Scheme 613
Scheme 614
Scheme 615
Scheme 616
Scheme 617
- Remove the upper engine cover.
- Detach the ground cables and unplug the connectors of the engine control module. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
- Remove the engine control module with mounting. The lower hole of the mounting is slotted.
- Unplug the atmospheric pressure sensor connector.
- Remove the cable duct from the plate bracket.
- Remove the plate bracket from the intake manifold.
- Detach the brake vacuum hose from the intake manifold.
- Remove the holder and check valves for crankcase ventilation and tank bleeding.
- Unplug the ignition coil connectors. At cylinder 4, the ignition coil must be loosened and lifted slightly in order to unplug the connector.
- Remove the ignition coils.
- Remove the spark plugs using «83 95 485 SPARK PLUG SOCKET, WITH GUIDE SLEEVES»(ref-275849-S41291283842007122900000) .
Scheme 618
Scheme 619
Scheme 620
Scheme 621
Scheme 622
- Check the spark plug gap.
- Fit the spark plugs using «83 95 485 SPARK PLUG SOCKET, WITH GUIDE SLEEVES»(ref-275849-S41291283842007122900000) . Tightening torque 28 Nm (21 lbf ft)
- Fit the ignition coils. At cylinder 4, the connector must be plugged in before the ignition coil is fitted.
- Plug in the ignition coil connectors.
- Fit the holder and check valves for crankcase ventilation and tank bleeding.
- Attach the brake vacuum hose to the intake manifold.
- Fit the plate bracket to the intake manifold.
- Fit the cable duct to the plate bracket.
- Plug in the atmospheric pressure sensor connector.
- Fit the engine control module with mounting. The lower hole of the mounting is slotted.
- Attach the ground cables to the engine control module and plug in the connectors. IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
- Replace the upper engine cover.
Scheme 623
- Unplug the connector from the solenoid valve.
- Detach the hoses from the valve.
- Press down the catch carefully with a screwdriver and remove the control valve from its mounting.
Scheme 624
- Fit the valve to its mounting.
- Connect the hoses to the valve.
- Plug in the connector.
Overview
- Generator (2)
- Starter motor (4)
- Ignition switch unit (20)
- Brake light switch (29)
- Relay, fuel pump (102)
- Clutch switch, cruise control (133)
- Brake switch, cruise control (134)
- Cruise control switch (141, included in 703)
- Relay, A/C compressor (156)
- Main relay, engine management system (229)
- Relay, secondary air injection pump (324)
- Relay, +50 (517)
- Mass air flow sensor (205)
- Boost pressure control valve (179a)
- Coolant temperature sensor (202)
- Injectors (206a-f)
- Level sensor, engine oil (243)
- Ignition coil with integrated power amplifier (320a-f)
- Solenoid valve, EVAP canister purge (321)
- Motor, secondary air injection pump (326)
- Crankshaft position sensor (345)
- Accelerator pedal position sensor (379)
- Knock sensor, front cylinder bank (516F)
- Knock sensor, rear cylinder bank (516R)
- Atmospheric pressure sensor (539)
- Position sensor, intake camshaft, front cylinder bank (555F)
- Position sensor, intake camshaft, rear cylinder bank (555R)
- Manifold absolute pressure sensor (585)
- Solenoid valve, shut-off EVAP (588)
- Preheated oxygen sensor, front (592)
- Preheated oxygen sensor, rear (593)
- Throttle body actuator unit (604)
- Solenoid valve, turbo by-pass (605)
- Control module, Motronic E9, V6 petrol (608)
- A/C pressure sensor (620)
- Fuel pressure sensor, fuel rail (653)
- Intake air sensor (688) contains: Intake air temperature sensor (407) Charge air pressure sensor (603)
- Fuel pump unit (689) contains: Level sensor, fuel (46) Engine, fuel pump (323)
- Solenoid valve, intake camshaft, front cylinder bank (695F)
- Solenoid valve, intake camshaft, rear cylinder bank (695R)
- Engine oil pressure sensor (696)
- Control module, fuel pump (697)
- Relay unit, radiator fans (706a)
- Column Integration Module (703, contains 141)
Scheme 625
The Bosch ME 9.6 engine management system can be used for the engine variants with either 230 hp/??? kW or 250 hp/??? kW, although with different software content. The main task of ECM is to regulate torque (air mass), fuel and ignition. The control module is mounted on the plenum chamber of the intake manifold and is connected via two 64-pin connectors - one to the car's wiring harness and one to the engine's wiring harness.
The software in ECM can be updated via SPS.
Scheme 626
ECM ensures that the correct engine torque is achieved during any driving condition. It does so by combining all external torque requests (accelerator pedal, cruise control and TCS/ESP) with the internal ones. The internal torque requests (e.g. idle control) can be positive or negative (limiting). Some examples of limitations are maximum permissible torque or maximum permissible vehicle speed. When the external and internal torque requests are compiled, a result is calculated, i.e. requested engine torque in Nm. This is then converted to necessary (requested) air mass per combustion (mg/c) for the actual point of operation.
The requested air mass is converted to
- Throttle area request
- Turbo request
- Camshaft position
Scheme 627
ECM uses the actual air mass per combustion and engine speed to calculated ignition timing. Ignition timing is retrieved from a matrix in which air mass per combustion and engine speed indicate a specific value. This value then undergoes a number of corrections based on operating conditions, e.g. coolant temperature and charge air temperature. The ignition coils are regulated based on the corrected value for camshaft angle and ignition timing. The value is calculated for each combustion to optimize function. The ignition coils have an integrated power amplifier.
Scheme 628
Combustion in a petrol engine can be of a good nature (normal combustion) or a bad nature (knocking). Knocking can be very damaging to the engine and must therefore be monitored. The engine is equipped with one piezoelectric knock sensor per cylinder bank. The sensor is mounted on the cylinder bank and can be equated to a microphone that listens to engine noise. Knocking generates characteristic noises that are caught by the sensors, which are connected to ECM.
Knock control is individual to each cylinder. This means that, for example, the ignition timing of a knocking cylinder can be temporarily retarded which the other cylinder retain their normal ignition timing. If ignition retardation does not stop the knocking, engine torque is reduced to prevent engine damage.
Note that it is completely normal to hear single knocks even though there is no fault. If the engine continually knocks loudly, however, there is a fault.
Scheme 629
Continuous variable cam phasing (CVCP) is a system that makes continual variation of the intake camshafts' position, i.e. phasing, possible. The duration (the number of degrees the values are hold open) remains constant. It is the position of the cam lobes, i.e. the camshaft angles when the intake values open or close, that are different. This is controlled by ECM via hydraulic valves in order to obtain the optimal intake camshaft setting at any given operating point.
Since ECM regulates the hydraulic valves with a PWM voltage, the valves can be steeplessly moved into the requested position. To compensate for the oil delivery pressure, the engine is equipped with a pressure sensor that measures engine lubricating oil pressure.
CVCP has the following advantages
- High engine output
- High engine torque over a broad RPM range
- Reduced emissions, especially NOx
- Reduced fuel consumption