Assembly and Installation of an Engine Control Module Bachelor’s thesis HAMK Valkeakoski Automation and Electrical Engineering 2018-2019 Apolinarii Sorokin ABSTRACT Automation and Electrical Engineering Valkeakoski Author Apolinarii Sorokin Year 2019 Title Assembly and Installation of an Engine Control Module Supervisor(s) Rainle Lehto, Juhani Hentonen ABSTRACT The main goal of this thesis was to study and review the operating principles of Internal Combustion Engines Control Systems. After this background research the engine control module was built using electrical components and open source Megasquirt printed circuit board. The theoretical part of the thesis is focused on engine management technologies and their applications. The practical part of work started from the construction of the engine control module and it continued with connecting the module to the BMW 3 Series E36 to replace the standard Bosch DME Motronic control Unit. Installation of the system allowed switching the engine from natural aspiration to forced induction using the turbocharger. Keywords ECU, EFI, Engine Control, Megasquirt, Internal Combustion. Pages 40 pages including appendices 2 pages CONTENTS 1. INTRODUCTION ........................................................................................... 1 1 FUEL INJECTION IN GENERAL ................................................................... 1 1.1 Internal Combustion ..................................................................... 1 1.1.1 History of Fuel Injection Control ........................................................................ 1 1.1.2 History of Ignition Timing Control ...................................................................... 2 1.1.3 Ignition Advance and AFR ................................................................................ 2 1.1.3.1. Ignition Timing .............................................................................................. 2 1.1.3.2. Air to Fuel Ratio ........................................................................................... 3 1.2 EFI Systems ................................................................................. 4 1.2.1 Inputs and Outputs ............................................................................................ 4 1.2.2 Algorithm ........................................................................................................... 5 1.2.3 Racing EFI Systems compared to Civilian ........................................................ 7 1.3 Systems Used in The Project ....................................................... 7 1.3.1 Air System ......................................................................................................... 7 1.3.1.1. Intake Manifold ............................................................................................. 8 1.3.1.2. Throttle Body ................................................................................................ 8 1.3.1.3. Turbocharger ................................................................................................ 9 1.3.1.4. Intercooler .................................................................................................. 10 1.3.1.5. Air Filter ...................................................................................................... 10 1.3.1.6. Air Box ........................................................................................................ 10 1.3.2 Fuel System .................................................................................................... 10 1.3.2.1. Fuel Pump .................................................................................................. 10 1.3.2.2. Fuel Filter ................................................................................................... 11 1.3.2.3. Fuel Pressure Regulator ............................................................................ 11 1.3.2.4. Fuel Injectors .............................................................................................. 12 1.3.3 Standard Electronic System (ECU) ................................................................. 13 1.3.4 Sensors (Inputs) .............................................................................................. 16 1.3.4.1. Crankshaft Sensor ..................................................................................... 16 1.3.4.2. Coolant Temperature Sensor ..................................................................... 17 1.3.4.3. Intake Air Temperature Sensor .................................................................. 17 1.3.4.4. Throttle Position Sensor ............................................................................. 18 1.3.4.5. Mass Air Flow Sensor ................................................................................ 18 1.3.4.6. Mass Air Pressure Sensor ......................................................................... 18 1.3.4.7. Wideband Lambda Sensor ........................................................................ 19 1.3.4.8. Clutch sensor ............................................................................................. 19 1.3.5 Outputs ............................................................................................................ 19 1.3.5.1. Fuel Injectors .............................................................................................. 19 1.3.5.2. Ignition Coils ............................................................................................... 19 1.3.5.3. Ignition Coil Drivers and Schematic ........................................................... 20 1.3.5.4. Idle control valve ........................................................................................ 20 2 MEGASQUIRT ASSEMBLY ........................................................................ 21 2.1 Components ............................................................................... 21 2.2 V3.0 PCB Schematic ................................................................. 27 2.3 Soldering .................................................................................... 28 2.4 Inputs and Outputs ..................................................................... 29 2.5 Casing ........................................................................................ 29 2.6 Schematic of Ignition Modules ................................................... 30 3 WIRING AND INSTALLATION..................................................................... 31 3.1 Wiring Harness .......................................................................... 31 3.2 Installation of Wideband Lambda Sensor................................... 32 4 TUNING ....................................................................................................... 32 4.1 Tuning Software for MS ............................................................. 32 4.2 Basic Settings ............................................................................ 33 4.2.1 Trigger Wheel Settings .................................................................................... 33 4.2.2 Injector criteria ................................................................................................. 34 4.3 Ignition Settings ......................................................................... 35 4.3.1 Ignition Advance Table .................................................................................... 35 4.4 Fuel Settings .............................................................................. 37 4.4.1 AFR Table ....................................................................................................... 37 4.4.2 VE Table.......................................................................................................... 38 4.5 Fine Tune ................................................................................... 39 4.5.1 Dynamometric Stand ....................................................................................... 39 4.5.2 Fine tuning the Ignition Advance ..................................................................... 39 4.5.3 Fine tuning the VE-table .................................................................................. 40 5 CONCLUSION ............................................................................................. 40 REFERENCES ................................................................................................. 42 1 1. INTRODUCTION This project was aimed at modernizing the engine control system of an old car and to explore the possibilities of the open source Megasquirt engine control module. 1998 BMW 320 E36 was bought as a donor for that project. As a result of this project an electronic engine control system which supported fully sequential injection and sequential ignition and all different kinds of modern engine control features was built. Also, it will be possible to increase the power of the car using the Turbo- or Super- chargers in the future according to the plan created during the project. First of all, in the second chapter, the evolution of engine control systems is reviewed, from old fully mechanical systems to modern EFI systems and their details. Inputs and Outputs of these systems and their algorithms is described, the difference between racing and civilian applications is evaluated. General information is followed by a review of the system, used in the donor vehicle, in a very detailed manner. Described chapter will also