Transcript GM High Feature V6 Ignition System Cam Sensor

High Feature V6 Ignition System
BOSCH Ignition System Components
Training Seminars for
GM Regional Service Engineers
September 26, 2002
Spark Plug
Coil
Cam Sensor
Crank Sensor
Knock Sensor
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
1
High Feature V6 Ignition System
Spark Plug
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
2
High Feature V6 Ignition System
Spark Plug
Component Definition:
• J-Gap type
• Conical seat
• M14 thread
• 1 inch (25mm) thread length
• 5/8 inch (16mm) hex size
• Fired in suppressor
• Precious metal tipped center electrode
• Copper core ground electrode
• Standard SAE terminal
• Smooth insulator head
• Silicone coated (pink color) insulator foot
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
3
High Feature V6 Ignition System
Spark Plug
Component Specification:
• 100.000 Miles service interval
• .044 +.004 inch (1.1 + 0.1 mm) gap
• 6  3 kW fired in suppressor
• 35.000 V ceramic dielectric strength
• 135 lbf (600 N) max. allowed lateral load
on insulator
• 392°F (200°C) max. allowed seat
temperature
• 13  2 lbf ft (18  2 Nm) tightening torque
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
4
High Feature V6 Ignition System
Spark Plug
Notes for Service:
• Always use torque wrench
• Always use proper spark plug socket
• Service only in cold engine
• Do not use anti-seize or similar lubricant on threads
• Do not gap
• Discard if dropped
• Only service cylinder with fault code
• Over 90% of spark plugs removed due to misfire fault
code are diagnosed “No trouble found”
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
5
High Feature V6 Ignition System
Ignition Coil
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
6
High Feature V6 Ignition System
Ignition Coil
Component Definition:
• Pencil type ignition coil
• Located directly on spark plug
• 4 pin primary connector with slide lock
• Serviceable spark plug boot
• Spring loaded spark plug
• Integrated power stage
• Integrated suppression components
• Captured fastener M6x35
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
7
High Feature V6 Ignition System
Ignition Coil
Component Specification:
• 6-16V permanent operating voltage
• 26.5V short time (max 2 min) for jump start
• 14V, 9A nominal operating conditions
• >30.000 V available secondary voltage
• 45mJ spark energy
• 20mA ECU control signal (different from other GM
systems)
• 7.5  1.5 lbf ft (10  2 Nm) tightening torque
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
8
High Feature V6 Ignition System
Ignition Coil
Function:
• ECU commands dwell time with 20mA signal
• Dwell time calculated as function of temperature, battery voltage
• Spark delivered at end of dwell
30000
Primary Current
ECU Signal
Secondary Voltage
20
20000
15
10
10000
5
0
-1
0
0
1
2
3
4
5
6
-5
-10000
Secondary Voltage [V]
ECU Signal Current I [mA]; Coil Primary Current IC [A]
25
-10
-15
-20000
-20
-25
-30000
t [ms]
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
9
High Feature V6 Ignition System
Ignition Coil
Notes for Service:
• Spark plug boot and spring to be serviced at 100.000 Mile spark
plug service
• Never probe ignition coil with 12V tester for component diagnosis.
Ignition coil will be damaged. Shock hazard!
• Attention! Primary connector under high voltage.
• Ignition coil resistance cannot be measured due to integrated
components (power stage, diodes)
• Only service cylinder with fault code
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
10
GM High Feature V6 Ignition System
Cam Sensor
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
11
GM High Feature V6 Ignition System
Cam Sensor
Component Definition:
• Dual Hall sensing principle
• True Power On Functionality (TPO)
• M6 mounting bolt
• Captured fastener (Axi-Rad)
• Reverse polarity protected
• Additional resistor in output line for EMC
• Housing made from PA66 GF35
• FPM O-ring
• Stainless Steel cap over sensing elements
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
12
GM High Feature V6 Ignition System
Cam Sensor
Definition (cont’d):
Captured Fastener
Busbar
Connector
(overmolded)
Holder
(premolding part)
Covered by
metal cup
IC board
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
13
GM High Feature V6 Ignition System
Cam Sensor
Component Specification:
• Speed range: 0 to 4000 RPM
• Allowable air gap: 0.1 to 1.8 mm
• Allowable lateral displacement: 0.5 mm
• Temperature range: -40 to +150°C
• Supply: 4.75V to 5.25V (max 16.5V)
• Max output current: 20 mA
• Output signal:  0.5V,  4.25V
• Fall time:  1s
• Rise time:  70s
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
14
GM High Feature V6 Ignition System
Cam Sensor
Component Function:
Bfield
t
Is
UH
UH = RH
IS * Bfield
* t
UH
RH
IS
Bfield
t
=
=
=
=
=
Hall voltage
Hall constant
Supply current
Magnetic induction
Thickness of the hall-element
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
15
GM High Feature V6 Ignition System
Cam Sensor
Component Function (cont’d):
Track 1
Sensor 1
S2
S1
Track 2
Output
U (S1-S2)
Hall
Voltage
Differential
Voltage
Operating Principle
Sensor 2
GM High Feature V6 System
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
16
GM High Feature V6 Ignition System
Cam Sensor
Notes for Service:
• Seat sensor 100% into cam cover bore
before threading bolt
• Always use torque wrench (10±2 Nm)
• Do not use the bolt to pull sensor into
the bore!
• Only mineral based lubricant on o-ring
if needed (no silicone)
• It is not abnormal for the plastic AxiRad to melt around the bolt
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
17
GM High Feature V6 Ignition System
Crank Sensor
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
18
GM High Feature V6 Ignition System
Crank Sensor
Component Definition:
• Variable reluctance sensing principle
• Independent of rotational orientation
• 2 pc “Cup” design for thermal resistance
• Insertion guide ribs
• Increased surface for pressing into bore
• M6 mounting bolt
• Captured fastener (Axi-Rad)
• Housing made from PA66 GF35
• Brown viton O-ring
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
19
GM High Feature V6 Ignition System
Crank Sensor
Definition (cont’d):
Bobbin with
Busbar and Coil
O-Ring
Final
Overmolding
with Connector
Geometry
Mounting
Bolt
Plastic
Retainer
Cup with
Molded
Bushing
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
20
GM High Feature V6 Ignition System
Crank Sensor
Definition (cont’d):
DG8 Differences
DG8
HFV6 Improved Design
DG6
Old Design
Magnetic airgap =
geometric airgap + 0.5mm
Magnetic airgap =
geometric airgap
• cup design (over poletip)
• enforced magnetic circle
Overmolding
Poletip
DG8
DG6
Magnetic
Airgap
Geometric
Airgap
DG8
Magnetic
Airgap
Cup
Magnet
Polepiece
Target Wheel
(not to scale)
Target Wheel
(not to scale)
Coil
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
21
GM High Feature V6 Ignition System
Crank Sensor
Component Specification:
• Speed range: 20 to 7000 RPM
• Allowable air gap: 0.1 to 1.5 mm
• Temperature range: -40 to +150°C
• Coil resistance 860W (ref.)
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
22
GM High Feature V6 Ignition System
Crank Sensor
Component Function:
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
23
GM High Feature V6 Ignition System
Crank Sensor
Notes for Service:
• Seat sensor 100% into engine bore
before threading bolt
• Always use torque wrench (10±2 Nm)
• Do not use the bolt to pull sensor into
the engine bore!
• Only mineral based lubricant on o-ring
if needed (no silicone)
• It is not abnormal for the plastic AxiRad to melt around the bolt
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
24
GM High Feature V6 Ignition System
Knock Sensor
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
25
GM High Feature V6 Ignition System
Knock Sensor
Component Definition:
 Linear Wideband Type
 Simple compact Design (piezo ring)
 Frequency range 3…… 22 kHz
 Sensitivity at 5 kHz - value 30 ± 6 mV/g
 Gold plated pins inside the connector
 26 mm housing diameter
 Temperature resistance - 40°C …. 150°C
 Crimped composite
 No threaded ring
 Fastener M8 held via O-Ring
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
26
GM High Feature V6 Ignition System
Knock Sensor
GM HFV6 GMT257 FWD left side
GM HFV6 GMX365 FWD left side
GM HFV6 all the other Applications
60
55
50
Sensitivity [mV/g]
45
40
35
30
25
20
15
10
5
0
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Frequency [kHz]
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
27
GM High Feature V6 Ignition System
Knock Sensor
Component Specification:
 150,000 miles or 15 years lifetime
 Temperature Range
Sensor head and wire :
-40°C ….150°C
Short term after engine stop, without
vibration :
-40°C …. 180°C
 Rz = 16 also indicated on offer drawing
 Mounting torque 5.17 lbf or 23 ± 3 Nm
 Capacitance sensor head C= 1150 ± 200 pF
 Capacitance wire
C= 100 ± 20 pF/m
 Shunt Resistor
4.9 MW ± 20%
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
28
GM High Feature V6 Ignition System
Knock Sensor
Component Function:
Characteristic U= f ( f )
mV/g
50
40
30
20
10
0
5
10
15
20 kHz
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
29
GM High Feature V6 Ignition System
Knock Sensor
Notes for Service:
• Seat sensor 100% into engine bore before
threading bolt
• Always use torque wrench
• Sensor mounting orientation according to
GM PAD
• Do not use any washers etc. between the
sensor sleeve and engine block boss
• Do not torque the sensor more than 25 Nm
and less than 15 Nm
APEEC 02 217
September 24, 2002
© Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties
30