YE3 FTB Ppt Final Submission Dheeraj
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Transcript of YE3 FTB Ppt Final Submission Dheeraj
FTB Wiring and Engine Harness preparation for New model introduction
(YE3) in ES-3
ByDheeraj saini
(Staff ID 232246)
Under the Guidance of
Mr. Rakesh RawatEAE Dept (PE)
FTB – An Overview• FTB stands for Fire Test bench.
It is used to check the critical engine parameters after whole of the engine assembly is finished.
Various engine parameters and sensors that are checked in FTB are as follow:
• Parameters :
(a)Idle RPM
(b)Oil Pressure
(c)Vacuum (Intake manifold)
(d) Any type of leakage from E/G
• Sensors
FTB Nomenclature
Water OUT
Water INE/G resting Fixture
FTB Control Panel
FTB Exhaust
DISPLAY PANEL
Run Engine at 3000-4000 rpm and allow it to reach Idle rpm (950 +/- 100)
Oil pressure check Idle rpm (Min- 1.2 bar); At 4000 rpm (Min-3.5bar)
Check vacuum pressure at idle rpm- 485 mm of Hg (max)
Check Engine Vibration & abnormal noise
ENGINE TESTING CYCLE ON FTB
Oil leakage from Camshaft seal, cylindrical head, Gasket cylinder head, tappet cover& Cam sensor.
Water leakage from Gasket cylinder head, Intake manifold block plate, water pump
Accelerating beyond 4000 rpm to check Cam sensor working
Check oil color: if white send to repair
Tightening of OPS & DP (Set OPS at 140 Kgf cm & DP at 350 Kgf cm)
5 Minutes
Remove Drain Plug
1. VTA (Throttle Positioning Sensor)
• Monitors the throttle valve position & sends signal to ECU
2. CMP ( Cam
Positioning Sensor )
•Sends signal about positioning of cam during its rotation to ECU.• ECU uses this information to determine spark timing and fuel delivery.
3. CKP ( Crank Positioning Sensor)
• Monitors the position or rotational speed of the crankshaft.
4. ISC ( Idle
Speed Controller )
• Receives signal from ECU about the idle speed at which the engine should run at particular condition.
5. KNK ( Knock Sensor) •Senses the knocking level in the middle cylinder & sends the signal to ECU.
6. IGT ( Ignition Coil) • Receives signals from ECU regarding the spark timing depending upon the load conditions.
7 TMAP (Temperature
Manifold Absolute pressure sensor)
•Combination of PM & THA.• Measures the vacuum from the engine & temperature of water.
Sensors used in YE3 FTB
THROTTLE (VTA)
IGNITION COIL (IGT)CAM (CMP)
INJECTOR
VACUUM
IDLE SPEED CONT.(ISC)
CRANK (CKP)
SENSOR Nomenclature
FTB modification & Harness preparation for New model Introduction :- 1. ECU drawing & Engine harness drawing study : a. ECU DRAWING is used to study and finalize the sensor connections for FTB wiring.
b. Wiring routes of sensors to ECU are taken from E/G HARNESS DRAWING.
2. Harness preparation drawing is made consisting of connection between various sensors & ECU.
Harness is made in 2 steps : a. E/G HARNESS ( from sensors to 16 pin connectors ) b. CABLE HARNESS ( from 16 pin to 37 MS pin connector in FTB )
3. FTB WIRING is done to connect the cable harness to the ECU.
4. External Connections like Power Supply & ground are also provided through FTB wiring.
Example to make the Harness ConnectionsTo understand the making of harness from the drawing lets take an ISC
connector for YE3 and study all its connections and how the connections are made in ECU.
ISC Connector :
According to engine harness drawing, connector shown is :
• It has 3 ports, now from the harness table we can get the destinations
EA75 EA24 ED1B
FROM TO
From Harness Table, we get:
EA 75- Signal is coming from ECU #2 to ISC.EA 24- Signal is coming from ENG BONDER #2 to ISC.ED 1B- Signal is coming from ENG BONDER #3 to ISC.
E/G Harness drawing Table
EA75 EA24 ED18
ECU #2
ENG BONDER #2
• Out of the two connections going to ENG BONDER, one is for the external power supply & other one is grounded.
• So in ECU the final connection will be.
ENG BONDER #3
ECU #2ECU connections from E/G Harness drawing Table
ECU CONNECTOR FOR YE3 BSIV
+BB STA
IMC IMD IGS
DNL
E26 E24
ECU #1 :
IGT1
+B1 +B2 E03 E01 E02 E1
CMPCKP+CKP- IGT2IGT3 ISC
KNK+KNK- E31
E32
ECU #2 :
SOXH OXH #3 #2 #1
E33 E22 S0X THW THA PM
VTA
FPR
VCC1VCC3 VCC2
OX
VCC4E21 E23 E34
ECU #3 :
LAYOUT OF FTB HARNESS
16 Pin Maleconnector
16 Pin Femaleconnector
16 Pin Maleconnector
16 Pin FeMaleconnector
THW
CMP
ISC
TMAP VTA CKPKNK
IGT1
IGT2
IGT3
37 Pin Connector to 16 Pin M/F Connectors
960mm
770mm
850mm 910mm
760mm
900mm
710mm
750mm
780mm 970mm770mm
900mm
795mm
680mm
Starter
710mm
37 Pin MS Connector
YE3 FTB Harness
ECU
Ground
Power supply
Suggestions for Process Improvement
1) Provision of online sensor testing for some sensors which are not tested in FTB. Eg- oxygen sensor, Air temprature sensor.
2) A test Rig setup to check the FTB Engine harness and provide information about the harness testing details in the form of Barcode.