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Ignition Systems Application Manual

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Ignition Systems Application Manual Ignition Systems Application Manual Energy and Chassis IGNITION SYSTEMS APPLICATION MANUAL Revised Jan 2005 Ignition Systems Delphi Energy and Chassis Systems Tech Center Brighton 12501 E. Grand River Brighton, Mi., 48114, USA 1999 Delphi Automotive Systems Updated January 2005 Ignition Systems Application Manual Release/Revision Summary Sheet CHANGE DATE REASON FOR CHANGE Originator PAGE(S) NO. Original 30/AUG/99 Released C.R. Strange N/A 1 Jan 2005 Update, pencil coil information added B. Griffith 3-15 – 3-19 Information and graphics added, Ion Sense. Various Ignition Systems Application Manual Table of Contents 1.0 INTRODUCTION..................................................................................................................................1-1 1.1 SCOPE OF DOCUMENT ............................................................................................................................1-1 1.2 CLASSIFICATION .....................................................................................................................................1-1 1.3 DOCUMENT MANAGEMENT ......................................................................................................................1-1 1.3.1 Document Release and Updates .................................................................................................1-1 1.3.2 Mailing List....................................................................................................................................1-2 1.3.3 Document Revision Procedure.....................................................................................................1-2 1.4 COMMERCIAL CONSIDERATIONS..............................................................................................................1-2 1.5 OBJECTIVES OF THIS MANUAL .................................................................................................................1-3 1.6 HOW THIS MANUAL IS ARRANGED............................................................................................................1-4 1.7 CONVENTIONS USED IN THIS MANUAL......................................................................................................1-6 1.8 APPLICABLE DOCUMENTS .......................................................................................................................1-7 1.8.1 Order of Precedence ....................................................................................................................1-7 1.8.2 Government Documents...............................................................................................................1-7 1.8.3 Other Delphi-E Reference Documents.........................................................................................1-7 1.8.3.1 Ignition System Components P/N’s.......................................................................................1-7 1.8.3.2 Delphi-E Engineering Specification, Number, Date ..............................................................1-7 1.8.3.3 SFMEA ..................................................................................................................................1-7 1.8.3.4 DFMEA..................................................................................................................................1-7 1.8.3.5 OBD-II Diagnostic Procedures ..............................................................................................1-7 1.8.3.6 Validation Plan ACR #2066...................................................................................................1-7 1.8.4 Industry Documents......................................................................................................................1-7 1.8.4.1 SAE Standard Procedure J1829...........................................................................................1-7 2.0 FUNDAMENTALS ...............................................................................................................................2-1 2.1 GENERAL ...............................................................................................................................................2-1 2.2 ENGINE COMBUSTION FUNDAMENTALS ....................................................................................................2-2 2.2.1 Air/Fuel Ratio Effects on Combustion...........................................................................................2-2 2.2.1.1 Stoichiometric “Ideal” Combustion Mixtures .........................................................................2-3 2.2.1.2 Rich Mixtures.........................................................................................................................2-4 2.2.1.3 Lean Mixtures........................................................................................................................2-4 2.3 ELECTROMAGNETIC INDUCTION ...............................................................................................................2-5 2.3.1 Self-Induction................................................................................................................................2-6 2.3.2 Mutual Induction ...........................................................................................................................2-7 2.4 AVAILABLE VOLTAGE ..............................................................................................................................2-8 2.4.1 Coil Current Limiting and Dwell Control .....................................................................................2-11 2.4.2 Increased Ignition Energy...........................................................................................................2-13 2.5 RADIO FREQUENCY (RF) SUPPRESSION................................................................................................2-14 2.6 GENERAL DESCRIPTION........................................................................................................................2-16 Delphi Energy and Chassis Revision: 4/19/2005 i Table of Contents Ignition Systems Application Manual 3.0 PRODUCT DESCRIPTION..................................................................................................................3-1 3.1 DELPHI IGNITION MILESTONES ................................................................................................................3-1 3.2 IGNITION COIL - FUNCTION......................................................................................................................3-2 3.3 APPEARANCE .........................................................................................................................................3-2 3.4 EXTERIOR OUTLINE ................................................................................................................................3-2 3.5 IGNITION TYPES......................................................................................................................................3-3 3.5.1 Ignition Specifications...................................................................................................................3-3 3.5.2 High Voltage Switch (HVS) System …………………………………………………………………... 3-4 3.5.2.1 High Value Ignition Features ……………………………………………………………………... 3-6 3.5.2.2 High Value Ignition Performance ………………………………………………………………… 3-6 3.5.3 Waste Spark Ignition Concept.................................................................................................. …3-6 3.5.3.1 Direct Ignition System (DIS)..................................................................................................3-9 3.5.3.2 ICE.........................................................................................................................................3-9 3.5.3.3 Dual Coil Pack (DCP)..........................................................................................................3-10 3.5.3.4 Features- Gen 2 ICE and DCP ...........................................................................................3-10 3.5.3.5 Dual Pencil Coil Pack ..........................................................................................................3-12 3.5.4 Coil Per Cylinder (CPC)..............................................................................................................3-13 3.5.4.1 Coil Near Plug ……………………………………………………………………………………..3-13 3.5.4.2 Plug Top Coil ……………………………………………………………………………………….3-15 3.5.4.3 Pencil Coil (in plug hole) …………………………………………………………………………..3-17 3.5.5 Ion Sense....................................................................................................................................3-20 3.5.5.1 Knock Control ......................................................................................................................3-23 3.6 SPARK PLUG ........................................................................................................................................ 3.24 3.6.1 Spark Plug Design......................................................................................................................3-24 3.6.2 Spark Plug Types .......................................................................................................................3-25 3.7 SENSOR FUNCTION...............................................................................................................................3-25 3.7.1 Variable Reluctance (VR) Sensor ..............................................................................................3-26
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