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The engine controller is a pre-programmed digital computer.

The engine controller regulates ignition timing, airfuel ratio, emission control devices, cooling fan, charging system, speed control, and idle speed. The engine controller can adapt its requirement to meet changing operating conditions.

system, the information is stored in memory. Technicians can display fault information through the instrument panel Check Engine lamp or by connecting the Diagnostic Readout Box II (DRB II). For fault code information, refer to On Board Diagnostics in 2.2L/2.5L Single Point Fuel InjectionÐGeneral Diagnosis section of this group.

Various sensors provide the inputs necessary for the engine controller to correctly regulate fuel flow at the fuel injector. These include the manifold absolute pressure, throttle position, oxygen sensor, coolant temperature, and vehicle distance sensors. In addition to the sensors, various switches and relays provide important information and system control. The inputs include the park/neutral switch and air conditioning clutch switch. The outputs include the auto shutdown relay and fuel pump relay.

All inputs to the engine controller are converted into signals. Based on these inputs the engine controller adjusts air-fuel ratio, ignition timing and other controlled outputs. The engine controller adjusts the air-fuel ratio by changing the injector pulse width. Injector pulse width is the period of time the injector is energized.

SYSTEM DIAGNOSIS

The engine controller tests many of its own input and output circuits. If a fault is found in a major

CCD BUS

Various controllers and modules exchange information through a communications port called the CCD Bus. The engine controller transmits vehicle load data on the CCD Bus.

ENGINE CONTROLLER

The engine controller is a digital computer containing a microprocessor (Fig. 2). The controller receives input signals from various switches and sensors that are referred to as Engine Controller Inputs. Based on these inputs, the controller adjusts various engine and vehicle operations through devices that are referred to as Engine Controller Outputs.

Engine Controller Inputs:

²Air Conditioning Controls

²Battery Voltage

²Brake Switch

²Coolant Temperature Sensor

²Distributor (Hall Effect) Pick-up

²Manifold Absolute Pressure (MAP) Sensor

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Fig. 2 Engine Controller

²Oxygen Sensor

²SCI Receive

²Speed Control System Controls

²Throttle Position Sensor

²Park/Neutral Switch (automatic transmission)

²Vehicle Distance (Speed) Sensor

Engine Controller Outputs:

²Air Conditioning Clutch Relay

²Alternator Field

²Automatic Idle Speed (AIS) Motor

²Auto Shutdown (ASD) Relay

²Canister Purge Solenoid

²Check Engine Lamp

²Diagnostic Connector

²Electronic EGR Transducer

²Fuel Injector

²Ignition Coil

²Part Throttle Unlock Solenoid (Automatic Transmission)

²Radiator Fan Relay

²Speed Control Solenoids

²Tachometer Output

Based on inputs it receives, the engine controller adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and canister purge operation. The engine controller regulates operation of the EGR, cooling fan, A/C and speed control systems. The controller changes alternator charge rate by adjusting the alternator field.

The engine controller adjusts injector pulse width (air-fuel ratio) based on the following inputs.

²battery voltage

²coolant temperature

²exhaust gas content

²engine speed (distributor pick-up)

²manifold absolute pressure

²throttle position

The engine controller adjusts ignition timing based on the following inputs.

² coolant temperature

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²engine speed (distributor pick-up)

²manifold absolute pressure

²throttle position

The Auto Shutdown (ASD) and Fuel Pump relays are mounted externally, but turned on and off by the engine controller through the same circuit.

The distributor pick-up signal is sent to the engine controller. If the engine controller does not receive a distributor signal within approximately one second of engine cranking, it de-activates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off from the fuel injector, fuel pump, ignition coil, and oxygen sensor heater element.

The engine controller contains a voltage converter that changes battery voltage to a regulated 9.0 volts to power the distributor pick-up and vehicle speed sensor. The controller also provides a 5.0 volts supply for the coolant temperature sensor, manifold absolute pressure sensor and throttle position sensor.

AIR CONDITIONING SWITCH SENSEÐENGINE CONTROLLER INPUT

When the air conditioning or defrost switch is put in the ON position and the low pressure and high pressure switches are closed, the engine controller receives an input indicating that the air conditioning has been selected. After receiving this input, the engine controller activates the A/C compressor clutch by grounding the A/C clutch relay. The engine controller also adjusts idle speed to a scheduled RPM to compensate for increased engine load.

BATTERY VOLTAGEÐENGINE CONTROLLER INPUT

The engine controller monitors the battery voltage input to determine fuel injector pulse width and alternator field control.

If battery voltage is low the engine controller will increase injector pulse width.

BRAKE SWITCHÐENGINE CONTROLLER INPUT

When the brake switch is activated, the engine controller receives an input indicating that the brakes are being applied. After receiving the input, the controller vents the speed control servo. Venting the servo turns the speed control system off.

COOLANT TEMPERATURE SENSORÐENGINE CONTROLLER INPUT

The coolant temperature sensor is installed behind the thermostat housing and ignition coil in the hot box. The sensor provides an input voltage to the engine controller (Fig. 3). As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the engine controller.

The engine controller demands slightly richer airfuel mixtures and higher idle speeds until the engine reaches normal operating temperature.

This sensor is also used for cooling fan control.

Fig. 3 Coolant Temperature Sensor

DISTRIBUTOR (HALL EFFECT) PICK-UPÐENGINE CONTROLLER INPUT

The distributor pick-up supplies engine speed to the engine controller. The distributor pick-up is a Hall Effect device (Fig. 4).

Fig. 4 Distributor Pick-UpÐTypical

A shutter (sometimes referred to as an interrupter) is attached to the distributor shaft. The shutter contains four blades, one per engine cylinder. A switch plate is mounted to the distributor housing above the shutter. The switch plate contains the distributor pick-up which is a Hall Effect device and magnet. The

shutter blades rotate through the distributor pick-up. As the shutter blades pass through the pick-up, they interrupt the magnetic field. The Hall effect device in the pick-up senses the change in the magnetic field and switches on and off (which creates pulses), generating the input signal to the engine controller. The engine controller calculates engine speed through the number of pulses generated.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORÐENGINE CONTROLLER INPUT

The engine controller supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The engine controller monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately.

During cranking, before the engine starts running, the engine controller determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the controller determines intake manifold pressure from the MAP sensor voltage.

Based on MAP sensor voltage and inputs from other sensors, the engine controller adjusts spark advance and the air/fuel mixture.

The MAP sensor mounts on the dash panel (Fig. 5). A vacuum hose connects the sensor to the throttle body.

Fig. 5 Manifold Absolute Pressure (MAP) Sensor

Location

OXYGEN SENSOR (O2 SENSOR)ÐENGINE CONTROLLER INPUT

The O2 sensor is located in the exhaust manifold and provides an input voltage to the engine controller. The input tells the engine controller the oxygen content of the exhaust gas (Fig. 6). The engine controller uses the information to fine tune the air-fuel ratio by adjusting injector pulse width.

The O2 sensor produces voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust

Fig. 6 Oxygen Sensor

gas. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces a low voltage. When there is a lesser amount present (rich air-fuel mixture), it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch.

The oxygen sensor is equipped with a heating element that keeps the sensor at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle.

In Closed Loop operation the engine controller monitors the O2 sensor input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the engine controller ignores the O2 sensor input. The controller adjusts injector pulse width based on a preprogrammed (fixed) oxygen sensor input value and inputs from other sensors.

SPEED CONTROLÐENGINE CONTROLLER INPUT

The speed control system provides four separate voltages (inputs) to the engine controller. The voltages correspond to the On/Off, Set, and Resume.

The speed control ON voltage informs the engine controller that the speed control system has been activated. The speed control SET voltage informs the controller that a fixed vehicle speed has been selected. The speed control RESUME voltage indicates the previous fixed speed is requested. The speed control OFF voltage tells the controller that the speed control system has deactivated. Refer to Group 8H for further speed control information.

Fig. 7 Park/Neutral Switch

THROTTLE POSITION SENSOR (TPS)ÐENGINE CONTROLLER INPUT

The Throttle Position Sensor (TPS) is mounted on the throttle body and connected to the throttle blade shaft (Fig. 8). The TPS is a variable resistor. The sensor provides an input signal (voltage) to the engine controller representing throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes.

Fig. 8 Throttle Position Sensor

The engine controller supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the engine controller) represents the throttle blade position. The engine controller receives an in-

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put signal voltage from the TPS varying in an approximate range of from 1 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors, the engine controller uses the TPS input to determine current engine operating conditions. The controller adjusts fuel injector pulse width and ignition timing based on these inputs.

VEHICLE DISTANCE (SPEED) SENSORÐENGINE CONTROLLER INPUT

The distance sensor is located in the transmission extension housing (Fig. 9). The sensor input is used by the engine controller to determine vehicle speed and distance traveled.

FUEL SYSTEMS 14 - 21

on position. When the engine controller senses low idle speeds or wide open throttle through the throttle position sensor, it de-energizes the A/C clutch relay. The relay contacts open, preventing air conditioning clutch engagement.

On AC, AG and AJ models, the A/C clutch is located in the power distribution center. Refer to the Wiring and Component Identification section of Group 8W.

ON AA and AP models, the A/C clutch relay is mounted to the inner fender panel, next to the drivers side strut tower (Fig. 10).

Fig. 9 Vehicle Distance (Speed) Sensor Ð Typical

The distance sensor generates 8 pulses per sensor revolution. These signals, along with a closed throttle signal from the TPS, determine if a closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the engine controller adjusts the AIS motor to maintain a desired MAP value. Under idle conditions, the engine controller adjusts the AIS motor to maintain a desired engine speed.

AIR CONDITIONING (A/C) CLUTCH RELAYÐENGINE CONTROLLER OUTPUT

The engine controller operates the air conditioning clutch relay ground circuit. The radiator fan relay supplies battery power to the solenoid side of the A/C clutch relay. The air conditioning clutch relay will not energize unless the radiator fan relay energizes. The engine controller energizes the radiator fan relay when the air conditioning or defrost switch is put in the ON position and the low pressure and high pressure switches close.

With the engine operating, the engine controller cycles the air conditioning clutch on and off when the A/C switch closes with the blower motor switch in the

Fig. 10 Relay Identification

ALTERNATOR FIELDÐENGINE CONTROLLER OUTPUT

The engine controller regulates the charging system voltage within a range of 12.9 to 15.0 volts. Refer to Group 8A for charging system information.

AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP RELAYÐENGINE CONTROLLER OUTPUT

The engine controller operates the auto shutdown (ASD) relay and fuel pump relay through one ground path. The controller operates the relays by switching the ground path on and off. Both relays turn on and off at the same time.

The ASD relay connects battery voltage to the fuel injector and ignition coil. The fuel pump relay connects battery voltage to the fuel pump and oxygen sensor heating element.

The engine controller turns the ground path off when the ignition switch is in the Off position. Both relays are off. When the ignition switch is in the On or Crank position, the engine controller monitors the distributor pick-up signal. From the distributor signal, the controller determines engine speed and igni-

tion timing (coil dwell). If the engine controller does not receive a distributor signal when the ignition switch is in the Run position, it will de-energize both relays. When the relays are de-energized, battery voltage is not supplied to the fuel injector, ignition coil, fuel pump and oxygen sensor heating element.

On AC, AG and AJ models, the ASD relay and fuel pump relay are located in the power distribution center. Refer to the Wiring and Component Identification section of Group 8W.

On AA and AP models, the ASD relay and fuel pump relay are mounted on the drivers side fender well, next to the strut tower (Fig. 10).

AUTOMATIC IDLE SPEED (AIS) MOTORÐENGINE CONTROLLER OUTPUT

The automatic idle speed stepper motor is mounted on the throttle body (Fig. 11). The engine controller operates the AIS motor. The engine controller adjusts engine idle speed through the AIS to compensate for engine load or ambient conditions.

Fig. 11 Automatic Idle Speed Motor

The throttle body has an air bypass passage that provides air for the engine at idle (the throttle blade is closed). The AIS motor pintle protrudes into the air bypass passage and regulates air flow through it.

The engine controller adjusts engine idle speed by moving the AIS motor pintle in and out of the bypass passage. The adjustments are based on inputs the controller receives from the throttle position sensor, speed sensor (distributor pick-up coil), coolant temperature sensor, and various switch operations (brake, park/neutral, air conditioning). Deceleration die out is also prevented by increasing airflow when the throttle is closed quickly after a driving (speed) condition.

CANISTER PURGE SOLENOIDÐENGINE CONTROLLER OUTPUT

Vacuum for the Evaporative Canister is controlled by the Canister Purge Solenoid (Fig. 12). The solenoid is controlled by the engine controller.

Fig. 12 Canister Purge Solenoid

The engine controller operates the solenoid by switching the ground circuit on and off based on engine operating conditions. When grounded, the solenoid energizes and prevents vacuum from reaching the evaporative canister. When not energized, the solenoid allows vacuum to flow to the canister.

During warm-up and for a specified time period after hot starts, the engine controller grounds the purge solenoid. Vacuum does not operate the evaporative canister valve.

The engine controller removes the ground to the solenoid when the engine reaches a specified temperature and the time delay interval has occurred. When the solenoid is de-energized, vacuum flows to the canister purge valve. Vapors are purged from the canister and flow to the throttle body.

The purge solenoid is also energized during certain idle conditions to update the fuel delivery calibration.

CHECK ENGINE LAMPÐENGINE CONTROLLER OUTPUT

The Check Engine Lamp comes on each time the ignition key is turned ON and stays on for 3 seconds as a bulb test. The Check Engine Lamp warns the operator that the engine controller has entered a Limp-in mode. During Limp-in-Mode, the controller attempts to keep the system operational. The check engine lamp signals the need for immediate service. In limp-in mode, the engine controller compensates for the failure of certain components that send incorrect signals. The controller substitutes for the incorrect signals with inputs from other sensors.

Signals that can trigger the Check Engine Lamp.

²Coolant Temperature Sensor

²Manifold Absolute Pressure Sensor

²Throttle Position Sensor

²Battery Voltage Input

²An Emissions Related System

²Charging system

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The Check Engine Lamp can also be used to display fault codes. Cycle the ignition switch on, off, on, off, on, within five seconds and any fault codes stored in the Engine controller will be displayed. Refer to On Board Diagnostics in the General Diagnosis Ð 2.5L TBI Engines section of this Group for Fault Code Descriptions.

Fig. 13 Electronic EGR Transducer

Fig. 14 EGR Valve and Electric EGR Transducer

FUEL SYSTEMS 14 - 23

DIAGNOSTIC CONNECTORÐENGINE CONTROLLER OUTPUT

The diagnostic connector provides the technician with the means to connect the DRB II tester to diagnosis the vehicle.

ELECTRONIC EGR TRANSDUCERÐENGINE CONTROLLER OUTPUT

The electronic exhaust gas recirculation transducer (EET) is a back pressure transducer/electric vacuum solenoid assembly (Fig. 13). The EET assembly mounts above the EGR valve (Fig. 14).

The solenoid turns the vacuum supply to the transducer on and off. The electric vacuum solenoid portion of the EET energizes when the engine controller provides a ground path. When the solenoid energizes, vacuum is prevented from flowing to the transducer. When the solenoid de-energizes, vacuum flows to the transducer. The solenoid energizes during engine warm-up, closed throttle (idle or cruise), wide open throttle, and rapid acceleration/deceleration. If the solenoid wire connector is disconnected, the EGR valve will operate at all times.

FUEL INJECTORÐENGINE CONTROLLER OUTPUT

The Fuel Injector is an electric solenoid operated by the engine controller (Fig. 15).

14 - 24 FUEL SYSTEMS

Fig. 15 Fuel Injector

Based on sensor inputs, the engine controller determines when and how long the fuel injector should operate.

The amount of time the injector fires is referred to as injector pulse width. The auto shutdown (ASD) relay supplies battery voltage to the injector. The engine controller supplies the ground path. By switching the ground path on and off, the engine controller adjusts injector pulse width. When the controller supplies a ground path, a spring loaded needle or armature lifts from its seat. Fuel flows through the orifice and deflects off the sharp edge of the injector nozzle. The resulting fuel sprays forms a 45° cone shaped pattern before entering the air stream in the throttle body.

Fuel is supplied to the injector constantly at regulated 270 Kpa (39 psi). Unused fuel returns to the fuel tank.

IGNITION COILÐENGINE CONTROLLER OUTPUT

The engine controller provides a ground contact (circuit) for energizing the ignition coil. When the controller breaks the contact, the energy in the coil primary transfers to the secondary causing the spark. The engine controller will de-energize the ASD relay if it does not receive an input from the distributor pick-up. Refer to Auto Shutdown (ASD) Relay/Fuel Pump RelayÐEngine Controller Output in this section for relay operation.

The ignition coil is mounted on the hot box next to the thermostat housing (Fig. 16).

PART THROTTLE UNLOCK SOLENOIDÐENGINE CONTROLLER OUTPUT

Three-speed automatic transaxles use a part throttle unlock solenoid. The engine controller controls the lock-up of the torque convertor through the part throttle unlock solenoid. The transmission is locked up only in direct drive mode. Refer to Group 21 for transmission information.

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RADIATOR FAN RELAYÐENGINE CONTROLLER OUTPUT

The radiator fan is energized by the engine controller through the radiator fan relay. The engine controller grounds the radiator fan relay when engine coolant reaches a predetermined temperature. For more information, refer to Group 7, Cooling Systems.

On AC, AG and AJ models, the radiator fan relay is located in the power distribution center. Refer to the Wiring and Component Identification section of Group 8W.

On AA and AP models, the radiator fan relay is mounted on the drivers side fender well, next to the strut tower (Fig. 10).

SPEED CONTROL SOLENOIDSÐENGINE CONTROLLER OUTPUT

The speed control vacuum and vent solenoids are operated by the engine controller. When the engine controller supplies a ground to the vacuum solenoid, the speed control system opens the throttle plate. When the controller supplies a ground to the vent solenoid, throttle blade closes. The engine controller balances the two solenoids to maintain the set speed. Refer to Group 8H for speed control information.

TACHOMETERÐENGINE CONTROLLER OUTPUT

The engine controller supplies engine RPM to the instrument panel tachometer. Refer to Group 8 for tachometer information.

MODES OF OPERATION

As input signals to the engine controller change, the engine controller adjusts its response to the out-

Fig. 16 Ignition Coil

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put devices. For example, the engine controller must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). There are several different modes of operation that determine how the engine controller responds to the various input signals.

There are two different areas of operation, OPEN LOOP and CLOSED LOOP.

During OPEN LOOP modes, the engine controller receives input signals and responds according to preset engine controller programming. Input from the oxygen (O2) sensor is not monitored during OPEN LOOP modes.

During CLOSED LOOP modes, the engine controller does monitor the oxygen (O2) sensor input. This input tells the controller if the calculated injector pulse width results in an air-fuel ratio of 14.7 to 1. By monitoring the exhaust oxygen content, the can controller fine tune injector pulse width for optimum fuel economy and low emissions.

The single point fuel injection system has the following modes of operation:

²Ignition switch ON - Zero RPM

²Engine start-up

²Engine warm-up

²Cruise (Idle)

²Acceleration

²Deceleration

²Wide Open Throttle

²Ignition switch OFF

The engine start-up (cranking), engine warm-up, and wide open throttle modes are OPEN LOOP modes. The acceleration, deceleration, and cruise modes, with the engine at operating temperature are CLOSED LOOP modes (under most operating conditions).

IGNITION SWITCH ON (ZERO RPM) MODE

When the single point fuel injection system is activated by the ignition switch, the following actions occur:

²The engine controller determines atmospheric air pressure from the MAP sensor input to calculate basic fuel strategy.

²The engine controller monitors the coolant temperature sensor and throttle position sensor inputs. The engine controller modifies fuel strategy based on these inputs.

When the key is in the ON position and the engine is not running, the (ASD) and fuel pump relays are not energized. Therefore, battery voltage is not supplied to the fuel pump, ignition coil, fuel injector or oxygen sensor heating element.

ENGINE START-UP MODE

This is an OPEN LOOP mode. The following actions occur when the starter motor is engaged.

FUEL SYSTEMS 14 - 25

If the engine controller receives a distributor signal it energizes the auto shutdown (ASD) relay and fuel pump relay to supply battery voltage to the fuel injector, ignition coil and oxygen sensor heating element. If the engine controller does not receive a distributor input, it de-energizes the ASD and fuel pump relays after approximately one second.

When the engine idles within 664 RPM of the target RPM, the controller compares the current MAP value with the atmospheric pressure value it received during the Ignition Switch On (Zero RPM) Mode. If a minimum difference between the two is not detected, a MAP sensor fault is set into memory.

Once the ASD relay and fuel pump relay have energized, the engine controller:

²Supplies a ground path to the injector. The injector is pulsed four times per engine revolution instead of the normal two pulses per revolution.

²Determines injector pulse width based on coolant temperature, MAP sensor input, throttle position, and the number of engine revolutions since cranking was initiated.

²Monitors the coolant temperature sensor, distributor pick-up, MAP sensor, and throttle position sensor to determine correct ignition timing.

ENGINE WARM-UP MODE

This is a OPEN LOOP mode. The following inputs are received by the engine controller:

²coolant temperature

²manifold absolute pressure (MAP)

²engine speed (distributor pick-up)

²throttle position

²A/C switch

²battery voltage

The engine controller provides a ground path for the injector to precisely control injector pulse width (by switching the ground on and off) and fires the injector twice per engine revolution. The engine controller regulates ignition timing. It also adjusts engine idle speed through the automatic idle speed motor.

CRUISE OR IDLE MODE

When the engine is at operating temperature this is a CLOSED LOOP mode. During cruising speed and at idle the following inputs are received by the engine controller:

²coolant temperature

²manifold absolute pressure

²engine speed

²throttle position

²exhaust gas oxygen content

²A/C control positions

²battery voltage

The engine controller provides a ground path for the injector to precisely control injector pulse width