Saip

ipaa X1
X100 wo
works
rksho
hopp traini
t raining
ng
X100RM2C/4/1

Sai p a X100

Bosch

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M7.9.7 ECU

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Gasoline Systems
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1 DGS-EC/EAA1 | 13/12/2010 | © Robert Bosch GmbH reserves all rights even in the event of industria
DGS-EC/EAA1
disposal such as copying and passing on to third parties.
industriall property rights. We reserve all rights of
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 Saip
ipaa X1
X100 wo
works
rksho
hopp traini
t raining
ng

Bosch components:
components:
• M7.9.7 Engine
ngi ne Cont
Control
rol Unit

• EV6 Gasoline
sol ine inj ector 
cto r 

• ZS-K-2x2V Igniti on coil

• DS-S3-TF Intake manifol
manif oldd pre
pr essure
ssu re and temperatu
temperature
re senso
sensor 
r 

• DG-6-K Engine
Engin e speed
speed sensor
senso r (Cranksh
(Crankshaft)
aft)

• PG-3-8 Phase
Phase detect
detectio
ionn sensor
senso r (Ca
(Camsha
msh aft)
ft )

• TEV 5 Canist
ni ster
er purge valv
valve
e

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• LSF 4.21 Oxygen sensor 

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• KS-4-S knock sensor 
sensor 

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• TF-W Engine
ngi ne cool ant temperature
temperature sensor 
sensor 

• SMA
SMA RTRA
RTRA 5 Immobiliser  N
Gasoline Systems
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2 DGS-EC/EAA1 | 13/12/2010 | © Robert Bosch GmbH reserves all rights even in the event of industria
DGS-EC/EAA1
disposal such as copying and passing on to third parties.
industriall property rights. We reserve all rights of
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 Saipa X100 workshop training

MegaMotor components (monitored by M797 ECU):

• Throttle position sensor
• Idle speed actuator (Steppermotor)
• Dashboard lamps (Hotlamp and MIL-Lamp)
• Engine Fan (relays)
• AC compressor (relay)
• Clutch switch
• Vehicle speed sensor 
• Battery (for ECU power supply)
• Fuel pump (relay)

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 Additional inputs (not monitored by M797 ECU):

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• Power steering pressure switch

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• Crash switch
• AC switch
• AC compressor switch
N
Gasoline Systems
FO
3 DGS-EC/EAA1 | 13/12/2010 | © 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.
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 Saipa X100 workshop training

Carbon canister 

Ignition coil/
Spark plug
Canister purge Fuel rail/
valve Injector  Phase
sensor 
Intake manifold
sensor 
Oxygen sensor 

Knock Temp.
Idle speed actuator  sensor  sensor  Catalyst

Electronic
control unit Throttle position sensor 
Speed
sensor 
M7.9.7

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Immobiliser 
Diagnosis
Interface

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Hotlamp
Engine Fan
 AC

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Diagnosis
Power steering
lamp
pressure switch
Clutch switch Delivery module with
low pressure pump
Vehicle speed Crash switch N
sensor 

Gasoline Systems
FO
4 DGS-EC/EAA1 | 13/12/2010 | © 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.
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 Saipa X100 workshop training

System principle M7 Oxygen sensor  Canister pur ge valve

uusvk_w LSF 4.21 TEV 5 tateout

Coolant temperature sensor 
fr_w mste
tmot
TF-W Fuel path

Intake manifold Intake manifold Relative Relative Injection Gasoline

pressure sensor  pressure air charge fuel mass time Injector 
Correction
udss_w Correction psdss_w rl_w rk_w ti_w
DS-S3-TF Conversion Conversion Correction EV 6
wtfa1_w Conversion tans ti_ev0-3
 Ad aptation
Intake
temperature

Correction
Throttle position Knock detection sensor 
Conversion
sensor 
wdkba
Driver 
KS-4-S
TPS
torque demand wkr 

Coordination

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Engine speed Torque demand
Ignition timing Ignition coil
sensor  Spark path
nmot_w Correction zwout

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DG-6-K Conversion ZSK
 Ad aptati on

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 Ai r d eman d Idle speed
Torque demand actuator 
 Ai r p ath
Correction msnllss_w
Conversion ISA
 Adaptation mompos
N
Gasoline Systems
FO
5 DGS-EC/EAA1 | 13/12/2010 | © 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.
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 M7.9.7 Block Diagram Order No. 0261B13919 / 0261S06634

INPUTS OUTPUTS Release date: November 29, 2010

Polarization input resistances:
Pullup Pulldown Pin CJ910 CJ910 Pin
(Inp.) MICRO- (Outp.)
CONTROLLER
U_U_UBD Battery Permanent Supply 12 32 5V Supply (MAP Sensor)  A_U_5V2
+ 33 5V Supply (T.P.S.)  A_U_5V1
U_U_UBR1 Battery Switched Supply 63
U_U_UBR2 Battery Switched Supply 44   FLASH 14 Main Relay A_S_HR
U_U_UBR3 Battery Switched Supply 45
EEPROM * 8 Engine Speed Signal (10mA)  A_T_TN
2.9k E_S_KL15 Ignition Switch KL15 13 * 9 Reserve (PWM-Fuel level) A_T_FSTG
* 10 Reserve (Fuel consumption) A_T_FCI
E_T_KWDGA Engine Speed 15
E_T_KWDGB Engine Speed 34

MUX CJ920
100k B_D_DIAK K-Line (Tester) 71   Engine
2.9k B_D_IMMO K-Line (Immobiliser) 52 2,2A/70V * 27 Injector Valve 1  A_T_EV1 Cyl. 1
2,2A/70V * 7 Injector Valve 2  A_T_EV2 Cyl. 3
2,2A/70V * 47 Injector Valve 3  A_T_EV3 Cyl. 4
2,2A/70V * 6 Injector Valve 4  A_T_EV4 Cyl. 2
Digital IN 2,2A/70V * 29 Cooling Fan Relay (High Speed)  A_S_FAN2
2,2A/70V * 26 Reserve
10k E_T_NWDG Phase Sensor 79 * 2,2A/45V 25 MIL Lamp A_S_MIL
10k E_T_VFZ Vehicle speed 59 * 2,7A/45V * 28 Reserve (LSF Heating Downstream)  A_T_LSHK
2,2A/45V * 46 Canister Purge Valve  A_T_TEV f/w diode
10k E_S_KO A/C Kompressor Switch 58 * 2,7A/45V * 48 LSF Heating Upstream  A_T_LSVK
10k E_S_CRA Inertia switch (crash detection) 74 * 0,6A/40V 68 Cooling Fan Relay (Low Speed)  A_S_FAN1
10k E_S_LHI Power Steering 76 * 0,6A/40V 50 HOT Lamp  A_S_L8
10k E_S_AC A/C Switch 75 0,6A/40V * 69 AC Relay  A_S_AC
10k E_S_KUP Clutch switch 77 * 0,6A/40V 70 Fuel Pump Relay A_S_EKP

10k E_T_ALT Reserve (PWM-alternator) 72 *

L9935
64 Stepper A A_T_SMA
 Anal og IN 65 Stepper D A_T_SMD
66 Stepper C A_T_SMC
2.49k 24.9k E_A_TMOT Engine Coolant Temperature 39 67 Stepper B A_T_SMB
3.48k E_A_TANS Intake Air Temperature 40
1M E_A_TPS Throttle Position Sensor 16
Voltage Divider ( x 0.178 ) E_A_FAN Fan Diagnostic 24
1M E_A_DS Manifold pressure 37
E_A_LSVK Lambda Sensor Upstream 18

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E_A_LSHK Lambda Sensor Downstream 55
E_A_KSB Knock Sensor (-) 20   IGN.
E_A_KSA Knock Sensor (+) 19
 IGBT
Batt. Voltage - * 5 Ignition 1 A_T_ZDG1 Cyl. 1 & 4
* 2 Ignition 2 A_T_ZDG2 Cyl. 2 & 3

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147 Ohm E_A_FSTG Reserve (fuel level) 42

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Ground

M_R_TMOT, _TPS TMOT, TPS sensor  17

M_R_LSVK O2-sensor   36
M_R_DS MAP sensor   35
M_R_FST R eserve (fuel level ground) 53

M_M_GND2 power ground 51

M_M_GND1 power ground 3

M_M_GND4 power ground 61
M_M_GND5 power ground 80
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* CAPCOM
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Changed
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 Saipa X100 workshop training

Restrictions for testing ECU Inputs and Outputs:

• Battery Pin’s 12, 13, 44, 45, 63 shortcut to ground not allowed
• Ground Pin’s 3,17,35,36,51,53,61,80 shortcut to Battery not allowed
• Ignition Pin’s 2 ,5 shortcut generally not allowed

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Ignoring these limitations will damage the ECU!

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Gasoline Systems
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6 DGS-EC/EAA1 | 13/12/2010 | © 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.
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Detailed description o f Immobiliser fault cod es
P1621 Immobiliser: unknown Key
P1622 Immobiliser: Auth. NOK, Key Learning process NOK
P1623 Immobiliser: EMS virgin/Neutral
P1624 Immobiliser
P1625 EEP: inconsistent immobiliser data
P1626 EEP: invalid write operation immobiliser data
P1627 Immobiliser communication: antenna error 
P1628 Immobiliser communication: wrong CS, invalid request/response
P1629 Immobiliser communication: timeout
P1630 Key communication: wrong TP mode/programming
P1631 Key communication: No TP
P1632 Key communication: ELP not OK
P1633 Immo tester diagnosis: Wrong CS, Invalid tester command
P1634 Immo tester diagnosis: Tester wrong access code
P1635 Immo tester diagnosis: Tester authentication failed
P1636 Other Smartra5 errors (A. LED Control Command Fail)
P1637 Smartra5 Teach/Neutralize command fail and smartra is locked
P1638 Virgin/neutral Smartra5 at learnt EMS
P1639  Authentication fail - ICU learnt different VSD (vehicle specific data / access code)

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 Component/ Time of MIL
Function Fault code Monitor strategy describtion Condition for error detection and threshold value(s) Enable conditions detection TYPE

Misfire P0300 Signal. Cumulative fault. Engine is running. MiL ON

detection Plausible Error. It depents on engine speed, load, error heaviness and adaption status: aft er  Time for detection > 180 s at signal error.
detection of misfire the MIL is blinking, 30 seconds later the Plausible error is checked during calibration.
% DMDFOF injection is cutted OFF and the MI L illuminated continiously.
This valid for all cylinders.

P0301 Signal and Plausible-Error ignition 1, cyl.1 ( PIN 5)

P0302 Signal and Plausible-Error ignition 2, cyl.2 ( PIN 2)

P0303 Signal and Plausible-Error ignition 3, cyl.3 ( PIN 2)

P0304 Signal and Plausible-Error ignition 4, cyl.4 ( PIN 5)

Mil lamp detection P0650 Signal-, Minimum and ECU memory shows "Mil ON" in case of MIL control line is faulty ignition ON Mil ON
%DMILE Maximum Error .
Engine hotlamp P0655 Signal-, Minimum and Engine hotlamp control line is faulty Engine running Mil ON
%DEKON Maximum Error.

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Relation of components to signals in M7.9.7 ECU on tester output (T2LID)

Component Monitoring method related signal name(s) in tester  to add to T2LID

short name long name
RB
EV6 Gasoline injector  electrical ti_ev0-3
ZS-K-2x2V Ignition coil plaus zwout
DS-S3-TF Intake manifold pressure
and temperature sensor  electrical and plaus psdss_w, tans
DG-6-K Engine speed sensor  plaus nmot_w
PG-3-8 Phase detection sensor  plaus B_phad
TEV 5 Canister purge valve electrical tateout_w, B_te
LSF 4.21 Oxygen sensor  electrical and plaus uusvk_w, fr_w, fra_w, rka_w
KS-4-S Knock sensor  plaus wkr, uadki_w B_kr  
TF-W engine coolant
temperature sensor  electrical and plaus tmot
SMARTRA 5 Immobiliser  electrical -- B_eculock

MM
TPS Throttle position sensor  electrical wdkba
ISA Idle speed actuator  electrical B_ll, mompos, solpos
Hotlamp electrical -- B_kshtlpe
MIL electrical B_mil
Fan1 engine Fan relay1 electrical B_lf1s

A
Fan2 engine Fan relay2 electrical B_lf2s
 AC compressor   AC relay electrical B_koe
Clutch switch plaus -- B_kuppl

C
VSS vehicle speed sensor  plaus vfzg_w
ECU power supply electrical and plaus ub
EKP Fuelpump electrical B_ekp

SE
additional
Power steering pressure
switch not monitored B_sl
crash switch not monitored B_airbag
 AC switch not monitored S_ac
 AC compressor switch not monitored b_ko
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 Function

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Extent shown: T2LID 50.50.2
Blocks chosen: ABK, APP, FB, FDEF, FW

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System:
Project:
Project code:

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Responsible: Rohit Nayak
Department: C/PJ-GC(RBEI)
Phone: +49(711)811-0
Date of issue: 22.NOV.2010

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    

Vivace (version fdr3-26i of Sep 30 2009 10:20:11), processed at Mon Nov 22 09:49:48 2010
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 Function T2LID 50.50.2 Page 9 of 10
22.NOV.2010
Rohit Nayak

Variable   Source Used by Type   Description

B_ngvdrm EIN CNG stop valve at pressure regulator turned on

B_ngvtank1 EIN Condition CNG stop valve of tank1(High pressure) turned on
B_ngvtank2 EIN Condition CNG stop valve of tank2(High pressure) turned on
B_nmot EIN condition engine speed: n > NMIN
B_phad EIN adaptation crankshaft/camshaft performed
B_phade EIN adaptation of camshaft(inlet) performed.
B_sa EIN Fuel cut-off
B_sl EIN Condition power steering
B_st EIN condition for start
B_te EIN Condition canister purge active
B_vl EIN Condition for wide open throttle
dmllr_w EIN desired torque change from the idle speed control (PD-part)
dmllri_w EIN desired torque change from the idle speed control (I-)
dmvad_w EIN Delta resistant torque from resistant torque adaptation
E_bm EIN error flag: reference mark sensor
E_n EIN error flag: engine speed sensor
evz_austot EIN injection cut off pattern total 8 bit only used if (SY_ZYLZA <= 8)
fcmActvNbr EIN Number of active entries inside fault code memory
fcmend EIN Number of entries inside fault code memory

A
fho_w EIN correction factor: altitude
fr_w EIN Lambda controller output (word)
fra_w EIN multiplicative correction of the mixture adaptation (word)

C
fstt_w EIN fuel level
gangi EIN Engaged gear
kldfpwmf EIN generator signal as PWM-signale filtrated by low-pass filter
kmp6km_w EIN Driving distance since powerfail (6km/inc.)

SE
kmst_l EIN Kilometers covered by vehicle (Odometer) 100m/Inc as 32bit-longword
kmstf_l EIN
kmstfng_l EIN
kmstmil_w EIN Drive distance with MIL on
kmstnf_l EIN
kmstnfg_l EIN

 .
kmstt_l
kmsttng_l
kvng_w
EIN
EIN
EIN
N
total mileage of vehicle

Consumed fuel, only CNG or sum of all fuels (calibration)

    s
    u
    o
     t
miist_w EIN indicated real engine torque
FO
    g ml_w EIN air mass flow filtered (Word)
    n
    o
     l
    e mompos EIN Actual position of stepper motor
     b
 , msnllss_w EIN desired standardised air mass flow through ISA (word)
    s
     t
     h
    g
     i
mtng_w EIN CNG mass in the tank
    r
    n mtngnpwm EIN Actual PWM value used to drive the CNG level indicator signal in Combi
    o
     i
    s nmot_w EIN Engine speed
    s
     i
    m
    s
nsol EIN idle reference speed
    n
    a
    r
png_w EIN Natural gas rail pressure
     t
R

     d psdss_w EIN Intake manifold pressure measured with pressure sensor at manifold (DS-S)
    n
    a ptng_w EIN Natural gas tank pressure, word
   -
    y
    p pu_w EIN Ambient pressure
    o
    c
    e pwmfst EIN Actual PWM value used to drive the Gasoline level indicator signal in Combi
TE

     k
     i
     l rk_w EIN Relative fuel mass
    y
     t
     i
    r
    o
rka_w EIN additive adaptive correction of the relative fuel amount
     h
     t
    u rkng_w EIN relative fuel mass, CNG
    a
    g rl_w EIN Relative air charge (Word)
    n
     i
     h
    s
rlp_w EIN rel. air charge predicted for injection calculation (Word)
     i
     l
     b
    u
S_ac EIN A/C stand-by position
AS

    p S_ko EIN A/C compressor active

     l
     l
     A
 . solpos EIN Desired position of stepper motor
    s
    n sztcalc_w EIN Dwell period in timer 1 increments
    o
     i
     t
    a tallss_w EIN desired duty cycle for idle speed actuator (word)
    c
     i
     l
    p tallsse_w EIN desired duty cycle for idle speed actuator (word) for limphome
    p
    a
    s
     t
tans EIN intake air temperature
     h tateout_w EIN
    g
     i
output duty cycle for canister purge valve (16 bit)
M

    r
    y
     t ti_ev0 EIN injection time 1. cylinder in firing sequence
    r
    e ti_ev1 EIN injection time 2. cylinder in firing sequence
    p
    o
    r
    p ti_ev2 EIN injection time 3rd cylinder in firing sequence
    g ti_ev3 EIN injection time 4th cylinder in firing sequence
    n
     i
    n
    r
    e
ti_ev4 EIN injection time 5th cylinder in firing sequence
    c
    n
    o
ti_ev5 EIN injection time 6th cylinder in firing sequence
    c
    e ti_ev6 EIN injection time 7th cylinder in firing sequence
    s
    o
     h
ti_ev7 EIN injection time 8th cylinder in firing sequence
     t
    o
    s
tmot EIN engine temperature
     l
    a
 ,
tmst EIN engine temperature at start
    s
     t
     h tngf EIN Natural gas temperature - sensor value
    g
     i
    r
     l
ttngaus EIN Final tank temperature value used for mass calculation
     l
    a tumgk_w EIN Ambient air temperature, output in Grad C, calc. in Kelvin
    s
    e
    v
    r tyreType EIN Tyre Type
    e
    s
    e
uadki_w EIN current integrator value
    r
     H
ub EIN Battery voltage
     b
    m uushk_w EIN ADC-voltage lambda sensor downstream catalyst (word)
     G
     h
uusvk_w EIN ADC voltage for lambda sensor upstream of catalyzer (Word)
    c
    s
    o
vfzerrctr EIN Vehicle Speed Sensor Error Counter
     B vfzg_w EIN vehicle speed
     t
    r
    e vsks_w EIN Volumetric flow of fuel in L/s
     b
    o
     R
    c
    

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 Function T2LID 50.50.2 Page 10 of 10
22.NOV.2010
Rohit Nayak

Variable   Source Used by Type   Description

wdk_w EIN Throttle position angle signal 16 bits

wdkba EIN throttle angle referred to lower limit
weer EIN resulting crankshaft angle for end of injection
weerng EIN resulting crankshaft angle for end of injection in CNG mode
wkr EIN cylinderindividual ignition retarding value knock control
wped_w EIN normalized angle acceleration pedal
zwout EIN Ignition angle output value
zwoutar EIN Ignition angle output array

FB T2LID 50.50.2 Function description

APP T2LID 50.50.2 Application hints

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    s
    e
    v
    r
    e
    s
    e
    r
     H
     b
    m
     G
     h
    c
    s
    o
     B
     t
    r
    e
     b
    o
     R
    c
    

Vivace (version fdr3-26i of Sep 30 2009 10:20:11), processed at Mon Nov 22 09:49:48 2010