common housing mounted above the spark plugs. The design of the module and coils eliminates the need for high voltage wires, as the coils are connected directly to the spark plugs. The ECM, based on the analysis of the information received from the information sensors of the position of the camshaft and crankshaft, in accordance with the program of the embedded processor, issues control electrical impulses to the ignition module, the configuration of which uniquely determines the ignition moment. In this case, the voltage supply to the primary windings of the ignition coils is interrupted, which leads to a sharp change in the electromagnetic field and, as a result, the generation of high voltage in the secondary winding. High voltage is applied to the spark plugs. The interelectrode gap of the spark plugs is set in such a way that when voltage is applied to the spark plug, sparking occurs between the electrodes «breakdown». The resulting «breakdown» a spark that ignites the air-fuel mixture. Control elements of the ignition system are not subject to wear and do not require regular maintenance. According to maintenance schedule (see chapter 1) only the spark plugs should be replaced.
4. On the Z16SE engine, high voltage (BB) voltage is generated in two ignition coils - each of which provides the functioning of two candles. Both ignition coils are placed in a single housing, which is mounted on the left side of the cylinder head. The coils are connected to the spark plugs with BB wires. The maintenance procedure for BB wires is given in Chapter 1.
5. The pre-heating system of a diesel engine is designed to warm up the combustion chambers in order to confidently ignite diesel fuel. Glow plugs are used as heating elements, the operation of which is controlled by an appropriate electronic unit. A glow plug is screwed into the combustion chamber of each cylinder. Spark plugs are heated by electric current before starting, during starting and for some time after starting the engine. The power supply to the glow plugs is controlled by the ECM. At the same time, the corresponding control lamp lights up on the instrument panel (see chapter «Controls and methods of operation»).
6. The fuel filter of the diesel engine power supply system can also be equipped with a heating system that prevents «waxing» diesel fuel. The heating element is installed between the fuel filter and its housing. Power for fuel heating is supplied by ECM commands through a temperature-sensitive sensor-switch mounted in the filter housing.
7. The charging system provides electrical power to the ignition system, lighting and signaling devices, radio and other consumers of electricity. It includes an alternator, a voltage regulator built into it, a charge control lamp (see chapter «Controls and methods of operation»), battery, fuses and wiring connecting the listed components. The generator is driven by a belt drive from the crankshaft pulley and is mounted at the front of the engine. The charging system does not require regular maintenance. However, the condition of the multi-ribbed belt, battery, connecting wiring and its terminal connections should be checked periodically (see chapter 1).
8. The starting system cranks the engine to start it. The main components of the system are a starter with a traction relay installed on it, a storage battery, an ignition switch and connecting wiring. The assembly of the starter with the traction relay is fixed on the power unit, near the clutch dome. When the ignition key is turned to position «III» (START) battery power is supplied through the launch control circuit to the starter traction relay. The relay switches the battery power directly to the starter motor. The motor begins to rotate, simultaneously turning the crankshaft of the engine by the ring gear of the flywheel / drive disk. The procedure for starting the engine is described in the relevant Section of the Chapter «Controls and methods of operation».
9. Engine management system (see also Chapter 4) is the main connecting element of all the above systems - this is the brain of the engine. The initial data is sent to the electronic module of the system from various information sensors and other electronic components (switches, relays, etc.). Based on the analysis of the data coming from the information sensors and in accordance with the basic parameters stored in the processor memory, the ECM generates commands for the operation of various control relays and actuators, thereby adjusting the engine's operating parameters and ensuring maximum engine efficiency with minimum fuel consumption.
10. The ECM is a complex set of electronic circuits and attempting to make any changes on your own will lead to malfunction and engine failure. A complete diagnosis of the engine management system can only be performed using special diagnostic equipment that allows you to read the failure codes stored in the processor memory. Analysis of the read information allows you to quickly identify the source of the failure and eliminate the cause of its occurrence.
Precautionary measures
Attention: In the electronic ignition system, a very high voltage is generated! Persons with an implanted pacemaker must not be allowed to service the components of the ignition system!
11. When servicing the components of electrical systems of the engine, special precautions should be taken to avoid the risk of failure of semiconductor elements, as well as to prevent electrical injury.
12. Be sure to remove watches, rings, and other metal jewelry when servicing electrical equipment. Even with the battery disconnected, discharging capacitors by accidentally grounding their terminals can result in electric shock or severe burns.
13. Avoid reverse polarity when connecting the battery. Components such as the alternator or electronic control units contain semiconductor elements that can be damaged if the wires are connected incorrectly.
14. When starting the engine from an external power source (see chapter «Introduction»), or when connecting the charger, also observe the polarity of the wires.
15. Never start the engine with the charger connected to the battery. Always disconnect both wires from the battery before charging from an external power source (first negative).
16. Remember that excessively long cranking of the engine by the starter may cause serious damage to the electric motor of the latter as a result of overheating. Avoid using the starter continuously for more than 20 seconds on petrol models and 30 seconds on diesel models, after which it should be allowed to cool for a minute.
17. Switch off the ignition when performing electrical checks and before connecting/disconnecting diagnostic equipment. Never disconnect electrical wiring from the battery, alternator, or diagnostic equipment while the engine is running.
18. Never test for generator output voltage by grounding its terminals. Do not also ground the ignition coil windings to ground.
19. When performing any electrical maintenance work, ensure that the negative cable is disconnected from the battery.
20. Always disconnect the battery, alternator, and components such as power/ignition control modules before using arc welding to avoid risk of damage.
21. Avoid getting hands, hair and loose clothing in contact with the rotating alternator drive belt during engine running checks.
22. Before starting the steam cleaning of the engine compartment, wrap the generator in a plastic bag, which should then be securely fastened with rubber bands.
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