FTB Wiring and Engine Harness preparation for New model introduction

(YE3) in ES-3

ByDheeraj saini

(Staff ID 232246)

Under the Guidance of

Mr. Rakesh RawatEAE Dept (PE)

FTB – An Overview• FTB stands for Fire Test bench.

It is used to check the critical engine parameters after whole of the engine assembly is finished.

Various engine parameters and sensors that are checked in FTB are as follow:

• Parameters :

(a)Idle RPM

(b)Oil Pressure

(c)Vacuum (Intake manifold)

(d) Any type of leakage from E/G

• Sensors

FTB Nomenclature

Water OUT

Water INE/G resting Fixture

FTB Control Panel

FTB Exhaust

DISPLAY PANEL

Run Engine at 3000-4000 rpm and allow it to reach Idle rpm (950 +/- 100)

Oil pressure check Idle rpm (Min- 1.2 bar); At 4000 rpm (Min-3.5bar)

Check vacuum pressure at idle rpm- 485 mm of Hg (max)

Check Engine Vibration & abnormal noise

ENGINE TESTING CYCLE ON FTB

Oil leakage from Camshaft seal, cylindrical head, Gasket cylinder head, tappet cover& Cam sensor.

Water leakage from Gasket cylinder head, Intake manifold block plate, water pump

Accelerating beyond 4000 rpm to check Cam sensor working

Check oil color: if white send to repair

Tightening of OPS & DP (Set OPS at 140 Kgf cm & DP at 350 Kgf cm)

5 Minutes

Remove Drain Plug

1. VTA (Throttle Positioning Sensor)

• Monitors the throttle valve position & sends signal to ECU

2. CMP ( Cam

Positioning Sensor )

•Sends signal about positioning of cam during its rotation to ECU.• ECU uses this information to determine spark timing and fuel delivery.

3. CKP ( Crank Positioning Sensor)

• Monitors the position or rotational speed of the crankshaft.

4. ISC ( Idle

Speed Controller )

• Receives signal from ECU about the idle speed at which the engine should run at particular condition.

5. KNK ( Knock Sensor) •Senses the knocking level in the middle cylinder & sends the signal to ECU.

6. IGT ( Ignition Coil) • Receives signals from ECU regarding the spark timing depending upon the load conditions.

7 TMAP (Temperature

Manifold Absolute pressure sensor)

•Combination of PM & THA.• Measures the vacuum from the engine & temperature of water.

Sensors used in YE3 FTB

THROTTLE (VTA)

IGNITION COIL (IGT)CAM (CMP)

INJECTOR

VACUUM

IDLE SPEED CONT.(ISC)

CRANK (CKP)

SENSOR Nomenclature

FTB modification & Harness preparation for New model Introduction :- 1. ECU drawing & Engine harness drawing study : a. ECU DRAWING is used to study and finalize the sensor connections for FTB wiring.

b. Wiring routes of sensors to ECU are taken from E/G HARNESS DRAWING.

2. Harness preparation drawing is made consisting of connection between various sensors & ECU.

Harness is made in 2 steps : a. E/G HARNESS ( from sensors to 16 pin connectors ) b. CABLE HARNESS ( from 16 pin to 37 MS pin connector in FTB )

3. FTB WIRING is done to connect the cable harness to the ECU.

4. External Connections like Power Supply & ground are also provided through FTB wiring.

Example to make the Harness ConnectionsTo understand the making of harness from the drawing lets take an ISC

connector for YE3 and study all its connections and how the connections are made in ECU.

ISC Connector :

According to engine harness drawing, connector shown is :

• It has 3 ports, now from the harness table we can get the destinations

EA75 EA24 ED1B

FROM TO

From Harness Table, we get:

EA 75- Signal is coming from ECU #2 to ISC.EA 24- Signal is coming from ENG BONDER #2 to ISC.ED 1B- Signal is coming from ENG BONDER #3 to ISC.

E/G Harness drawing Table

EA75 EA24 ED18

ECU #2

ENG BONDER #2

• Out of the two connections going to ENG BONDER, one is for the external power supply & other one is grounded.

• So in ECU the final connection will be.

ENG BONDER #3

ECU #2ECU connections from E/G Harness drawing Table

ECU CONNECTOR FOR YE3 BSIV

+BB STA

IMC IMD IGS

DNL

E26 E24

ECU #1 :

IGT1

+B1 +B2 E03 E01 E02 E1

CMPCKP+CKP- IGT2IGT3 ISC

KNK+KNK- E31

E32

ECU #2 :

SOXH OXH #3 #2 #1

E33 E22 S0X THW THA PM

VTA

FPR

VCC1VCC3 VCC2

OX

VCC4E21 E23 E34

ECU #3 :

LAYOUT OF FTB HARNESS

16 Pin Maleconnector

16 Pin Femaleconnector

16 Pin Maleconnector

16 Pin FeMaleconnector

THW

CMP

ISC

TMAP VTA CKPKNK

IGT1

IGT2

IGT3

37 Pin Connector to 16 Pin M/F Connectors

960mm

770mm

850mm 910mm

760mm

900mm

710mm

750mm

780mm 970mm770mm

900mm

795mm

680mm

Starter

710mm

37 Pin MS Connector

YE3 FTB Harness

ECU

Ground

Power supply

Suggestions for Process Improvement

1) Provision of online sensor testing for some sensors which are not tested in FTB. Eg- oxygen sensor, Air temprature sensor.

2) A test Rig setup to check the FTB Engine harness and provide information about the harness testing details in the form of Barcode.