Analyze and Evaluate Electrical

and Electronic Faults in Engine

Management Systems
AURT575093A

Name: Hyun Hak Han

Group: 108
Teacher: Brendon Couch
 • Vehicle Details
Vehicle make and model

Ford (Falcon AU3 FORTE SR)

Year of manufacture

2002

Engine configuration and size

4.0L (3995cc), Inline 6 cylinder

Engine Performance specifications

Horse power: 178 hp (102 kW) at 5200 rpm

Torque: 240 KW, 5200rpm

• Engine Management System overview

Function

 The car running best performance and good fuel consumption.

Basic operation

 It collects information from various sensors such as throttle

position sensor, air flow sensor, air temperature, air mass,
engine temp. , oxygen sensor, engine speed etc, then process
all the information to actuate the engine part efficiently

Performance

 good fuel consumption, good engine performance , and very

clean emission
• Engine Management Sub Systems

Air system
 Function

To control the air flow into the cylinder and deliver the
sufficient and filtered air to the engine and signal to the ECU
air flow, temp. , throttle position.

 Basic operation

Filter the air by the air filter and measure the air flow and
temp. Also throttle position then send signals to the PCM

 Performance

No impurities in the air, signal correct sensor readings

 Diagnostic equipment

Scan tool, test light

 Test procedures

Firstly visual inspection, resistance and voltage test by a multi

meter at sensors – instruction is indicated Sub system
components section

Fuel injection system

 Function

Deliver to the correct amount of fuel which is determined by

PCM to the combustion chambers

 Basic Operation
 Pump the fuel from the fuel tank and deliver it to the each
injector then inject the fuel with the correct amount and the
correct timing

 Performance

Delivering to the correct amount of fuel which is calculated by

PCM

 Diagnostic equipment

Multi meter, test light, Scan Tool

 Test procedures

Visual and smelling check for any leaks, sensor check

Ignition system
 Function

To provide the sufficient voltage of spark at the correct timing

 Basic Operation

Transform the low voltage to the required high voltage and

provide the sparks in the combustion chambers by the spark
plugs

 Performance

Sufficient voltage of sparks, sparks at the right timing

 Diagnostic equipment

Multi meter, test light, test spark plug

 Test procedures

Voltage test by using the test spark plug

 Electronic Control System
 Function

To calculate the ideal amount of fuel and control the whole

engine management system

 Basic Operation

It receives all the information from various sensors, by

analyzing the data it could determine the ideal amount of fuel
and the correct spark timing then actuate the injector to spray
the specific amount of fuel and ignition system for sparks

 Performance

Very good fuel consumption, engine performance, low

emission

 Diagnostic equipment

Scan tool, Multi meter, test light

 Test procedures

Use the scan tool

Perform the self diagnostic procedure

• Sub System components and Electrical details

Air system components
 Throttle Position Sensor

 Function – To signal to the ECU how far the throttle valve

is open

 Basic Operation – It generates the different voltage

depending on the throttle valve position

 Performance – Signal to ECU

  Diagnostic Equipment – Multi meter

 Test Procedure – Touch the negative lead of the multi

meter to the ground wire and the positive lead to the
signal wire then start the engine. The reading should be
between 1V-5V while you move the throttle valve.

Component’s Wiring ECU Pin Performance purpose

name color number

Throttle BW No.91 GROUND

position sensor

Throttle GB No.89 SIGNAL

position sensor

Throttle OB No.90 5V
position sensor

 Oxygen Sensor

 Function – To measure the amount of oxygen in the

exhaust

 Basic Operation – when oxygen touches the sensor which

is the ceramic zirconium with a thin layer of platinum
coating one side it makes electric charges causing the
voltage reading.

 Performance – voltage signal to ECU

 Diagnostic Equipment - Multimeter

 Test Procedure – remove the oxygen sensor from the

vehicle, place it on a vice then connect each terminal to
the corresponding lead on the multimeter. Heat the
sensor with a flame torch the voltage reading should
fluctuate between 0.1-0.9V
Component’s Wiring ECU Pin Performance purpose
name color number

Oxygen sensor SY No.71 IGN / B+

Oxygen sensor SW No.4 GROUND

Oxygen sensor BW No.91 GROUND

Oxygen sensor GL No.35 SIGNAL

Fuel system components

 Fuel Injector

 Function – to spray proper amount of fuel at the right

timing

 Basic Operation – it receives signal from ECU and open

the solenoid for fuel to spray into the intake manifold

 Performance – Correct amount of fuel and fine spray

 Diagnostic Equipment - multimeter

 Test Procedure – unplug the injector wire and measure

the resistance of the two injector terminals by a
multimeter

Component’s Wiring ECU Pin Performance purpose

name color number

Injector #6 R No.71 IGN / B+

Injector #6 XO No.99 GROUND

Injector #5 R No.71 IGN / B+

Injector #5 AB No.73 GROUND

Injector #4 R No.71 IGN / B+

Injector #4 NZ No.100 GROUND

Injector #3 R No.71 IGN / B+

Injector #3 NY No.74 GROUND

Injector #2 R No.71 IGN / B+

Injector #2 W No.101 GROUND

Injector #1 R No.71 / IGN / B+ ,

No.97 IGN / B+

Injector #1 A No.75 GROUND

 Pressure regulator

 Function – To keep the constant pressure in a fuel rail

 Basic Operation – it keeps the fuel pressure by a

diaphragm and a spring in the regulator and increase the
pressure when acceleration and also returns any
excessive fuel to the tank

 Performance – sufficient fuel pressure , increased fuel

pressure when the throttle opens far

 Diagnostic Equipment -

 Test Procedure –

 Fuel Pump

 Function – To deliver fuel from the tank to the fuel

injection system

 Basic Operation – it pumps fuel by a diaphragm and one-

way valve then build pressure and deliver fuel to fuel
injection system.

 Performance – constant fuel pressure

  Diagnostic Equipment – test light

 Test Procedure – have an assistant turn the ignition on,

pump should operate for 2 sec making sound. If not
check the EFI fuse and short in the circuit between the
fuel pump relay and the fuel pump

Component’s Wiring ECU Pin Performance purpose

name color number

FUEL PUMP B No. GROUND

FUEL PUMP BY RELAY NO.87 SWITCH

Ignition system components

 Ignition coil

 Function – to transform the low voltage to high voltage

 Basic Operation – it is a step-up voltage transformer

which can be achieved by the different numbers of
winding in the two coils.

 Performance – high enough voltage

 Diagnostic Equipment - Multimeter

 Test Procedure – Use the multimeter, measure the

resistance between the positive and negative terminals
then compare the reading with the primary coil
resistance specification. And measure the resistance
between the positive and high-tension terminal then
compare it with the secondary coil resistance
specification.
Component’s Wiring ECU Pin Performance purpose
name color number

Ignition RG 34 12V
coil#1<1.6>

Ignition YB 27 GROUND
coil#1<1.6>

Ignition RG 34 12V
coil#2<5.2>

Ignition YR 21 GROUND
coil#2<5.2>

Ignition RG 34 12V
coil#3<4.3>

Ignition YW 19 GROUND
coil#3<4.3>

 Distributor

 Function – to direct the high voltage to the spark plugs in

order at the right timing

 Basic Operation – it turns as the crankshaft turns then

direct the high voltage to the right spark plug to fire in
order

 Performance – right firing order , correct timing

 Diagnostic Equipment – multimeter and feeler gauge

 Test Procedure – measure the air gap with a feeler gauge

and measure the resistance between the specific
terminals as listed in the specification below

Component’s Wiring ECU Pin Performance purpose

name color number
 ECU components
 ECU (computer)

 Function – to control the whole engine management

system efficiently

 Basic Operation – Collects all the information from the

sensors then determines the proper amount of fuel to
inject and activate the necessary parts

 Performance – good engine performance , high fuel

efficiency and low emission

 Diagnostic Equipment – scanning tool

 Test Procedure – connect a scanning tool to the OBD

connector then follow the self diagnosis procedure

• Engine Management System Faults

Engine Check Light On, Codes indicate:
Check engine coolant temperature.

Check throttle position sensor

Check Ignition system

a) Fault Symptoms

Abnormally higher idle speed all the time, poor fuel economy,
hesitation under acceleration, poor engine performance

b) Causes of the fault

Faulty coolant temperature sensor, faulty thermostat, faulty

throttle position sensor, faulty ignition coil or any broken
wiring

c) Diagnostic Equipment and Procedures

Multimeter is used to test the sensors

Checking a TPS and an ignition coil is indicated above in the

sub system components part section.
 Checking a thermostat can be done by putting the thermostat
in hot water and seeing if it is open

Poor Fuel Economy

a) Fault Symptoms

Excessive fuel consumption

b) Causes of the fault

Dirty or clogged air filter, incorrectly set ignition timing, faulty

fuel injector, low tire pressure

c) Diagnostic Equipment and Procedures

Visual inspection at air filter

Use the timing check light to check the ignition timing, it

should line up with 10-degree on the scale

Check the tire pressure with a tire pressure gauge

Check the injectors as indicated above in the sub system

components part section.

Engine detonation / spark knock

a) Fault Symptoms

Knocking noise, vibration, lack of power

b) Causes of the fault

Incorrect spark timing

c) Diagnostic Equipment and Procedures

Use the timing check light to check the ignition timing, it

should line up with 10-degree on the scale
 Hesitation under acceleration
a. Fault Symptoms

Slow acceleration pedal response, poor acceleration

b. Causes of the fault

Fuel filter clogged, faulty injectors, blocked exhaust system,

faulty TPS

c. Diagnostic Equipment and Procedures

Replace the fuel filter

Check the injectors as indicated above in the sub system

components part section.

Test drive with the unbolted exhaust manifold

• References

http://en.wikipedia.org/wiki/Engine_management_system

Relic Wiring Diagrams – Volume 1 (Greg Williams, Chris Anderson and Les
Gram)

Electronic fuel injection diagnosis and testing manual no2. (Published by

David Boyce)

EFI and Powertrain management systems. (Published by greg willams,

chris Anderson and les garam.)

• COLOR CODE
A - tan N - brown V – violet

B - black O - orange W – white

G - green P - purple Y – yellow

K - pink R - red X – light green

L - blue S - gray Z – light blue