3-10 PREVENTIVE MAINTENANCE Engine oil Replacement • Remove underbelly pan structure front mounting bolts (1 nos. bolt at RH side and 2 nos. bolts at LH side) with 8 mm T-spanner. • Pull radiator assembly towards front wheel side. • Remove radiator mounting nuts (4 nos.) with metal washers using 10 mm spanner. • Remove horn mounting nut with 12 mm spanner. LH RH • Remove terminal from horn.
3-11 PREVENTIVE MAINTENANCE Engine oil Replacement • Take out underbelly pan structure front. • Cut the cable tie (circle) and remove oxygen sensor coupler connection. • Remove 2 nos. exhaust pipe nuts with 12 mm spanner. • Remove 1 nos. exhaust pipe clamp bolt with 12 mm spanner, remove clamp. • Take out exhaust pipe from vehicle. • Use new silencer gasket during fitment. Note Use new cable tie during fitment. • Remove 1 nos. exhaust mounting bolt with 12 mm spanner.
Brush 3-12 PREVENTIVE MAINTENANCE Engine oil Replacement • Pull plug from evacuation strainer. • Clean evacuation strainer using a brush by kerosene or diesel and blow air of 2 bar pressure. 1 - Ensure that evacuation strainer ‘O’ rings are in good condition. 2 - Clean evacuation strainer plug. • Replace ‘O’ rings evacuation strainer plug with new one once opened. 1 2 • Remove evacuation strainer plug using 13 mm spanner and take out evacuation strainer along with plug. Air Blower Brush
3-13 PREVENTIVE MAINTENANCE Engine oil Replacement • Fit evacuation strainer on evacuation strainer fitment tool (P/N : 37 0042 82) as shown in photograph. • Fit evacuation strainer in crankcase LH. • Pre-fit evacuation strainer plug and tighten it to recommend torque. Re-fit all removed parts. • Remove engine oil filter cover mounting bolts (2 nos.) with 8 mm spanner. • Take out evacuation strainer fitment tool.
‘O’ Ring 3-14 PREVENTIVE MAINTENANCE Engine oil Replacement • Rotate engine oil filter cover and take out engine oil filter cover. • Replace engine oil filter cover ‘O’ ring with new one once opened. • Take out engine oil filter using circlip plier and replace it with a new one. Important : Ensure that engine oil filter is dipped in engine oil (10W 50) before fitment. • Pre-fit engine oil filter cover mounting bolts and tighten it to recommended torque by torque wrench (1 - 1.2 Kgf-m) as shown picture A. • Fit oil strainer as shown picture B. • Pre-fit drain bolt and tighten it to recommend torque by torque wrench (1 - 1.2Kgf-m). • It is important to measure oil quantity after draining. This is important to understand the oil consumption pattern. During interval - from oil change to next oil change, engine oil consumption quantity should not be more than 50 ml per 1000 kms. If oil drop is more, check for external oil leakage, Smokey exhaust and piston ring wear. • Use genuine engine oil only as per recommended grade (10W50). Oil Filter A B
3-15 PREVENTIVE MAINTENANCE Engine oil Replacement • Measure fresh 1700 ml of 10W50 engine oil in calibrated jar. • Ensure that engine oil filler cap ‘O’ ring is in good condition. • Ensure that engine oil filler cap is fully tighten. • Fill 1700 ml of 10W50 engine oil in engine with funnel. • Drain and Refill Quantity : 1700 ml • Overhaul Quantity : 1950 ml • Remove engine oil filler cap.
3-16 PREVENTIVE MAINTENANCE Engine oil Replacement Engine Oil Top Up • Wash the vehicle thoroughly. • Ensure oil filling and drain quantity get measured in calibrates measuring jar. • Plastic measuring jar level marking to be verified by transferring oil in borosil make measuring jar. • Drain the engine oil as explained in engine oil replacement SOP. • Warm up engine, ensure engine oil temperature is 60ºC OR • Run vehicle Multi Roller Test Bench (MRTB) for 3 mins @ 50 kmph speed. • Measuring engine oil drained quantity (while measurement jar to be kept on flat surface). • Check the quantity of drained engine oil.
3-17 PREVENTIVE MAINTENANCE Engine oil Replacement • Refit oil strainer and pre-fit drain bolt followed by tightening to recommended torque by torque wrench. Tightening torque : 1.0 - 1.2 Kgf-m • Remove engine oil filter cap. • Ensure that oil filter cap ‘O’ ring is in good condition. • Top up drained oil with fresh 10W 50 engine oil so as to match 1700 ml volume (considering @ 150 ml engine oil is available at evacuation chamber side). • Example : Drained engine oil - 1350 ml Engine oil in evacuation side chamber -150 ml Engine to be top up = 1700 - (1350 + 150) = 1700 - 1500 = 200 ml • Refill the engine oil in engine. • Ensure that engine oil filler cap is fully tighten. • Reconfirm engine oil level in vehicle upright position, it should be in between MIN and MAX level.
3-18 PREVENTIVE MAINTENANCE Engine Oil Checking Level Checking • Check engine oil level every day at vehicle upright position on level surface (at engine cold condition). • Check oil level through oil level ‘B’. • Always maintain engine oil level between upper (C) and lower (D) mark provide on Cover RH. Top up with specified grade of oil if the oil level is below lower level mark. Engine Oil Capacity • Refill at servicing : 1700 ml. • During engine overhaul : 1950 ml. Recommended Engine Oil : Always insist on Bajaj Genuine Engine Oil or recommended engine oil for optimum engine performance and warranty benefits. It is a specially formulated oil for Dominar 400UG Euro 4. A : Oil Filler Cap B : Oil Level Gauge B A C D C : Engine Oil Level Upper Limit D : Engine Oil Level Lower Limit Model Recommended Engine Oil Grade Dominar 400 UG Euro 4 Bajaj 10W50 Compliant JASO MA2 API SN, Fully Synthetic • For all Dominar 400 UG Euro 4 compliant engine oil is to be used only. Use engine oil will give prolonged life of catalytic convertor. • Engine oil replacement frequency: 1st service and then every 10,000Km. • Engine oil level top-up frequency : Every 5000 km. It is most important to adhere to recommended grade and frequency of oil change for the purpose of long life of critical engine components. For detail refer periodic maintenance chart. CAUTION
3-19 PREVENTIVE MAINTENANCE Spark Plug Cleaning • Remove LH and RH side spark plug caps. • Remove LH spark plug using spark plug removing special tool. (Part No. 37 25034). • Remove RH spark plug using spark plug removing special tool. (Part No. 37 104051). Do not remove spark plugs when engine in hot condition. Note
3-20 PREVENTIVE MAINTENANCE Spark Plug Cleaning 1. Use central spark plug removing universal joint (P/N : 37 104333) along with converter and extension rod. 2. Remove central spark plug using attachment as shown in photograph. • Fit central plug in spark plug pre-fitment pipe. • Use central spark plug pre-fitment pipe tool for spark plug pre-fitment (P/N : 37 104334). Central Spark Plug Remove • Remove petrol tank. • Remove central spark plug cap. • Tighten spark plug to specified torque (1.9 - 2.1 Kgf-m). 1 2 Do not remove spark plugs when engine in hot condition. Note
A 5 3-21 PREVENTIVE MAINTENANCE Tappet Clearance Setting 1 - Remove clutch cable bracket mounting bolts (2 nos.) with 8 mm spanner. 2 - Remove clutch cable from clutch release shaft. 3 - Remove clutch cover mounting bolts (10 nos.) with 8 mm spanner 4 - Take out clutch cover. 5 - Ensure the piston it at TDC by aligning primary gear mark with crankcase mark [A] using 24 mm spanner. 6 - Ensure horizontal lines mark on cam sprockets should be upwards align with cylinder head face as shown in [B]. • Locking Crankshaft Tool (P/N : 37 1044332) 4 6 B Piston TDC confirmation : • Remove dummy bolt from crankcase using 10 mm spanner and fit the crankcase locker tool (P/N : 37 1044332) in dummy hole. If the crankshaft locker fits in crankshaft, it means that piston is TDC (Top Dead Centre). 2 3 1
3-22 PREVENTIVE MAINTENANCE Tappet Clearance Setting • Remove air filter element (Refer page 3-2 until 3-5 for complete SOP). • Remove heat insulating rubber sheet from restraining slots. 3 - Remove cover cylinder head mounting bolts (4 nos.) using 10 mm spanner. 4 - By adjusting throttle cable, take out cover cylinder head and it’s gasket. • With the help of feeler gauge, check the tappet clearance. Specifications : Intake : 0.08 - 0.12 mm Exhaust : 0.13 - 0.17 mm 4 1 - Pull out breather pipe clip out and take out breather pipe from caver cylinder head. 2 - Take out central spark plug cap. 1 2 3
3-23 PREVENTIVE MAINTENANCE Tappet Clearance Setting If the tappet clearance is not as per specification :- Measure the tappet clearance : Intake 1 : ___________, Intake 2 : ______________ Exhaust 2 : ___________, Exhaust 2 : ______________ • Remove chain tensioner. • Using cotton cloth & plier, take out sleeve central spark plug. • Remove cam holder and Guide chain top mounting bolts (8 nos.) with 8 mm spanner. Length of bolts : Bolts shown by grey arrow : @ 41 mm. Bolts shown by white arrow : @ 46 mm. Bolts shown by black arrow : @ 51 mm. 1 - Take out guide chain top. 2 - By adjusting throttle cable, take out cam holder. • Holding the cam chain take out camshaft assembly. • Tie cam chain using copper wire & take out other cam shaft assembly. 2 1
3-24 PREVENTIVE MAINTENANCE Tappet Clearance Setting Intake side 2 1 2 1 Exhaust side • Shim calculation for increased tappet clearance : A - Existing Shim Thickness B - Standard Tappet Clearance C - Measured Tappet Clearance D - Increase in Tappet Clearance = C - D E - Shim to be used = A + D Shim A C B D • Lift all four Rocker Arms by hand. • At a one time, take out one shim only using Flexible Wire with Magnetic Tip (P/N : 37104345). Note down shim sizes removed from vehicle as follows : Intake 1 : ___________, Intake 2 : ______________ Exhaust 2 : ___________, Exhaust 2 : ______________ • Shim thickness to be check with calibrated Micrometer. • Shim to be used : For Exhaust valve : A - 2.40 mm, B - 0.10 mm C - 0.14 mm, D - 0.04 mm E - Shim to be used = A + D = 2.40 + 0.04 = 2.44 mm
3-25 PREVENTIVE MAINTENANCE Tappet Clearance Setting • Shim calculation for decreased tappet clearance : A - Existing Shim thickness B - Standard Tappet Clearance C - Measured Tappet Clearance D - Decrease in Tappet Clearance = B - C E - Shim to be used = A - D • Shim to be used : For Exhaust valve - A - 2.40 mm B - 0.10 mm C - 0.06 mm D - 0.04 mm E - Shim to be used = A - D = 2.40 - 0.04 = 2.36 mm Shim A B C D Assembly • Fit new shim. • Fit cam shaft assemblies. Note : Ensure that two horizontal lines on cam sprocket are parallel to cylinder head face as shown in [A] and primary gear mark is align with crankcase mark [B]. • Fit cam holder and chain guide top. • Fit tensioner. • Feeler gauge should have a mild resistance when being slid out after setting valve clearances. • Fit sleeve spark plug. • Fit cover cylinder, gasket cover head and heat resistant cover. • Refit all removed parts. A B
3-26 PREVENTIVE MAINTENANCE Coolant Level Check & Adjust • Ensure vehicle position upright on a level surface. • Check the coolant level as shown in photograph and ensure that coolant level in between MIN and MAX level. • If coolant level is below MIN mark, then Top-Up with recommended coolant using funnel. • Remove RH shroud mounting bolts (2nos.) with 4 mm Allen key and 2 nos. plastic plugs with screw driver. • Remove expansion tank cap. • Top up with recommended coolant using funnel. Recommended coolant : Motul Motocool Expert Castrol Radicool
3-27 PREVENTIVE MAINTENANCE Sealed Drive Chain Lubrication On Vehicle Sealed Drive Chain on Vehicle • Apply rear wheel stand. Normal dust should be wiped clean using a lint free cloth. • Hold the Chain Lube Spray Can (OKS Spray) vertically upright and shake it vigorously till the noisy of steel ball inside the can is heard uniformly. Fix the extension tube (red pipe provided with the can). • Hold the can at the back of the rear sprocket in line with chain rotation and keep the nose of the extension tube at about 5 - 10 cm away from the chain. • Rotate the wheel in reverse direction and spray the lube on the middle portion of the chain so that lubricant will get spread on roller and bushes and on both sides of the chain. Spray the lube on full length of chain by rotating the wheel to complete rotation. • Rotate the wheel 3 ~ 4 times so that the lubricant spreads and settles. Wipe out any excess lubricant if it has dripped down or sprayers on the wheel / tire. • If the drive chain is excessively dirty, then clean the drive chain with 50 : 50 diesel and SAE 90 oil by using nylon brush. • Hold the vehicle in such way that bike is perpendicular to surface and both wheels are touched to surface. • Rotate rear wheel slowly in one direction to find out position at which chain is getting tight. At this lowest point of chain slackness, lift and press down the chain to measure chain slackness by steel rule or chain slackness checking tool. (Std. chain slackness 20 - 30 mm). • If chain slackness is not as per specification then loosen rear axle nut using 22 mm spanner holding rear axle with 17 mm spanner.
3-28 PREVENTIVE MAINTENANCE Sealed Drive Chain on Vehicle • Hold the LH chain adjuster lock nut with 12 mm spanner and adjust the adjuster nut with 13 mm spanner to adjust chain slackness. • Repeat the same procedure for RH chain adjuster. • Ensure that LH and RH chain adjuster marks are equally aligned with marks on adjuster marking line. • Tighten rear axle nut to specified torque (10 Kgf-m). • Check and ensure that rear wheel is rotating freely. LH SIDE RH SIDE
3-29 PREVENTIVE MAINTENANCE Front Caliper Overhaul • Skill tip : Before removing caliper assembly from vehicle, pull out lock lock clip fitted on brake pad pin using plier to avoid clip bending / breakage issue. • Clean caliper assembly thoroughly by low pressure water spray before opening caliper bleeder nut. • Remove bleeder nut rubber cap. • Drain the brake fluid from caliper assembly by loosening air bleeder nut using 8 mm spanner using transparent PVC tube which will avoid spillage of brake fluid on caliper body / disc pads and also powder coating peel off / inefficient braking. • Remove front brake hose banjo bolt with copper washers (2nos.) using 14 mm spanner. • Loosen brake pad pin using star bit T - 30 from force ratchet box
3-30 PREVENTIVE MAINTENANCE Brake Pad Wear / Check / Replace. • Remove caliper mounting bolts (2 nos.) using 12 mm spanner and take out caliper assembly. While removing caliper mounting bolts, hold caliper mounting bolts, hold caliper body to avoid falling of caliper body (Refer photograph - A) • Check brake pads ‘U’ slot for wear, if ‘U’ slot is worn out then remove brake pads as explained in next steps. If ‘U’ slots is ok, clean the brake pads by polish / sandpaper and refit removed parts. If ‘U’ slot is not present then check brake pad thickness. As a precautionary measure, it is recommended to apply silicon grease on caliper anchor pin. 1 - Remove brake pad pin using star bit T-30 from force rachet box. • Remove bleeder nut using 8 mm spanner from caliper body. 2 - Take out brake pad pin, pad spring and brake pads. • Remove caliper pistons (4 nos.) by applying compressed air through banjo bolt hole. Use cotton cloth while removing pistons from caliper body as “piston fly out” may cause damage to it and any one the vicinity. 2 A Note Note Note 1
Brake Pad Wear / Check / Replace. 3-31 PREVENTIVE MAINTENANCE 1. Remove dust seals (4 nos.) and oil seals (4 nos.) from caliper body. 2. Clean the caliper body by diesel / kerosene. 5. Apply the silicon grease on piston OD and rubber seals. 6. Fit all the pistons in caliper body. Clean the brake pads by smooth sand paper. 1 2 3 4 6 5 4. Refit the seals and dust seals in caliper body. 3. Dry the caliper body by applying low pressure compressed air.
3-32 PREVENTIVE MAINTENANCE Brake Pad Wear / Check / Replace. • Fit pad spring, brake pads and prefit brake pad pin. Tighten the brake pad pin to recommended torque (5.0 - 7.0 Kgf-m) by torque wrench. • Hold lock clip on groove provided on brake pad pin and press lock clip in the direction of arrow as shown in photograph - B. • Prefit the bleeder nut using 8 mm spanner. • Fit the caliper assembly on LH fork leg. Prefit the caliper mounting bolts and tighten it to recommended torque by torque wrench (2.2 - 2.8 Kgf-m). • Prefit the brake hose mounting bolts and tighten it to recommended torque (21.0 - 28.0 Kgf-m) by torque wrench. A Note : Fit pad spring as shown in photograph - A. Note Always replace banjo bolt copper washers whenever opened with new one. B
3-33 PREVENTIVE MAINTENANCE Brake Fluid Replacement • Clean the surface area of a master cylinder from dust / dirt / oil. • Drain the brake fluid from caliper assembly by loosening air bleeder nut 8 mm and using transparent PVC tube which will avoid spillage of brake fluid on caliper body / disc pads and powder coating peel off / inefficient braking. • Remove master cylinder mounting screws (2 nos.) using Phillips head screw driver and take out master cylinder cover. • Take out PVC cap and rubber diaphragm. • Fill the master cylinder reservoir by recommended brake fluid (DOT3 or DOT4). • Carry out air bleeding. (Refer PM Encyclopedia page no. - 155 Air Bleeding SOP) • Tighten the bleeder nut and fit it’s rubber cap. • Fit rubber diaphragm, PVC cap and master cylinder cover.
3-34 PREVENTIVE MAINTENANCE Brake Fluid Top Up • Clean brake fluid level in front or rear master cylinder. • Ensure that brake fluid level is between “MIN” and “MAX” mark. • If brake fluid level is below “MIN” mark : - Remove master cylinder cover , PVC cap and rubber diaphragm. - Top up with recommended brake fluid such that brake fluid level is above “MIN” mark. - Refit all removed parts. - Check braking efficiency. If found spongy, do the air bleeding activity. MAX MIN Rear MAX MIN Brake Fluid Top Up Front And Rear Master Cylinder Front
3-35 PREVENTIVE MAINTENANCE Brake Pedal Pivot Pin Lubrication Brake Pedal Pivot Pin Lubrication • Apply rear wheel stand. • Remove end chamber mounting bolt with 14 mm spanner [A], holding nut with 17 mm spanner [B]. • Remove RH stay mounting bolts (3 nos.) with 6 mm Allen key and take out RH stay. • Put cotton cloth as shown in photograph in order to avoid scratches on painted parts. • Remove rear brake switch spring connection from brake pedal. A B
3-36 PREVENTIVE MAINTENANCE Brake Pedal Pivot Pin Lubrication • Hold RH stay as shown in photograph and remove brake pedal pivot bolt using 17 mm spanner and take out the brake pedal pivot pin. • Apply adequate quantity of AP grease. • Remove excess grease with lint free cotton cloth. • Refit all the parts. • Clean brake pedal pivot pin by diesel / kerosene / AP grease. Use sand paper (grade 1000) for removing solid grease with dust / rust before grease application. Note
3-37 PREVENTIVE MAINTENANCE Side Stand Pin Clean Side Stand Pin Clean And Lubrication • Apply rear wheel stand. • Remove side stand spring • Remove side stand mounting nut 17 mm spanner and take out side stand. • Clean side stand mounting bolt and side stand mounting bracket with diesel / kerosene and apply AP grease. • Refit all the removed parts.
3-38 PREVENTIVE MAINTENANCE Clutch Cable Free Play Check & Adjust Clutch Cable Free Play Check and Adjust : • Press and release the clutch lever to confirm smooth operation. • If clutch operation is jammed or sticky, replace clutch cable. • Slide clutch lever rubber boot. • If free play is not as per specification (2 ~ 3 mm), set it by using adjuster provided at clutch cover end. • Check clutch lever free play by scale or free play gauge. Clutch lever free : 2 - 3 mm.
3-39 PREVENTIVE MAINTENANCE Throttle Cable Free Play Check & Adjust • Check for smooth rotation of throttle grip. • Check throttle free play by scale or free play gauge. Throttle free play : 2 ~ 3 mm. • Adjust throttle free play if not as per specification (2 ~ 3 mm), set if using adjuster provided at throttle grip end.
3-40 PREVENTIVE MAINTENANCE Steering Play Check & Adjust • Lift the vehicle from front side using overhead structure. • Slightly turn the handle bar to the left hand side and leave the steering handle. Check whether the steering moves by it’s own weight till end stopper position. • Also check the movement of steering turning the handle on the right hand side. This conforms free and smooth operation of steering. • Check steering free play by pushing and pulling the fork from bottom side. • If the steering is sticky jam or having play, remove upper bracket. • Tighten steering slotted nut using steering slotted nut tightening special tool to recommended torque (0.5 Kgf-m). • Check and confirm that steering play is zero. Steering Play Check and Adjust
3-41 PREVENTIVE MAINTENANCE Control Switch Contacts Cleaning Control Switch Contacts Cleaning • Remove control switch mounting screws (2 nos.) with Philips head screw driver and open control switch. • Use only WD40 electrical contact cleaning spray for control switch contacts cleaning. • Remove excess spray with lint free cotton cloth.
3-42 PREVENTIVE MAINTENANCE EVAP Drain Tube Cleaning Evap Drain Tube Cleaning • Remove EVAP drain tube and remove it’s clamp using coolant clamp plier. • Take out plug from EVAP drain tube and drain accumulated petrol if any.
3-43 PREVENTIVE MAINTENANCE Ignition Switch Contacts Cleaning Ignition Switch Contacts Cleaning • Clean the top surface of ignition switch by clean lint / fiber free cotton cloth. • Use only WD40 electrical contact spray for ignition switch contact cleaning. Note : Do not lubricate ignition switch by oil.
1 4 Chapter 4 Fuel System And EMS Table Of Contents Exploded View ........................................................... 4-2 Wiring Harness Routing ............................................. 4-3 Evap Routing ............................................................. 4-10 Working Of System .................................................... 4-13 Fuel Injection System ................................................. 4-23 EMS Sensors And Actuators .......................................4-24 Diagnosis And Trouble Shooting Of Error Codes ........ 4-28
4-2 FUEL SYSTEM & EMS Exploded View Fuel Injector Injector & Throttle Body Throttle Body Cap Tank Tank Fuel Pump Fuel Filter Fuel Tank & Gauge Fuel Regulator HT Coil & Regulator HT Coil 2 (For LH And RH Spark Plug) HT Coil 1 (For Centre Spark Plug)
4-3 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts
4-4 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts : Cable ties are shown in BLACK color : Cable ties are shown in BLACK color
4-5 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts : Cable ties are shown in BLACK color : Cable ties are shown in BLACK color
4-6 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts : Cable ties are shown in BLACK color : Cable ties are shown in BLACK color
4-7 FUEL SYSTEM & EMS Wiring Harness Routing Location of Parts
4-8 FUEL SYSTEM & EMS : Cable ties are shown in BLACK color Wiring Harness Routing Location of Parts
Photo Part Name Remark H.T. Coil 1 For Central Spark Plug H.T. Coil 2 For LH and RH Spark Plug Roll Over Sensor Sends ignition cut of signal to ECU when bike inclination angle > 60° 4-9 FUEL SYSTEM & EMS Wiring Harness Routing Photo Part Name Remark Fuel Injector To inject the fuel into the intake manifold until the electric signal from solenoid is cut off by ECU. Oil Pressure Sensor It measures the pressure of the engine oil flowing thru the internal oil galleries and communicates the signal to the speedometer. TMAP It is a micromechanical sensor that measures the absolute pressure in the intake manifold and compares it with a reference vacuum, not with the ambient pressure. TPS To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU. Stepper Motor Stepper motor is a brushless DC electric motor that divides a full rotation into a number of equal steps. The motor's position can then be commanded to move and hold at one of these steps without any feedback sensor. Photo Part Name Remark ECU To collect information from various sensors and insure that correct quantity of fuel is injected into the intake manifold at precise timing at various engine load and speed condition Main relay A relay is an electrically operated switch. Most relays use an electromagnetic to mechanically operate a switch. Relays are used where it is necessary to control a circuit by a lowpower signal Fuel pump relay Radiator fan relay Reference Part
4-10 FUEL SYSTEM & EMS EVAP Routing Location of Parts JF171623
4-11 FUEL SYSTEM & EMS EVAP Routing Location of Parts
4-12 FUEL SYSTEM & EMS EVAP Routing Location of Parts
4-13 FUEL SYSTEM & EMS Working Of Systems Fuel Pump Function To draw the fuel from the fuel tank and push it along the fuel lines to the injector rail and keeping a constant pressure in the system. Also the fuel pump needs to ensure a high level flowing through the fuel line thus maintaining constant fuel delivery pressure. Part No : JF1718 02 (Fuel Pump). Construction Fuel Pump Module Assembly Working The fuel is pumped from the fuel tank by a roller cell pump through a fuel filter into a fuel rail at the end of which is a fuel pressure regulator. In order to keep the injector pressure differential constant despite variations of inlet manifold depression with load, the fuel pressure regulator senses the difference between pumping pressure and that of the inlet manifold. Excess fuel is returned to the fuel tank, the continuous flushing keeps the fuel cool and avoids formation of pockets of fuel vapor. The fuel pump is lubricated and cooled by the fuel flowing through the motor, including the brushes and across the armature hence it is important that never run the pump without adequate fuel inside the fuel tank. The fuel filter strains impurities out of the fuel. This is an important measure in preventing the fuel pump, fuel injector nozzles from clogging. Fuel Pump Resistance = 2.7 + 0.1 Ohms (Refer Chapter 7-13) Fuel Pressure Regulator Fuel Strainer Pressurized Fuel Out To Fuel Filter Fuel Filter To Injector Mounting Bracket Rubber Gasket For Sealing On To Petrol Tank Fuel Pump
4-14 FUEL SYSTEM & EMS Working Of Systems Fuel Injector Construction Fuel Supply Rail 'O' Ring Seal Integral Filter Coil Washer Pintle Protection Cap Pintle Valve Needle Manifold 'O' Ring Armature Return Spring Electric Connection To inject the fuel into intake manifold until the electric signal from solenoids is cut off by ECU. Working The fuel injector supplies the fuel in the form of spray from the injector pintle which is located on intake manifold. When the windings are energized the armature is attracted due to magnetism and compress the spring which lifts the needle valve. Thus pintle atomizers the fuel into a fine spray form with a pressure about 2.5 bars (36 lbf / in2) until the electric signal in the solenoid is cut off by the ECU. The injector internal movement is restricted just to < 0.1 mm. Also period that an injector remains open is very low (between 1.5 and 10 milliseconds). Thus the opening and closing time is critical for accurate fuel metering. The fuel spray mixes with the incoming air as both move towards the inlet valve giving a precisely metered combustion mixture.
4-15 FUEL SYSTEM & EMS Working Of Systems Sensors Signal Processing (SP) Vehicle Speed Sensor Side Stand Sensor Clutch Switch Engine Oil Pressure Sensor Roll Over Sensor Lambda Sensor Crank Angle Sensor and Neutral Switch T Map Sensor Throttle Position Sensor Coolant Temperature Sensor Actuators Analogue to Digital - (A-D) Input signals are received from various set of Sensors Signals given to operate following Actuators MPRD (Relay) Steeper Motor Motor Injector Fuel Pump H.T. Coil (Centre, LH & RH) Engine Malfunction Speedo Icon Radiator Fan It also supports in Diagnostic Trouble Codes assessment. Introduction The auto motive engine has power generation systems named as ‘Carburettor System’ and ‘Ignition System’ respectively. The carburettor supplies atomized / vaporizes air fuel mixture to the engine maintaining the desired air fuel ratio per engine requirement. The ignition system supplies igniting at the spark plug tip as precise engine demand (timing) to burn the compressed air fuel mixture inside the combustion chamber. However these 2 systems like carburettor and ignition has been dealt separately. In digital ignition circuits a microprocessor is used in the CDI unit. This microprocessor is capable of controlling various tasks. Hence it was logical to use this capacity for controlling fuelling also. Thus then developed a digital electronic control system for fuel injection and combined it with the digital ignition control to form a single unit controller. This unit named as ‘ Electronic Control Unit’ (ECU). Function It collect information from various sensors and ensure that a correct quantity manifold at precise time considering various load and speed conditions. It is brain of the engine and controls various device. Also it controls / supports on vehicle diagnostic instrument for diagnosing the problem in fuel injection system. Construction It consists of micro computer A-D Convertor (Analog to Digital and I - O Unit (Input - Output). Engine Control Unit (ECU) Please pull or slot in the ECU in paralel from or to the ECU socket. Note :
4-16 FUEL SYSTEM & EMS Working Of Systems Engine Control Unit ( ECU ) Working The ignition and fuel injection is controlled by a single control unit named as ‘ECU’. In ECU the inputs from various sensors are fed into a signal processor circuits to ensure that all outputs to the computer are in from of digitals pulses. These inputs received may be steady or slowly varying voltages. These are said to be in analogue from and which are converted into equivalent digital valves by an analogue to digital (AD) convertor. The digital output are fed to the input I output rail for transporting to the main heart of the computer. Thus the ECU collects all signals, calculates them and process them to actuators to delivery precise ignition advance timing and fuel injection requirement for the engine at various load and speed conditions. Set Of Various Sensors A sensor is a device which detects or measure a quantity, usually in electrical from so that it may be used in measurement or control. The analogue signal processing is added to the sensor, this improves the resistance to interference. Set Of Various Actuators Actuators is a general term used to describe a control mechanism i.e. a device that converts electrical signals into mechanical movement e.g. : • Fuel Injector. • Fuel Pump. • Solenoid Starter Relay.