Practice Manual

Automotive
Electrical/Electronics
System Training Panel
(Volkswagen Jetta 1.6L)

Practice Manual

FXB CO., LTD.

www.fengxb.com/www.fxbgroup.cn
 Practice Manual

Contents

I. Construction of product................................................................................................................. 1
1.1 Overview of Product........................................................................................................... 1
1.2 Product Components and Basic Parameters................................................................. 2
1.2.1 Product Components.............................................................................................. 2
1.2.2. Basic Parameters................................................................................................... 4
1.3 Product Functions............................................................................................................... 5
1.4 Precautions.......................................................................................................................... 5
II. Lecture............................................................................................................................................ 6
2.1 Composition and operating principles of electricity system from the automotive..... 6
2.1.1 Starting up system...................................................................................................7
2.1.2 Charging system......................................................................................................8
2.1.3 Ignition system....................................................................................................... 10
2.1.4 Lighting system...................................................................................................... 11
2.1.5 Instrument system................................................................................................. 11
2.1.6 Wiper system......................................................................................................... 12
2.2 Operation procedures...................................................................................................... 12
III. Fault Setting Lecture................................................................................................................. 15
3.1 Fault Detecting and Elimination of No.9 Crankshaft Position Sensor Signla Line. 15
3.2 Fault Detecting and Elimination of Injection Nozzle....................................................15
3.3 Fault Detecting and Elimination of Cylinder 1-4 Ignition Control Line......................18
3.4 Fault Detecting and Elimination of Fuel Pump.............................................................20
IV. Appendix......................................................................................................................................25
4.1 Fault Point Description.....................................................................................................25
4.2 Circuit Diagram of Automotive Electrical/Electronics System Training Panel

(Volkswagen Jetta 1.6L)................................................................................................... 26

 Practice Manual

I. Construction of product
1.1 Overview of Product

The device is designed based on the electric equipment system of the finished Volkswagen
Jetta 1.6 to holistically demonstrate structures and operation of the meter, lighting, wiper,
horn, ignition, electric window, electric door lock, sound, startup, and charging systems. It
applies to the teaching of automobile electric equipment theories and maintenance
practicing in secondary and senior vocational skill schools, normal education and training
institutions.

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1.2 Product Components and Basic Parameters

1.2.1 Product Components

No. Name Specification and model Unit Quantity

With various detection

Panel on the instruction
1 terminals and a color circuit Set 1
board
diagram

Engineer control unit

2 Volkswagen Jetta 1.6 Set 1
(ECU)

3 Diagnosis socket OBD II Unit 1

4 Anti-burglar control unit Set 1

5 Ignition switch With anti-burglar reader coil Unit 1

6 Anti-burglar indicator Unit 1

7 A full set of meters Set 1

8 Switchgroup Set 1

Front, left and right

9 Set 1
headlights assembly

Left and right front fog

10 Set 1
lights

Left and right turn signal

11 Set 1
lights

Left and right turn signal

12 Set 1
side lights

Left and right combination

13 Set 1
taillights

14 Number-plate light Set 1

15 Reading light Set 1

16 Switch for headlight Set 1

17 Switch for fog light Set 1

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18 Switch for the brake light Set 1

19 Switch for the back-up light Set 1

Switch for the warning

20 Unit 1
flasher

21 Harness Set 1

22 Flash relay Unit 1

23 Wiper assembly Set 1

24 Wiper controller Unit 1

25 Washer pump Set 1

26 Sprayer Set 1

27 Horn Unit 2

28 Horn relay Unit 1

29 X contactor relay Unit 1

30 Fog light relay Unit 1

Including a crankshaft position

Non-distributor grouping
31 sensor, an igniter assembly, Set 1
ignition system
and a spark plug

Indicator lamp for the

32 simulated oil injection Set 1
nozzle

33 Fuel pump relay Unit 1

34 Fuel pump indicator lamp Unit 1

Crankshaft position sensor

35 Set 1
and signal wheel

Master switch for the

36 Set 1
electric window

Motor for the front, left and

37 Set 1
right electric windows

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Central control unit for the

38 Set 1
front, left door lock

Motor for the front, right

39 Set 1
door lock

Motor for the rear, left and

40 Set 1
right electric windows

Switch for the rear, left and

41 Set 1
right electric windows

Motor for the rear, left and

42 Set 1
right door locks

43 Sound assembly Set 1

44 Speaker 6", 200 W Pair 1

45 Starter assembly Set 1

46 Generator assembly Set 1

Three-phase
47 127V 1Phase Set 1
asynchronous motor

48 Accumulator Set 1

49 Fuses Unit Many

50 Master power switch 50A Unit 1

Intelligent fault-setting and

51 FXB-688 Set 1
appraisal system

Movable framework (with 2400mm × 700mm × 1900mm

52 Set 1
self-retention wheels) (length x width x height)

1.2.2. Basic Parameters

1. Size: 2400mm × 700mm × 1900mm (length x width x height)
2. Driving power supply: 220V 60HZ
3. Operating voltage: 12V DC
4. Operating temperature: –40ºC to +50ºC
5. Three-phase asynchronous motor
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1.3 Product Functions

1) A real and operable electric equipment system is used to illustrate the structure of the
system.
2) After the electric equipment system is powered on, switches and buttons of various
electric equipment can be operated to demonstrate operation of the meter, lighting,
wiper, horn, ignition, electric window, electric door lock, sound, startup, and charging
systems.
3) A color circuit diagram on the instruction board is fixed with aluminum rims. The
diagram and electric equipment system can help trainees learn and analyze the
operating principle of the system.
4) The instruction board is installed with detection terminals to detect electric signals, for
example, resistance, voltage, current, and frequency, of circuit components of the
electric equipment system of the finished automobile.
5) The instruction board is installed with a diagnosis socket connecting a dedicated or
universal automobile decoder. The diagnosis socket reads fault codes, clears fault
codes, and reads data stream from the engineer control unit (ECU).
6) The teaching board's base frame is made of steel and the surface is paint-coated.
Self-retention wheels are installed.
7) Intelligent fault-setting and appraisal system.

1.4 Precautions

1) AC power supply is required for training bench and power connection should be
operated by a professional electrician in high voltage. Experiment can only be
conducted under the condition that electrical safety and mechanical movement safety
are guaranteed.
2) During the experiment, trainees should keep proper distance from the training bench in
case of accidentally touching some parts in motion. Any moving parts or components
with high voltage should not be touched so as to avoid injury.
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3) Trainees must fully comprehend the circuit diagram and related data of panel if
demonstration or fault diagnosis should be performed through external wiring of
terminal on the panel to avoid burning of power source and components.
4) Never disconnect the battery switch when the training bench is in operation. In case of
disusing the diagnosis bench, keep it from water and dust.

II. Lecture
2.1 Composition and operating principles of electricity system from the

automotive

Electric equipment of finished automobile consists of instrument system, lighting system,

wiper system, horn system, ignition system, power window system, power door lock, audio
system, starting system, charging system, etc.

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2.1.1 Starting up system

1) Operating principle of starting system
Starting system is mainly composed of battery, starter, starting control circuit, etc. Under the
control of ignition switch, starter will convert electric energy in battery to mechanic power,
thus driving rotation of engine crankshaft through gear ring of the flywheel.
2) Mechanical feature of starting system
Based on different transmission mechanisms and control units, starters can be classified
into inertial engaged drive starter, mechanically engaged drive starter, pre-engaged drive
starter and sliding armature starter. The first two categories now have basically been not
adopted due to structure limitations, and the sliding armature starter is mainly applied to
high-power diesel engine. Pre-engaged drive starter is the most popular one in gasoline
starting system and generally consists of DC motor, electromagnetic control mechanism
and transmission mechanism.

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2.1.2 Charging system

The charging system is mainly composed of battery, alternator, voltage regulator, ignition
switch and charging indicators, etc. Provide electric energy for electric equipment in the
automobile.
1) Storage battery
When the battery is shut down or fails to generate electricity, provide electricity for electrical
equipments to initiate the generator. When the battery is insufficient in electricity due to low
load of the charging system, the excessive power of the charging system can be converted
into chemical energy for storage. This convertible DC current with low-voltage can be jointly
used with the generator and served as a huge capacitance to absorb transient voltage and
protect electrical components.
2) Alternator

With such obvious features of small, light, simple structure, easy maintenance, long
lifespan and good charging performance with low speed, the alternator is widely used in the
automobile. As the main power driven by the pulley for the automobile, the alternator
provides power for electrical equipments and accumulator (except the starter) when the
engine operates at a speed higher than the idle speed. The alternator is mainly composed
of following parts:
a) Rotor: Being composed of spindle, claw pole of field winding and traveler, the rotor is to
form a magnetic field. There are two claw poles press fitted on the rotor shaft with fine

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spline, each with 6 poles of beak shape. The cavity between two poles installed with the
magnetic yoke which has field winding.
b) Stator: also referred to as armature. With iron core and winding, the stator is to produce
AC electromotive force. The iron core is generally piled by cyclic silicon steel sheet which is
mutually insulted and is inner cyclic with groove. The winding part installed in the groove of
iron core is composed of three pairs of symmetrical winding.
c) Rectifier: Usually composed of 6 silicon rectifier diodes and heating panel, the rectifier
can convert the three-phase AC from stator winding into DC and output to prevent the
accumulator from generating electricity with the generator. Covers of three positive diodes
are installed separately in the three holes of heating panel. Covers of these three diodes
and the heating panel which is the binding post of the generator by channeling to the
outside with bolt (the bolt is insulted with rear housing) that binding the heating panel, will
serve as positive pole of the generator. Covers of three negative diodes press fitted
separately in the three holes of rear housing will serve as negative pole of the generator
together with the cover of the generator.
d) Belt pulley and fan: the belt pulley is installed on the front end of rotor shaft (outside the
motor) and driven by the belt of the engine; the fan is installed on the front end of rotor shaft
(inside the motor) to cool the coil of rotor and rectifier.
e) Electric brush assembly: the electric brush is equipped in the hole of brush rocker and
stays touched to the traveler via pressure of the brush spring so as to provide magnetic
current for rotor winding of the generator.
f) Terminal cover: the front and rear terminal cover are both forged with aluminum alloy of
non-magnetic material, so the terminal cover boasts such features of less flux leakage,
handy and good heat dispersion.
3) Voltage regulator
Automatically regulate the voltage output from the generator within specified range when
the load and rotational speed of engine change.
4) Ignition switch
Connect the ignition circuit to start the engine and power the generator on to connect

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ignition circuit so as to start generator for power generation.

5) Charging indicator
Indicate working condition of the charging system. If the indicator is on, the generator is
supplying power or the charging system is in fault (normal condition: the indicator should be
on when turning on the ignition switch and off when starting the engine).

2.1.3 Ignition system

The basic function of ignition system is to periodically provide sufficient high voltage
electricity to spark plug in accordance with the ignition order of cylinder at the end of engine
compression travel, which can produce spark between the electrodes of spark plug so as to
ignite inflammable mixture compressed in the cylinder. Timely and reliable ignitions is
required so as to provide sufficient voltage at proper time under different engine speeds
and loads so that the spark plug can produce enough spark to ignite the gas mixture, thus
ensuring the best combustion efficiency of engine.a

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2.1.4 Lighting system

Lighting system mainly consists of lighting system and signal system and its primary
purpose is to ensure operating safety and conformity with transportation regulations. During
driving, display the work conditions of the automobile through luminous signs in different
colors, thus conveying information to other vehicles and passengers.

2.1.5 Instrument system

Instrument system is installed on the instrument panel of cab and used to detect the
operating status of engine, enabling driver to observe and know work status of various
systems at any time.

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2.1.6 Wiper system

Wiper system consists of wiper motor, transmission mechanism, wiper arm, wiper brush,
etc. and is used to clean water, snow or dust on windscreen, thus ensuring that driver has
relatively clear sight in heavy rain or snow to drive safely.

1-motor; 2-crank; 3-connecting rod; 4-rocker arm; 5-wiper blade

2.2 Operation procedures

1．Inspect whether fuses set at the panel works normally
2．Turn on the battery switch,if battery power indicator on the panel is on, it shows the
power works normally.
3．Correctly connect the motor power line to ensure the motor rotate in clockwise
direction.
4．Open ignition key, the motor rotate, and charge for the battery, and perform the
following functions by setting various switches on the panel:
1) Starting system: turn on ignition switch to STA gear, connect working power of starting
motor and then the starting motor installed under training bench begins to operate until
ignition switch leaves STA position.
2) Charging system: turn on ignition switch to ON gear. If the charging indicator on
combination instrument is constantly on, it indicates that the charging system is not working.
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Trigger STA position and go back to ON status. Three-phase motor begins to operate after
electrified and drives through belts the generator to run, in which electricity is generated. At
this moment, charging indicator in the instrument board shall be off and voltage at
accumulator terminal measured by voltmeter shall be over 14 V, indicating that charging
system is working.
3) Lighting system: operate light switches to control parking lamp and headlamp; when
controlling parking lamp and headlight, operate fog lights switch to control front and rear fog
light; operate combination switch to control headlight hazard light and turning light; operate
hazard light switch to control hazard lights; operate stoplight to control stoplight inside
combination tail light; operate reversing light switch to control reversing light inside
combination tail light; operate horn switch to control horn.
4) Instrument system: oil pressure indicator: the flash of oil pressure lamp when ignition
switch is on, indicates that there is no or not enough oil pressure in the engine; pump up the
high and low oil pressure switch by using the matched pump, and simulate the pressure
meter of oil canal. Pump only the low oil pressure switch, if the value of oil pressure gauge
exceeds 0.03 MPA, the oil pressure lamp is off. Adjust the rotation speed signal simulator to
make the tachometer points above 2050 R/MIN, and pump up both the high and low oil
pressure indicators at the same time; if the value of low tachometer exceeds 0.03 MPA, the
oil pressure lamp is off, and if the value of high tachometer exceeds 0.18 MPA, the oil
pressure lamp flashes again. Turn on the high beam of headlamp, the high beam signal
indicator on instrument is on; turn on the turning light or warning light, the turning signal
indicator on instrument flashes.
5) Wiper system: operate wiper and water injection switches beside combination switch to
choose the functions of inching wiping, wiping in interval, low-speed wiping, high-speed
wiping, wiper washing, etc. of wiper motor. Wiper motor, link gear and water injection gear
installed on chassis of training bench can demonstrate the actual process.
6) Engine ignition system: There are ignition coil, plug ect. Ignition devices and simulate
injector, fuel pump working indicator devices;Also the crankshaft position sensor & signal
wheel, camshaft position sensor & signal wheel and some signal input devices;Rotate the

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timing belt to drive the signal wheel equals engine is normally working, and the four
sparking plugs ignite, four injector start inject, fuel pump is working, then it can finish the
demonstration for the ignition and injection.
7) Diagnosis system: The OBD diagnositc socket is installed on the panel, the user can
use volkswagen scan tool to make the testing for the engine electronic system
8) Powe window system: Use the power window switch can control the left front, right front,
left rear and right rear windows acuators to rotate, which equals windows up and down.
9) Central door lock system: The left, rear, front and rear door lock assembly are installed
on the panel.
10) Anti-theft system: Through volkswagen decoder, we can programme new keys.
11) Audio system: The auto audio assembly, two speakers, antenna are installed on the
panel, users can obtain audio function, CDLfunction ect..
12) Fault setting and clearing functions: The chassis of experiment bench is equipped with
fault setting interface which has two terminals - short circuit terminal and fault setting
terminal. When the short circuit terminal is connected to fault setting interface, the whole
circuit system operates normally without fault setting function. When the fault setting
terminal is connected to fault setting interface, the whole circuit system will also operates
normally while fault setting can be done to the circuit system. When the fault setting
interface is connected to intelligent fault setting box, set on the intelligent fault setting box
through keys on the screen to accomplish fault setting and clearing function on the circuit
system, for example open circuit, grounding short circuit and bad contact.

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13) After accomplishing normal use and fault setting function, turn off ignition key, cut off
power and battery switch and restore fault setting interface

III. Fault Setting Lecture

3.1 Fault Detecting and Elimination of No.9 Crankshaft Position Sensor

Signla Line

3.1.1 Experiment purpose

(1) Know well about the operational principle of Crankshaft Position Sensor.
(2) Grasp the methods of how to detect and clear the faults
3.1.2 Training hours
Two class hours in total, an hour for demonstration and instruction by the teacher; an hour
for student operation; a group of 8 to 10 persons is recommended.
3.1.3 Training Instrument and Equipment
1) Tools: one set of common tools, 2 multi-meters, and 1 diagnostic apparatus such as
K81 and X431;
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2) Equipment: a set of training panel;

3) Teaching aids: 5 pieces of crankshaft position sensors;
3.1.4 Basic Knowledge
1. Installation position and structure
Engine speed sensor is normally called engine rotation speed sensor, crankshaft rotate
angel sensor ect..Volkswagen adopts magnetic crankshaft position sensor and installed left
side of cylinder which is near No.4 cylinder.

2. Function
The crankshaft position sensor is of primary function in engine electronic control system,
and provides ignition time (ignition advance angle) and signal to determine crankshaft
position so as to detect the dead center of piston, corner of crankshaft and rotational speed
of the engine.

3.1.5 Data Detection and Analysis

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Fault Set the signal line of crankshaft position sensor as open circuit with intelligent fault

setting setting box

Fault With fault code(P0322)

There are obvious fault phenomena and the fault may be caused by the fault in the

crankshaft position sensor. However, it is still necessary to determine through detection

whether the fault is caused by open circuit of the signal wire or the fault of the sensor

Circuit fault itself.

analysis

1. Diagnosis device testing:

1) Clear former faults codes

2) Open ignition switch and rotate signal wheel(simulate system is working)

3) Reading fault codes P0322, that means engine rotational sensor G28 do not have

signal
Fault
2. Multimeter testing:
detecting
1) Switch off ignition switch, the resistance value between T121/106 and CKPS No.3
method
SL is less than 1Ω, the resistanc value between CKPS No.2 circuit and No.3 circuit is

standard value.( The normal resistance value is around from 450Ω to 1000Ω)

2) Open ignition switch and trun it to ON gear, the circuit between T121/98 and No.2 of

CKPS do not have voltage change and resistance value is infinite, that means CKPS is

open circuit.

3) Other is normal

The fault in CKPS can be seen through the detected fault number P0322. No
Fault
changeable AC voltage between T121/98 and T2 of CKPS, and the wire resistance is
conclusion
infinite between T121/98 and CKPS T2. So the signal line of crankshaft position sensor

is open circuit. 17

Fault
Repair the signal line of crankshaft position sensor with intelligent fault setting box
elimination
 Practice Manual

3.2 Fault Detecting and Elimination of Injection Nozzle

I. Training Purpose and Requirement

1. Know well about the structure and working principles of the injector.
2. To grasp influence of injector fault on the whole electronic control system
3. To master detection methods and fault causes analysis of the injector.

II. Training Hours

4 class hours in total: one hour for demonstration and instruction by the teacher; three
hours for students operation; a group of 8 to 10 persons is recommended.

III. Training Instrument and Equipment

1. Tools: one set of common tools and 2 multimeters;

2. Equipment: one fault diagnosis tester such as VGA1552, K81, X431, etc.;

3. Teaching aids: a set of training panel;

4. Five injection nozzles.

IV. Basic Knowledge

1. Installation position and structure

It is installed at intake manifold, consisting of fuel screen, harness circuit, solenoid coil,
needle valve body, valve seat, reset spring and "O" shape seal ring.

2. Function

Fuel injection is conducted based on ECU injection signal, receive injection pulse signal
sent by engine control unit and inject accurately-calculated fuel into intake manifold.
Injection quantity is only related to the time of injection while the time of injection depends
on the width of injection pulse signal. ECU inputs high voltage pulse into base electrode of
power triode based on injection quantity signal. At this time, power triode is working and
injector circuit is connected. When the current passes through solenoid coil,
electromagnetic force generated by the coil overcomes spring force to attract armature,
then ball valve leaves the valve seat and gasoline injects from oil jet. When solenoid coil is
in open circuit, ball valve returns to the valve seat under the force of reset spring and oil jet

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is closed and injector stops injecting.

V. Fault Detecting and Elimination

Fault Use intelligent fault setting box to set Cylinder-4 injector as open circuit
setting
Fault Indicator of Cylinder-4 injector is off

Circuit
fault
analysis

1. Detection performed by the problem, the electricity to injector 4 is

diagnostic apparatus: also normal.

1) Clear the previous fault code; Then use multimeter to test voltage
between battery negative port and
2) Turn the start switch to
T121/86 terminal, the value is around
START and rotate the singal
panel; 3V. The normal voltage is 12V.
Fault At last, turn the multimeter to resistance
3)Detected fault code P0270:
detecting gear, test the resistance value between
"Cylinder-4 injection valve-N33
method open circuit". T121/86 and injector 4 right signal line,
the value is infinite, that means it is
2. Fault Detection:
open circuit.
Firstly, use multimeter to test
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voltage between Battery

negative port and Injector 4 right
side signal line, the value is 12V,
that means the injector has no

Fault Based on test lamp detection and infinitely large resistance between
conclusion T121/86 and related terminal of Cylinder-4 injector, it is confirmed that
Cylinder-4 injector control line is in open circuit
Fault
Repair Cylinder-4 injector control line with intelligent fault setting box
elimination

3.3 Fault Detecting and Elimination of Cylinder 1-4 Ignition Control Line

I. Training Purpose and Requirement

1. To master structure and working principles of ignition coil;

2. To grasp influence of ignition coil fault on the whole electronic control system;

3. To master detection methods and fault causes analysis of the ignition coil.

II. Training Hours

4 class hours in total: one hour for demonstration and instruction by the teacher; three
hours for students operation; a group of 8 to 10 persons is recommended.

III. Training Instrument and Equipment

1. Tools: one set of common tools and 2 multimeters;

2. Equipment: one fault diagnosis tester such as VGA1552, K81, X431, etc.;

3. Teaching aids: a set of training panel;

4. Five ignition coils.

IV. Basic Knowledge

1. Installation position and structure

It is installed at engine cylinder block, the electronically controlled ignition way is no packet

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distributor ignition system.

2. Function

Turn the ignition switch, ECU determines ignition timing based on crankshaft position
sensor CKP, camshaft position sensor CMP, throttle position sensor TPS, a temperature
sensor CTS and other signals, ECU control pulse transistor to turn off, the primary current
of ignition coil is cut off, a secondary winding to produce high voltage electricity, so the
cylinder ignition plug arcing.

V. Fault Detecting and Elimination

Fault Use intelligent fault setting box to set Cylinder1-4 ignition control line as
setting open circuit

Fault Ignition plug of cylinder 1-4 don’t work.

Circuit
fault
analysis

Measured value Standard value

1. Detection performed by the diagnostic apparatus:

1) Clear the previous fault code;

2) Turn on the ignition switch to START and rotate the signal panel;

Fault 3) Detected "No Fault".

detecting 2. Test lamp detection:

method Connect one end of test lamp with Terminal 2 of ignition coil and the other
end with Terminal 121/112. When test lamp indicates injection, change the

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connection with Terminal 121/112 to Terminal 1 of ignition coil. The test
lamp is off, so there is fault.

3. Detection by multimeter:

Turn off ignition switch; the resistance between Terminal 121/112 and
Terminal 1 of ignition coil is detected to be infinitely large; thus, open circuit
fault is confirmed.

Fault Based on test lamp detection and infinitely large resistance between
conclusion T121/112 and Terminal 1 of ignition coil, it is confirmed that cylinder 1-4
ignition control line is in open circuit

Fault
Repair Cylinder 1-4 ignition control line with intelligent fault setting box
elimination

3.4 Fault Detecting and Elimination of Fuel Pump

I. Training Purpose and Requirement

1. To get familiar with the structure and working principles of fuel pump;

2. To analyze and determine common faults according to the operating principle;

II. Training Hours

Two class hours in total, one for demonstration and instruction by the teacher and one for
student operation; a group of 8 to 10 persons is recommended.

III. Training Instrument and Equipment

1. Tools: one set of common tools, 2 multi-meters

2. Device: a set of training panel

3. Instruction aids: two sets of fuel pumps

IV. Basic Knowledge

1. Structure

The fuel pump mainly comprise of pump body, permanent magnet motor and enclosure.

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Nowadays, it is generally installed in the fuel tank (combining with the measurer for fuel
amount to be a whole) considering the thermal dissipation, acoustic insulation and air
resistance.

2. Operating principle

When being electrified, the fuel pump motor will motivate turbo pump vanes to rotate with
the vanes within tanks around wheels tightly pressed to enclosure by centrifugal force so as
to transfer the fuel from fuel inlet chamber into outlet chamber. The increasing fuel in inlet
chamber contributes to a certain degree of vacuum, absorbing the fuel from the inlet; the
increasing fuel in outlet chamber increases the pressure of fuel, and when certain value has
been reached, such pressure will push the delivery valve open for fuel output. In addition,
the delivery valve functions as obstruction for fuel to inflow back to the tank with the pump
is not working so as to maintain a certain pressure in fuel line for next initiation.

V. Data Detection and Analysis

Fault
Open the control line of fuel pump relay with intelligent fault setting box
Setting

Fault Injector doesn’t work

1. IG input end of fuel pump relay coil is in open circuit; 2. The negative control
line of fuel pump relay coil is in open circuit; 3. The fuel pump relay contact is
damaged (fails to actuate normally); 4. The constant electric voltage of fuel
pump relay is 12 V; 5. The control coil of fuel pump relay is damaged; 6. The
main fuse of injector is damaged; 7. The line between fuel pump relay and
Circuit injector fuse is in open circuit.

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fault
analysis

1. Turn the ignition switch to ON gear, measure the IG wire of the fuel pump
relay coil by voltage method and measure the positive pole to IG end by
Fault multimeter with the negative connecting to the ground; the voltage is normal.

detecting 2. Turn the ignition switch to ON gear and rotate crankshaft signal wheel,
method measure the negative pole wire of the fuel pump relay coil by voltage method
and the 0 V voltage by multimeter (at the time, the computer ECU receives
signals from revolution speed sensors; control the T121/80 wire of fuel pump;
and the computer ECU is internally grounded).

3. Turn off the ignition switch and measure coil resistance (terminal between
80 and IG) with resistance method. The normal value is around 80 Ω; if it is
infinitely great as measured, there is open circuit within the coil.

4. Others are normal.

Fault Through the detection on the fuel pump relay by multimeter, voltage of T121/
conclusion 80 is 0 V and the wire resistance between it and relay is infinitely great. Based
on this, the fault is determined to be open circuit in control line of oil pump
relay.
Fault
Repair the control line of fuel pump relay with intelligent fault setting box.
elimination

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IV. Appendix
4.1 Fault Point Description

Fault Fault description Fault Fault Phenomenon

No. description
(Abbreviation)
Right Front Steering RFSL L Right front steering
1
Lamp Line lamp does not work
Right Front Small Lights RFSL L Right front small light
2
Line does not work
3 Horn Relay Line Horn Relay L Horn does not work
Cylinder 4 Injector Line C 4 Injector L Cylinder 4 does not
4
inject
Cylinder 2 Injector Line C 2 Injector L Cylinder 2 does not
5
inject
Fuel Pump Relay Coil FPRC CL No injection
6
Control Line phenomenon
Cylinder 1& 4 Ignition C 1 & 4 CL Cylinder 1 & 4 does not
7
Control Line ignite
Cylinder 2& 3 Ignition C 2 & 3 CL Cylinder 2 & 3 does not
8
Control Line ignite
Crankshaft Position CPS SL With fault code
9
Sensor Signal Line
Left Front Door Lock LFDL ACU Line Left front door lock does
10 Assembly Control Unit not work
Line
Right Rear Small Lamp RRSL L Right rear small lamp
11
Line does not work
12 Right Rear Brake Lamp RRBL L Right rear brake lamp
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 Practice Manual

Line does not work

Right Rear Reversing RRRL L Right rear reversing
13
Lamp Line lamp does not work
Right Rear Steering RRSL L Right rear steering lamp
14
Lamp Line does not work

4.2 Circuit Diagram of Automotive Electrical/Electronics System Training

Panel (Volkswagen Jetta 1.6L)

26