Note: This Chapter covers only those systems that are directly related to engine operation. The location, procedure for replacing control devices, design of lighting fixtures, procedure for replacing lamps and other equipment are described in Chapter 12, and the principles of their operation and the procedure for managing them are described in Chapter "Controls and operating techniques".
1. The engine electrical equipment includes components of the ignition systems (petrol models), preheating (diesel models), charging and starting, as well as an electronic engine management system.
2. The ignition system ensures the ignition of the air-fuel mixture supplied to the combustion chambers of the cylinders of gasoline engines. To form a spark of the required intensity, the 12-volt voltage of the on-board network is converted into high-voltage voltage in the ignition coils (up to 30,000 V). Its main working components are spark plugs, coils and ignition module. Distribution of high-voltage supply to spark plugs is controlled by the engine control unit (ECM) - manual adjustment of ignition timing is not performed - if the required settings are violated, the failed components should be replaced.
3. All gasoline engines covered in this manual, except the Z16SE engine, have 3 or 4 ignition coils (one per cylinder) are combined into a single ignition module. The coils are placed in a common housing installed above the spark plugs. The design of the module and coils eliminates the need for high-voltage wires, since the coils are connected directly to the spark plugs. The ECM, based on the analysis of the data received from the camshaft and crankshaft position sensors, in accordance with the program of the built-in processor, sends control electrical pulses to the ignition module, the configuration of which uniquely determines the ignition moment. In this case, the voltage supply to the primary windings of the ignition coils is interrupted, which leads to a sharp change in the electromagnetic field and, as a consequence, the generation of high voltage in the secondary winding. High voltage is supplied to the spark plugs. The interelectrode gap of the spark plugs is set in such a way that when voltage is supplied to the plug, a "breakdown" occurs between the electrodes, accompanied by sparking. The spark resulting from the "breakdown" ensures ignition of the air-fuel mixture. The control elements of the ignition system are not subject to wear and do not require regular maintenance. In accordance with the maintenance schedule (see Chapter 1) only the spark plugs should be replaced.
4. On the Z16SE engine, high voltage (HV) voltage is generated in two ignition coils - each of which ensures the operation of two spark plugs. Both ignition coils are placed in a single housing, which is mounted on the left side of the cylinder head. The coils are connected to the spark plugs via HV wires. The procedure for servicing the HV wires is given in Chapter 1.
5. The diesel engine preheating system is designed to warm up the combustion chambers for the purpose of confident ignition of diesel fuel. Glow plugs are used as heating elements, the operation of which is controlled by the corresponding electronic unit. A glow plug is screwed into the combustion chamber of each cylinder. The plugs are heated by electric current before starting, during starting and for some time after starting the engine. The power supply to the glow plugs is controlled by the ECM. In this case, the corresponding control lamp is displayed on the instrument panel (see Chapter "Controls and operating techniques").
6. The fuel filter of the diesel engine fuel system can also be equipped with a heating system that prevents diesel fuel from "waxing". The heating element is installed between the fuel filter and its housing. Power for heating the fuel is supplied by ECM commands through a temperature-sensitive switch built into the filter housing.
7. The charging system supplies electrical power to the ignition system, lighting and signaling devices, radio receiver and other consumers of electrical energy. It includes an alternating current generator, a voltage regulator built into it, a charge control lamp (see Chapter "Controls and operating techniques"), battery, fuses and wiring harnesses connecting these components. The alternator is belt driven from the crankshaft pulley and is mounted at the front of the engine. The charging system does not require regular maintenance. However, the condition of the multi-rib belt, battery, connecting wiring harness and its terminal connections should be checked periodically (see Chapter 1).
8. The starting system ensures that the engine is turned over in order to start it. The main components of the system are the starter with the traction relay installed on it, the battery, the ignition switch and the connecting electrical wiring. The starter assembly with the traction relay is secured to the power unit, near the clutch dome. When the ignition key is turned to position "III" (START), power from the battery is supplied via the starting control circuit to the starter traction relay. The relay switches the battery power directly to the starter electric motor. The motor begins to rotate, simultaneously turning the engine crankshaft by the toothed ring gear of the flywheel/drive disk. The engine starting procedure is described in the corresponding Section of the Chapter "Controls and Operating Techniques".
9. Engine management system (see also Chapter 4) is the main connecting element of all the above systems - it is the brain of the engine. The initial data comes to the electronic module of the system from various information sensors and other electronic components (switches, relays, etc.). Based on the analysis of data received from information sensors and in accordance with the basic parameters stored in the processor memory, the ECM generates commands to operate various control relays and actuators, thereby adjusting the engine operating parameters and ensuring maximum efficiency with minimum fuel consumption.
10. The ECM is a complex set of electronic circuits and independent attempts to make any changes will lead to disruption of its functioning and engine failures. A complete diagnosis of the engine management system can only be performed using special diagnostic equipment that allows reading the failure codes stored in the processor memory. Analysis of the read information allows you to quickly identify the source of the failure and eliminate the cause of its occurrence.
Precautionary measures
Warning: The electronic ignition system generates very high voltage! Persons with an implanted pacemaker must not be allowed to service ignition system components!
11. When servicing components of the engine electrical systems, special precautions must be taken to avoid the risk of failure of semiconductor elements, as well as to prevent electrical injuries.
12. When servicing electrical equipment, be sure to remove wristwatches, rings, and other metal jewelry. Even with the battery disconnected, the discharge of capacitors when their terminals are accidentally grounded can result in an electric shock or severe burn.
13. Do not reverse the polarity when connecting the battery. Components such as the generator or electronic control units contain semiconductor elements that can be damaged if the wires are connected incorrectly.
14. When starting the engine from an external power source (see Chapter "Introduction"), or when connecting the charger, also observe the polarity of the wires.
15. Never start the engine with the charger connected to the battery. Always disconnect both cables from the battery before charging it from an external power source (negative at first).
16. Remember that excessively long cranking of the engine with the starter can cause serious damage to the electric motor of the latter due to overheating. Try not to use the starter continuously for more than 20 seconds on petrol models and 30 seconds on diesel models, after which it should be allowed to cool for a minute.
17. When performing electrical checks and before connecting/disconnecting diagnostic equipment, turn off the ignition. Never disconnect electrical wiring from the battery, generator or diagnostic equipment while the engine is running.
18. Never check the presence of generator output voltage by grounding its terminals. Also, do not ground the ignition coil windings to ground.
19. When performing any maintenance work on electrical equipment, ensure that the negative cable is disconnected from the battery.
20. Before using arc welding, always disconnect the battery, generator and components such as fuel/ignition control modules to avoid the risk of damage.
21. Avoid allowing hands, hair and loose clothing to come into contact with the rotating alternator drive belt during checks performed with the engine running.
22. Before steam cleaning the engine compartment, wrap the generator in a plastic bag, which should then be securely fastened with rubber bands.
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