ZEST BOLT Service Manual

ENGINE 1.3L QUADRAJET (90PS) 100 Note: All Fuses referred below are in Fuse Box B1/B99 located in Engine Compartment. Power Supply and GND Engine management control unit (ECU) controls and governs the entire electronic injection system. ECU is powered through fuse 7.5A at pin 23 of connector V of ECU. Direct Battery supply to ECU arrives from line protected by fuse 7.5A at pin 50 of connector V of ECU. Pins 1, 2 and 3 of connector V of ECU are earthed. Main relay Main relay (T8) controls the entire system - it is energized by line protected by fuse 7.5A, an earth signal from pin 80 of connector V of Engine control unit and then provides power supply to To pin 5 of connector V of the control unit, through fuse 10A. To pins 4 and 6 of connector V of the ECU, through fuse 20A. To lambda sensor K40, EGR Solenoid L30, Turbo VGT solenoid L36, Vehicle Speed Sensor (K57) and Glow plug Controller M15 through the fuse 15A. To Water in fuel & temperature sensor(K101) through fuse 20A To Air Flow Meter HFM Sensor K41 through fuse 10A Fuel Pump Relay Fuel pump relay is energized by a control signal coming from pin 85 of connector V of Engine control unit. Power to Fuel pump relay (T7) contact is supplied through the fuse (15A) & it provides power supply for the electric fuel pump (N40), after fuel pump relay gets energized. Fuel pump is earthed via the inertia switch (I50), which interrupts the circuit in the case of any impact and stops the supply of fuel. Glow Plug Controller (M15) Glow Plug Controller M15 manages the preheating of the glow plugs A40 is supplied directly from the battery via a line protected by MAXIFUSE 50A Glow plug controller is powered from the main relay by fuse 15A which controls the Glow plugs A40. Glow Plug Command is given to glow plug controller (M15) from pin74 of Connector V of ECU Glow Plug Feedback is given from glow plug controller (M15) to pin70 of Connector V of ECU The engine management control unit ECU receives signals from the various sensors thereby keeping all the engine operating parameters under control. Crank Angle Sensor (K46) The (RPM) Crank Angle sensor (K46) provides information to pins 43 and 59 of connector M of the engine control unit, about the engine speed. CAM Phase Sensor (K47) CAM Phase (Timing) sensor K47 is connected as given below, Power is supplied from pin 25 of connector M of Engine control unit. Reference earth from pin 21 of connector M, Sensor sends signal corresponding to the phase to pin 56 of connector M of the Engine control unit. Water Temperature sensor (K36) Water (Engine coolant) temperature sensor K36 receives a reference earth from pin 29 of Connector M of ECU, and sends a signal proportional to engine coolant temperature to pin 54 of Connector M. Air Flow meter (K41) The air flow meter K41 - supplied by fuse 10A and receives a reference earth from pin 27 of Connector M of ECU Sensor sends a signal proportional to the air flow rate at pin 14 of Connector M. An air temperature sensor inside K41 also sends an air temperature signal to pin 10 of Connector M of ECU. Accelerator Pedal Sensor (K55) The accelerator pedal K55 has two bui l t in potentiometers (1. Main, 2 .Safety). The former receives power and earth signals from pins 35 and 83 of connector V of ECU and sends a corresponding signal to pin 65.