Bosch Motronic ME 7 - ME 7.1 - ME 7.1.1 - ME 7.5 System Strategy PDF
Bosch Motronic ME 7 - ME 7.1 - ME 7.1.1 - ME 7.5 System Strategy PDF
Bosch Motronic ME 7 - ME 7.1 - ME 7.1.1 - ME 7.5 System Strategy PDF
5 System Strategy
Table of Contents
.01.00.00 CATALYST MONITORING ........................................................................................................................4
.01.01.00 PASSIVE MEASUREMENT OF AMPLITUDE RATIO .............................................................................................4
.01.01.01 General description..................................................................................................................................4
.01.01.02 Monitoring Structure................................................................................................................................5
.01.01.03 Flow Chart Catalyst Monitoring..............................................................................................................5
.01.02.00 ACTIVE MEASUREMENT OF OSC ...................................................................................................................6
.01.02.01 General description..................................................................................................................................6
.01.02.02 Monitoring Structure................................................................................................................................7
.01.02.03 Flow Chart Catalyst Monitoring............................................................................................................10
.02.00.00 HEATED CATALYST MONITORING ....................................................................................................11
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
.07.05.01 General description................................................................................................................................49
.07.05.02 Monitor function description .................................................................................................................49
.07.05.03 Chart(s) and flow chart(s)......................................................................................................................51
.07.06.00 OXYGEN SENSOR HEATER MONITORING (SULEV)....................................................................................56
.07.06.01 General description................................................................................................................................56
.07.06.02 Monitor function description) ................................................................................................................56
.07.06.03 Chart(s) and Flow Chart(s) ...................................................................................................................58
.08.00.00 EGR Monitoring ...........................................................................................................................................60
.13.00.00 VARIABLE VALVE TIMING AND/OR CONTROL (VVT) SYSTEM MONITORING ....................73
.19.00.00 RESERVED...................................................................................................................................................89
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
.21.00.00 PARAMETERS / CONDITIONS FOR 2ND CLOSED LOOP OPERATION.........................................93
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
There are two diagnostic functions, which are used for monitoring of the catalyst
efficiency. Both are based on measure of the Oxygen within the catalyst determined
by at least two Oxygen sensors. Each of the functions can be correlated between
Oxygen / Hydrocarbon and Oxygen/ Oxides of Nitrogen.
The method compares the signal amplitudes obtained from the downstream
sensor to the modelled signal amplitudes. The modelled signal amplitudes are
derived from a borderline catalyst. The data for borderline catalysts are taken
from measurement results on real life deteriorated catalysts. In case the
measured amplitudes exceed those of the model, the catalyst is considered
defective. This information is evaluated within one single engine load and speed
range (detection over full range of engine load versus speed).
According to the described operating principle the following main parts can be
distinguished:
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start
no
Enable?
Models stabilized?
yes
Calculate:
- catalyst model
- modeled sensor
- downstream sensor
Count accumulation
time
no
Time > limit
yes
no Fault management
Catalyst okay
MIL
End
-5-
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Oxygen is stored in the catalyst during fuel-cut conditions happening while driving
the vehicle. After fuel-cut, the catalyst is operated with a rich air-fuel ratio (A/F) and
the amount of removed oxygen is determined. If this passive test indicates an OSC
value highly above the borderline catalyst, the catalyst is diagnosed without an
error. This monitoring path can only generate a pass result.
For purposes of monitoring, the ECM cycles the A/F ratio by commanding a rich and
a lean fuel mixture as follows.
First, ECM commands a rich A/F ratio until a minimum of oxygen has been
removed (cumulated rich gas > threshold).
Then, the catalyst is operated with a lean A/F ratio commanded by ECM and
the Oxygen Storage Capability is calculated from the oxygen mass stored in the
catalyst as follows:
The catalyst is operated in this mode until the oxygen stored in the catalyst
exceeds a calibrated limit or the downstream oxygen sensor indicates that the
catalyst is completely saturated with oxygen.
The catalyst is then diagnosed by comparing its oxygen storage capability to
the calibrated threshold of a borderline catalyst.
-6-
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
According to the operating principle described above the following main parts of the monitor
can be distinguished:
Monitoring the amount of removed oxygen after fuel cut off
Check of monitoring conditions for active test
Lambda request (interface to lambda controller)
Mixture enrichment in order to remove any stored oxygen
Measurement of oxygen storage capacity (OSC) by lean A/F ratio operation
Processing
Fault detection
Check Monitoring
Conditions
mixture
Mixture Enrichment control
(remove oxygen ) Lambda Request
L
Measurement of
Lambda sensor upstream OSC
Lambda sensor downstream (lean A/F ratio)
fail
Processing
Oxygen Removal Fault Detection pass
after fuel cut off
Processing:
-7-
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
For a catalyst system with 3 Oxygen-Sensors this measuring procedure can be applied to different
portions. The different alternatives are shown in the table below.
first second
-sensor -sensor
front- catalyst main- catalyst
catalyst-system
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
If the secondary parameters for the different catalyst portions are met at the same time, the diagnostic
functions can run simultaneously.
Table 2: Results, which can be obtained after the diagnosis of the different catalyst volumes
-9-
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start
? all
Yes monitoring No
conditions
No catalyst fulfilled
temperature ?
in range Yes
?
Yes
calculate amount of oxygen apply rich mixture to catalyst
after fuel cut off (oxygen removal)
accumulate amount of
applied rich mixture
amount of No
No rich mixture >
osc > calibration
calibration
?
?
Yes
Yes
accumulate amount of
oxygen stored in
osc > No
calibration or catalyst
saturated
?
Yes
number of No
measurements >
threshold
?
Yes
NO osc< Yes
threshold
?
pass fail
End
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Not applicable
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Data acquisition
The duration of the crankshaft segments is measured continuously for
every combustion cycle and stored in a memory.
Misfire detection
The following operating steps are performed for each measured segment,
corrected by the sensor wheel adaptation.
Based on this fact, the periodicity of the engine roughness value is used as
additional information during multiple misfiring. The engine roughness
values are filtered and a new multiple filter value is created. If this filter
value increases due to multiple misfiring, the roughness threshold is
decreased. By applying this strategy, multiple misfiring is detected reliably.
- 12 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Determination of misfiring
Random misfire
Comparing the engine roughness threshold value with the engine
roughness value performs misfire detection.
If the engine roughness value is greater than the roughness threshold value
a single misfire is detected. With this misfire determination it is possible to
identify misfiring cylinders individually.
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
In the case of catalyst related misfire, the Lambda closed loop system is
switched to open-loop condition according to the basic air/fuel ratio
calculation (Lambda=1).
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Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start of monitoring
procedure
Calculation of engine
roughness and threshold
Comparison of threshold
with engine roughness
no
roughness >
threshold?
- 15 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Interval yes
yes no no Interval
counter A
counter B
> 1,000?
>200?
- 16 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
In the case the reed switch is closed, the LDP is switched on in order
to supply pressure to the fuel tank system and the diagnostic is
continued with the step 2 to 3 (as described below).
- 17 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
start of monitoring
procedure
reed switch no
closed?
no yes
reed switch
closed?
LDP
self check
procedure
reed no
switch open within a error for failed "close to open
certain time? check"
yes
1
2
- 18 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
1 2
Pump Phase
fast pulse
no yes
gross leak detected
no yes
small leak detected
fault management
- 19 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The purge flow through the EVAP Purge Valve is checked when the vehicle
is at rest during an idle condition and the Lambda controller is active.
The EVAP Purge Valve is opened while monitoring the Lambda controller
and the airflow through the throttle unit.
After this procedure the EVAP Purge Valve is reset and the diagnosis is
completed.
- 20 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
- 21 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
After cold start condition (e.g. 5 .. 40C) the Air system blows for a certain
time air into the exhaust manifold. The exhaust gases will be enriched with
oxygen and post combustion of HC and CO occurs. By this exothermic
reaction the exhaust system will be heated and the time to reach the light-
off temperature of the catalyst will be accelerated.
Principal sketch and main components of Air System: (example 4 cyl.
Engine)
ECM;
Air pump relay
Air valve (solenoid valve)
Air valve (vacuum controlled)
AIR pump;
O2 Sensor;
- 22 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The following table shows an overview of the used function and monitor strategy for all test
groups:
Test Group Engine Standard Via Lambda deviation Via exhaust temperature sensor
Passive check Active check Passive check Active check
Functi Flow Functi Flow Functi Flow Functi Flow
onal Check onal Check onal Check onal Check
5ADXV01.8342 1.8T I-4 Turbo long. Bin 8 - - Yes - - - - -
5ADXV01.8356 1.8T I-4 Turbo Bin 8 yes - yes - - - - -
5ADXV01.8346 1.8T I-4 Turbo LEV I yes - yes - - - - -
5VWXV02.0223 2.0l I-4 LEV II - - Yes - - - - -
5VWXV02.0224 2.0l I-4 ULEV II - - Yes - - - - -
5VWXV02.0227 2.0l I-4 PZEV - - yes - yes - - -
5VWXV02.0240 2.0l I-4 Turbo ULEV II - - Yes - - - - -
5ADXV02.8334 2.8l V6 - 2 bank LEV I te - yes - - - - -
5ADXV03.0344 3.0l V6 - 2 bank LEV II yes yes - - - -
5ADXV04.2345 4.2l V8 - 2 bank LEV I yes - yes - - - - -
5ADXT04.2348 4.2l V8 - 2 bank Bin 10 yes - yes - - - - -
5ADXV02.7343 2.7l V6T - 2 bank LEV I yes - yes - - - - -
5VWXT03.2225 3.2 VR6 - 2 bank LEV II - - Yes - - - - -
5VWXV02.8228 2.8 VR6 - 2 bank LEV I - - Yes - - - - -
5VWXV03.2220 3.2 VR6 - 2 bank LEV I - - Yes - - - - -
5VWXV04.0229 4.0l W8 2 bank LEV I - - Yes - - - - -
5VWXV06.0221 6.0l W12 2 bank LEV I - - Yes - - - - -
5VWXV06.0501 6.0l W12T 2 bank LEV I - - Yes - - - - -
The monitor of the secondary air system distinguish between two functions:
a) Passive monitoring function will be carried out during normal secondary air injection
While engine is cold started and
b) Active monitoring function will be activated later during the driving cycle, if the passive
Monitoring function has not a pass result.
At idle state or under part load engine condition, the secondary air pump is switched on and the valve
opens either by pressure of the pump or vacuum operated by switching to open, causing an
increase in the air fuel ratio. The Oxygen Sensor control function (closed loop) enriches the mixture
consisting of exhaust gas of the engine and secondary air until the Lambda integrator signal will meet
a predetermined value (functional or flow check).
- 23 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Check Conditions
Furthermore, if the diagnosis has already been started and one of the
conditions has not been satisfied continuously, the process will be
interrupted.
- 24 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Following charts shows the phases of the AIR monitoring via lambda deviation for passive and active
monitoring.
expected
AIR mass kg
actual
AIR mass kg
Lambda =1
t 0 t1 t2 t3
on
Air Pump off
time
- 25 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
START
Adaptation inhibited
Start integration of air mass flow
PHASE 0
no
Timer 0 > t 0
yes
timer 1 > t 1 ?
yes
PHASE 2
calculate actual AIR mass flow with (optional)
actual Lambda value
no
timer 2 > t 2 ?
yes
no
timer 3 > t 3 ?
yes
yes
MIL
END
- 26 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
After cold start condition (e.g. 5 .. 40C) the Air system blows for a certain
time air into the exhaust manifold. The exhaust gases will be enriched with
oxygen and post combustion of HC and CO occurs. By this exothermic
reaction the exhaust system will be heated and the time to reach the light-
off temperature of the catalyst will be accelerated.
Additional to the principal sketch above, those systems using an exhaust
temperature sensor as an indicator of AIR mass.
- 27 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Passive Diagnostic
Start of Monitoring Procedure of Secondary Air System
no No
engine
restart?
yes
no ECTS
within
specified range?
yes
no Time after
engine
start> threshold
yes
Track exhaust
temperature
Calculate thermal
energy
no Perform active
Exhaust
temperature and thermal Diagnostic Function
energy > thresholds? later in that Driving Cycle
yes
- 28 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Lambda-controller
The ECM compares the Oxygen sensor signal upstream the catalyst with a
reference value and calculates a correction factor for the pilot control.
Fuel trim
The basic air/fuel ratio control using the signal from the front O2 sensors(s)
is corrected by an adaptation calculation. This adaptation results in a factor,
which is applicable for the whole working range. (e.g. 20%)
A further trim control based on the signal(s) from the rear O2 sensor(s) is
correcting the adaptation factor. Therefore this trim control is working in the
same way in the whole range.
If the trim control reaches the allowed limit (e.g. 2%) the fault code for fuel
delivery trim control is set.
Any deviation from the characteristic curve of oxygen sensor upstream
catalyst due to poison will be detected by the control loop downstream
catalyst.
- 29 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Injection
quantity
Range 3
Range 2
Range 1
Engine speed
Each value is adapted in its corresponding range only. But each adaptive
value corrects the pilot control within the whole load/speed range by using a
linear interpolation formula. The stored adaptive values are included in the
calculation of the pilot control just before the closed loop control is active.
Faults in the fuel delivery system can occur which cannot be compensated
for by the adaptive pilot control.
If the adaptive values exceed their plausible ranges, then the MIL is
illuminated and the fault is stored.
- 30 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start
Learning::
ACV = additive correction value rang 1
LMCV = lower multiplicative correction value range 2
UMCV = upper multiplicative correction value range 3
MLCC= multip. learning correction coefficient range 2
yes
ACV, LMCV
UMCV, MLCC remained
unchanged
no
Lower no
threshold of MLCC<=
LMCV <= upper threshold
of MLCC
yes
no
UMCVmin <=
UMCV <= UMCVmax Fault management
yes
no
ACVmin <= MIL
ACV <= ACVmax
yes
End
- 31 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no
abs(integrator
value) > threshold?
yes
Lambda control no
downstream catalyst
active?
yes
counter t1 > no
threshold?
yes
MIL
fault management
- 32 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
- 33 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Output voltage (P0137), Short to battery (P0138) and signal activity check
(P0140)
In case the rear O2 sensor readiness is given a certain sensor signal is
expected. If the sensor is bellow or above some signal thresholds, a fault
will be stored.
- 34 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
0,7 V
= 1,005
=1
= 0,995
= 0,95
0,3 V
lean 0.0 V
rich 0.0 V
- 35 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Heater
no
active
yes
abs(L1-L2)> no
threshold 1
yes
yes
yes
start counter t1
no
t1> threshold 4
yes MIL
Fault management
- 36 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no closed loop?
yes
Within engine
no
rpm window?
yes
Within engine
no
load window?
yes
artificial
no modulation
active?
yes
no dynamic
value < threshold1
yes
no counted
diagnostic
results>limit?
yes
- 37 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no
rear Lambda
control active?
yes
no
no fault stored ?
yes
no
sensor voltage>threshold1
within time t1?
no no
sensor voltage < threshold2 correct
within time t1? reaction of sensor
voltage?
yes yes
Fault management
MIL
sensor okay
- 38 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no
wait for next fuel cut off fuel cut off condition
condition (coasting) active?
yes
yes
no
sensor voltage < threshold? fault management
yes
MIL
sensor okay
- 39 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
For proper function of the Lambda sensor, the sensor element must be
heated.
.07.02.02 Monitor function description
- 40 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no
Dew point
exceeded
yes
no
Time > t1 Time > t2
yes
no
abs(delta
Duration fuel
Lambda)<
cut off > t3
threshold 1
yes
END
Signal < no
threshold 2
yes
MIL
- 41 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no
enable
diagnosis?
enable current pulse
yes
yes
store sensor voltage during current
pulse
no
sensor voltage within
permissible range
calculate internal resistance Ri
yes
no
Ri < Rmap Fault management
yes
- 42 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Rationality Check
Any deviation from the characteristic curve of oxygen sensor upstream
catalyst due to poison, ceramic cracks, characteristic shift down (CSD) or a
leakage between both Oxygen sensors will be detected by the control loop
downstream catalyst and by comparison of the sensor signals.
The integrator value of the second control loop detects small shifts of the
sensor characteristic to lean or to rich. The signal comparison during
steady state conditions quickly detects major deviations in sensor
characteristics caused by serious faults (e.g. ceramic cracks).
For the fault decision the downstream Oxygen sensor has to be checked
too (Oscillation and/or fuel cut-off check).
Dynamic Check
Any change in the dynamic behaviour of the Oxygen sensor due to ageing,
heater fault or contamination will be detected by check of actual amplitude
ratio check with stored values.
- 43 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Oscillation Check
The function checks whether the sensor output voltage of the oxygen
sensor downstream catalyst always remains above or below a specified
threshold.
- 44 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
sensor downstream
no heater fault and no
ready?
yes
Lambda = Lambda =
Lambda= 1? no lean side?
no rich side?
no
yes yes
yes
threshold1 <
Lambda<threshold2
and voltage <lean threshold no
or voltage > rich threshold?
yes
Perform
delay counter >
no yes Oscillation
threshold?
Check
- 45 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no rear Lambda
control active?
yes
downstream sensor no
voltage>threshold1
within time t1? correct no
reaction of Fault management
sensor voltage?
yes yes
MIL
sensor okay
downstream sensor no
voltage < threshold2
within time t1?
yes
- 46 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
For proper function of the Oxygen sensors, the sensor element must be
heated up. The heating up is controlled by the heater control.
- 47 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
.07.04.03 Chart(s) and Flow Chart(s)
yes
Fault Management
Heater Okay!
- 48 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The following checks will be performed on the linear oxygen sensor (LSU)
upstream catalyst:
Plausibility Check
Any deviation from the characteristic curve of oxygen sensor upstream
catalyst due to poison, ceramic cracks, characteristic shift down (CSD) or a
leakage between booth Oxygen sensors (LSU and LSF 1) will be detected
by the control loop downstream catalyst and by comparison of the sensor
signals.
The integrator value of the second control loop detects small shifts of the
sensor characteristic to lean or to rich. The signal comparison during
steady state conditions quickly detects major deviations in sensor
characteristics caused by serious faults (e.g. ceramic cracks).
For the fault decision the Oxygen sensor downstream the first portion of the
catalyst has to be checked too (Oscillation and/or fuel cut-off check).
Dynamic Check
Any change in the dynamic behavior of the Oxygen sensor due to aging,
heater fault or contamination will be detected by watching the slope of the
Lambda value during the switch from lean to rich fuel mixture (natural
frequency control of fuel mixture active). If the slope of the sensor signal
exceeds a specific value the monitoring function is calculating the ratio of
actual Lambda slope versus target Lambda slope. If a specific numbers of
those slope ratios are less than a threshold, a fault is detected.
- 49 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The hardware of the Oxygen sensor consists of an IC (CJ 125) with the
capability of self-diagnostics. The self-diagnostic functions of the IC detects
communication faults between ECM and the sensor, insufficient voltage
supply, shorts in the sensor lines to ground and to battery.
Open wire on the four sensor lines, adjustment line (IA), virtual mass line
(VM), pump current line (IP) and Nernst voltage (UN) will be detected by a
system plausibility check. The evaluations of the system plausibility is
based on sensor voltage, internal resistance, target Lambda, actual
Lambda and the reaction of the controller.
The following checks will be performed on the oxygen sensors (LSF1 and
LSF2) downstream catalyst:
Oscillation Check
The function checks whether the sensor output voltage of oxygen sensors
(LSF 1 and LSF2) downstream catalyst always remains above or below a
specified threshold.
The third control loop is designed as commanded control and based on the
Oxygen sensor (LSF2) post main catalyst. The controller maintains an
optimal constant voltage of the third control loop. The target voltage
depends on the operating point and is taken from a map. During active
control, the target voltage switches between rich and lean. In case of no
reaction of the Oxygen sensor (LSF2) output according the commanded
control, ECM is forcing the same enrichment/ lean out of fuel mixture in
order to monitor the sensor output voltage.
- 50 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Implausible voltages
+
engine catalyst
Sensor 1
Data Processing
Of Sensor 2
Oxygen Sensor
Sensor 3
Signals
- 51 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
sensor downstream
no heater fault and no
ready?
yes
Lambda = Lambda =
Lambda= 1? no lean side?
no rich side?
no
yes yes
yes
threshold1 <
Lambda<threshold2
and voltage <lean threshold no
or voltage > rich threshold?
yes
Perform
delay counter >
no yes Oscillation
threshold?
Check
- 52 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no rear Lambda
control active?
yes
no
no fault stored ?
downstream sensor no
voltage>threshold1
within time t1? correct no
reaction of Fault management
sensor voltage?
yes yes
MIL
sensor okay
downstream sensor no
voltage < threshold2
within time t1?
yes
- 53 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start of monitoring
procedure
no
wait for next fuel cut off fuel cut off
condition (coasting) condition active?
yes
yes
downstream oxygen no
sensor voltage < fault management
threshold?
yes
MIL
sensor okay
- 54 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no
Heater off
(Voltage Drop)?
yes
increment counter 1
no Slope of
Sensor Signal
> Threshold?
yes
increment counter 2
yes
Sensor okay
- 55 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
For proper function of the Oxygen sensors, their ceramic elements must be
heated. A non-functioning heater delays or prevents either the sensor
readiness (LSU) or the proper signal output (LSF1/LSF2) for closed loop
control and thus influences emissions.
The heater control loop is integrated within the oxygen sensor hardware
and has to achieve a target temperature of about 750 C of the ceramic
element.
For diagnostic of the sensor heater a specific current pulse is supplied via a load
resistance and the voltage is measured. The intern resistance of the sensor heater
is calculated with the voltage deviation. The result will be compared with a reference
map resistance, which considers aging and sampling deviations. In case of internal
resistance > map resistance the diagnosis stores a fault and the MIL will be
illuminated.
Operating readiness
time delay after
heater on delay>threshold
Sensor
&
heater defective
sensor ready NOT
- 56 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
- 57 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Flow Chart: LSU, Oxygen Sensor Heater Control Upstream Catalyst (SULEV calibration)
yes
no MIL
yes
yes yes
yes
Fault Management
Heater Okay!
- 58 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
SULEV applications
no
enable
diagnosis?
enable current pulse
yes
yes
store sensor voltage during current
pulse
no
sensor voltage within
permissible range
calculate internal resistance Ri
yes
no
Ri < Rmap Fault management
yes
- 59 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Not applicable
.09.00.00PCV MONITORING
The PCV system assures that no gas from the crankcase system escapes
into the atmosphere.
All connectors which are not necessary to open during typical maintenance /
repair actions are implemented as hard to open.
During heating up the Engine the coolant flows first inside the small cooling
circuit. After the coolant reach a sufficient temperature the thermostat valve
will open the large cooling circuit to integrate the engine cooler.
The engine coolant temperature sensor measures a mixed temperature
between the coolant coming from the small and large cooling circuit.
4
2
Engine 3
- 60 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Each of the engines cooling monitoring function has its own special engine
temperature range in which it will be enabled.
P0116
(stuck
40
P3081
-45C
P0118
- 61 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
In case that the engine coolant temperature does not reach an certain
value after a sufficient mass air flow under normal driving conditions, the
cooling system performance is considered to be reduced.
correct engine
warm-up
engine coolant temp.
wrong engine
warm- up
- 62 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Engine Start/
Start of m onitoring procedure Parameter Description
sufficient air
no m ass integral?
(airm ass_01)
yes
yes
yes
M IL
E nd of m onitoring procedure
- 63 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
In case that the engine coolant temperature does not fit to a reference
model temperature in an certain range, the cooling system is defective or
the sensor is not in a plausible range.
reference model
max. plausible
range
wron warming up
fault time
decision
- 64 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Parameter Description
Engine Start/
Start of monitoring procedure
modmx_01: maximum reference
temperature model value
no MIL
Fault management
- 65 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
After engine start the system stores continuously the lowest and highest
ECT above the thermostat control temperature for a driving cycle. In case
that after several driving conditions the difference between ECT max and
ECT min is lower than the threshold the sensor stuck at high values.
fault
decision
H1 L1 H2 Ln-1 Hn-1 Ln Hn
driving
conditions
H: driving condition with high cooling performance (vehicle
cruise)
- 66 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Parameter Description
Start of monitoring procedure temp_01: maximum engine start
temperature
temp_02: substitute model temp
thres_01: maximum diff. between
Engine start ECTmin/
temperature within
no
ECT max to detect a
window?
malfunction
temp_01/temp_02
ECT max. -
ECT min.>
yes Sensor okay!
threshold f(ECT)
(thres_01)?
no
yes
MIL
Fault management
- 67 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
After engine start the system stores continuously the lowest and highest
ECT below the thermostat control temperature for a driving cycle. In case
that after several driving conditions the difference between ECT max and
ECT min is lower than the threshold the sensor stuck at low values.
H1 L1 H2 Ln-1 Hn-1 Ln Hn
- 68 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Parameter Description
Start of monitoring procedure
temp_01: maximum engine start
temperature
temp_02: substitute model temperature
Engine start thres_01: maximum diff. between
temperature within ECTmin/
window? no
ECT max to detect a
temp_01/temp_02
malfunction
ECT max. -
ECT min.>
yes Sensor okay!
threshold f(ECT)
(thres_01)?
no
yes
MIL
Fault management
- 69 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Flow Chart Engine Coolant Temperature Sensor Stuck Test (all temperatures above threshold)
(P0116)
Monitoring of engine temperature during normal DCY and during engine shut off time
Part I:
yes
no
Sufficient time in driving
conditions during DCY
yes
no
no
Engine off ?
End of monitoring
yes
Part II
- 70 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Monitoring of engine temperature during normal DCY and during engine shut off time
Part II:
yes
no
no
ECU - keep alive time
completed ? MIL
yes
- 71 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The signal of Engine Coolant Temperature Sensor is evaluated and considered to
be electrically out of range if either the upper or the lower thresholds is exceeded.
Start of
Monitoring
Procedure
NO YES YES NO
Signal < lower
Signal > upper threshold
threshold
- 72 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
- 73 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Enable Criteria:
- No start
Check of Enable Criteria
- No fuel tank ventilation with high degree of saturation
- No active diagnosis of EVAP system and secondary
air
- No vehicle speed fault
- No throttle position fault
- No ECT fault
NO Enable - No intake air temperature fault
Conditions - No eve. purge valve fault
fulfilled?
- No limp home of engine speed sensor
- Idle switch closed
YES - Vehicle speed = 0 mph
- Engine speed @ idle
Check Idle Controller for
max. and min. Threshold
- ECT > 59.25 C
Idle Controller @
max. Limit YES
and Engine rpm < Idle rpm
- 80 rpm and Engine Load
< Threshold?
NO
Idle Controller @
min. Limit YES
and Engine rpm > Idle rpm
MIL
+ 80 rpm
NO
- 74 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start of monitoring
no no
flank counter comparison of
phase signal > threshold? counted teeth with total number
of teeth >= + / - 1
yes yes
MIL on
- 75 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
IAT
MAF
ECT
Camshaft position sensor
Charge pressure control valve
Start of
monitoring
procedure
NO YES YES NO
signal of sensor signal of sensor
signal of sensor
< lower threshold > upper threshold
MIL Fault
Management
End of Monitoring
Procedure
- 76 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
no no
Sensor okay
Fault management
MIL
- 77 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
to ta l m a s s a ir flo w < lo w e r th re sh o ld
or
to ta l m a s s a ir flo w > u p p e r th re sh o ld
or
no to ta l m a s s a ir flo w vs . c a lcu la te d m a s s a ir flo w
Sensors okay > th re s h o ld
a n d fu e l a d a p ta tio n < th re sh o ld
or
to ta l m a s s a ir flo w vs . c a lcu la te d m a s s a ir flo w
< th re s h o ld
a n d fu e l a d a p ta tio n > th re sh o ld
yes
MIL no
yes
mass air flow MAF1 < lower threshold mass air flow MAF2 < lower threshold
or or
no mass air flow MAF1 > upper threshold mass air flow MAF2 > upper threshold no
or or
total mass air flow vs calculatedmass air flow total mass air flow vs calculatedmass air flow
> threshold > threshold
and fuel adaptation < threshold and fuel adaptation < threshold
or or
total mass air flow vs calculatedmass air flow total mass air flow vs calculatedmass air flow
< threshold < threshold
and fueladaptation > threshold and fueladaptation > threshold
MIL
yes yes
- 78 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start of Monitoring
Procedure
engine rpm NO
within det.
range?
YES
coasting NO
condition?
YES
Check of VSS
Signal
Frequency of NO
VSS Signal <
lower threshold?
YES
Fault Code
Management
MIL
- 79 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
TPS 1 no no TPS 2
transformation to transformation to
voltage voltage
throttle position throttle position
out-of- range out-of- range
TPS 1 TPS 2
low/high low/high
no
rationality check rationality check
TPS 1 - calc. value TPS 2 - calc.value
>TPS2-calc. value >TPS1-calc. value
or no no or
TPS1-calc.value TPS2-calc.value
> thresh_02 >thresh_02
fault management
MIL
- 80 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
rationality check no
|APPS1 - APPS 2|
> threshold
yes
MIL
no no
sensors okay
- 81 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
|actual value|>
yes
threshold?
no
|actual value|>
yes
threshold?
no
MIL
- 82 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Start
no
Enable?
yes
Comparison of actual
charge pressure (cp) with
modeled charge pressure
no
no
Actual cp > Actual cp +
modeled cp + threshold<
threshold modeled cp
yes yes
Fault management
MIL
End
- 83 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
high
KL50 low
high
KL50R low
engine coolant
temperature > min.
no
threshold and < max.
Delay Time
threshold?
yes
Signal on no
KL 50?
yes
yes
yes
yes
MIL
Fault management
- 84 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The exhaust temperature sensor (ETS) is monitored for rationality during engine
cold start, where engine coolant temperature, intake air temperature and exhaust
temperature are expected within the same temperature range (stuck high check).
.16.14.02 Monitor function description
After engine has been cold started the slope of ETS is monitored and should not be
higher than a max. Threshold and not lower than a min. threshold.
Both plausibility checks are completed before the ETS information is used in other
monitors (e.g. secondary air).
Additionally the final stage check monitors for shorts to ground or to battery.
- 85 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
yes
no Cold Start
Condition?
yes
ETS
in range of
no
average temperature
+/- 25K?
yes
Delta
exhaust temp. <500 K?
no
or
Delta
exhaust temp.> 150 K?
MIL
- 86 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
.16.15.00 reserved
.16.16.00 reserved
.16.17.00 reserved
.16.18.00 reserved
.16.19.00 reserved
- 87 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Uin
Low high High Low High
Uout / Iout
Low high <0.25-0.37 UBatt >2.2-3.0A <0.65-0.84 UBatt
Fault
detection No fault Fault faut faut
Uin
Low high High Low High
Uout / Iout
Low high <0.22-0.4 UBatt >2.2-3.0A <0.54-0.78 UBatt
Fault
detection No fault Fault fault fault
- 88 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
.19.00.00 RESERVED
N.A.
- 89 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
General
The main condition for closed loop is a proper heated up Oxygen sensor
and the dew point must be exceeded. To guaranty the Oxygen sensor
readiness the heat-up strategy starts depending on engine temperature first
on a low level of heater power. Upon the exhaust temperature reaches a
level where no liquid water is expected to be in the exhaust system the
heater power is controlled to achieve normal ceramic temperature of the
Oxygen sensor. The ceramic temperature has to be >350 C for binary and
>685 C linear sensors. Specific temperatures are mentioned in the
individual summary tables of the concepts.
Additional heat-up of the Oxygen sensor is caused by the thermal energy of
the exhaust gas. The engine management system evaluates permanently
engine temperature and thermal energy introduced to calculate the exhaust
temperature based on a model. The main value therefore is the integrated
air mass after engine start. Upon the integrated air mass exceeds an
applicable threshold, depending on engine start temperature, the due point
is exceeded. In that case, the heater power will be increased until the
sensor readiness is achieved and sensor is considered to be ready for
closed loop control.
- 90 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The target is to begin closed loop operation in a very early state after
engine start. However closed loop is delayed if engine is operated
according the catalyst heat-up strategy. In the table below the importance
parameters are listed.
- 91 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The closed loop operation is the most dominant operation mode for the fuel
system. Despite that fact, there are operating conditions of the engine
where closed loop control must be temporary disabled.
Typical Values
Given a normal cold started FTP (around 20C) most of the concepts
reaches the closed loop condition for the first control loop within 20s to 60s.
Additionally closed loop is forced depending on engine start temperature
after a maximum time.
- 92 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
As already mentioned under General the 2nd control loop optimises the
adjustments of the first control loop over a longer time to achieve the
maximum conversion of the catalyst in a very small window of air/fuel ratio
close to Lambda=1. The second control loop uses a binary Oxygen sensor,
which is operated at a target value of sensor output voltage. Deviations
from the target voltage are corrected by adjusting the air/fuel ratio until the
target voltage is achieved again. The controller of the 2nd control loop is a
combination of proportional and integral (PI-) controller. The proportional
and the integral portion of the controller have individual enable criteria.
- 93 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Given a normal cold started FTP (around 20C) most of the concepts
reaches the closed loop condition for the second control loop within 60s to
100s.
- 94 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
General
The SULEV concept consists of 2 catalysts and 3 control loops. The first
control loop uses the Oxygen sensor pre catalyst (LSU) in the same
manner conventional concepts does. The Oxygen sensor between the two
bricks (LSF1) of the catalyst is the input for the second and the Oxygen
sensor after the last brick (LSF2) is the input for the third control loop. Both
sensors are binary Oxygen sensors. The closed loop operation of each of
the control loops are in a depending order of 1st, 2nd and 3rd control loop.
In comparison to post catalyst control loop on conventional concepts the 2nd
and 3rd control loop are high precision loops with specific requirements for
short-term correction and long-term adaptation. The driving conditions have
to be stable and constant to allow any corrections by these control loops.
The allowed correction steps are much smaller in comparison to post
catalyst control loop applications on conventional concepts.
The conditions for closed loop operation of the first control loop on the
SULEV concept are the same as described for conventional concepts.
- 95 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
- 96 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Given a normal cold started FTP (around 20C) most of the concepts
reaches the closed loop condition for the second control loop within 60s to
80s.
- 97 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
The third control loop is designed like the second control loop on
conventional concepts and achieves the maximum conversion of the 2nd
brick of the catalyst. The controller consists of very restricted correction
ranges for the short-term proportional and the long-term integral adaptive
portion (PI-controller). Both controller ranges have individual conditions for
closed loop operation.
- 98 -
Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy
Given a normal cold started FTP (around 20C) most of the concepts
reaches the closed loop condition for the third control loop within 90s to
100s.
- 99 -