The powertrain control module is housed in the engine compartment next to the battery.
The PCM is a Visteon Electronic Management System 7.
It has two connections for the wiring harness.
A comprehensive diagnosis can be performed through the DLC using the WDS diagnostic equipment.
KS sensors
Two knock sensors are used. The knock sensors are located on the cylinder block between cylinders 1 and 2 and between cylinders 3 and 4.
As a result, it is possible to maximise the ignition timing advance, which in turn provides even more torque at lower engine speeds.
If the combustion noise exceeds the permissible limits, then the CKP sensor and the CMP sensor first determine which cylinder is affected.
Then the PCM calculates a new ignition angle and the ignition timing of the corresponding cylinder is retarded.
Electronic throttle flap
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Coolant connection, outlet
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Coolant connection, intake
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Electronic throttle flap electric motor
NOTE:The stop of the throttle flap must never be adjusted.
The APP sensor sends the data containing the driver's acceleration request to the PCM. This information depends directly on the movement of the accelerator pedal.
The PCM processes this information and sends output signals for the electronic throttle valve, the ignition system and the injected fuel quantity.
The electric motor moves the throttle flap shaft using a set of gears.
The position of the throttle flap is set and monitored in a closed loop control circuit. The TP sensor supplies the PCM with the current throttle flap position information.
Should a fault appear at the electronic throttle flap, a substitute function is performed. This substitute function allows the throttle flap to be opened by a defined amount.
For this purpose, there is an throttle flap adjustment screw on the throttle housing. The return spring closes the throttle flap until the stop of the toothed wheel touches the stop screw. In this way a defined throttle flap gap is formed for limp home mode.
With the throttle flap kept in a constant position, the ignition angle and the injected fuel quantity are varied according to the position of the APP sensor in order to enable restricted operation of the engine.
The vehicle then drives with a limited top speed.
The stop screw of the throttle flap has a spring-loaded pin which permits the throttle flap to be closed beyond the emergency running position (e.g. idle speed control or engine overrun shutoff).
Intake manifold switchover solenoid and swirl valve solenoid
NOTE:The vacuum line leading to the vacuum motor of the intake manifold switchover system must not be swapped with the vacuum line leading to the vacuum motor of the swirl valves.
The solenoid for the intake manifold switching system is located together with the swirl valve solenoid on the transmission side of the cylinder head.
Vacuum is supplied by a central vacuum connection from the intake manifold.
The solenoid for the intake manifold switching system is supplied with either the maximum voltage or zero voltage, i.e. the valves are either fully open or fully closed.
Actuation depends on the engine speed and the engine load.
Direct ignition coils
The direct ignition coils are pushed onto the relevant spark plug and are bolted onto the valve cover.
The PCM actuates each direct ignition coil directly.
Each direct ignition coil is actuated individually by the PCM.
Because of the direct ignition coils the specification of the spark plugs has been changed. Irridium coated spark plugs are now used.
BPP switch and brake light switch
NOTE:Please refer to the current service literature for the exact procedures for servicing the stop lamp switch and the BPP switch.
The BPP switch and the stop lamp switch are located on the pedal box and provide the PCM with the information that the vehicle is being decelerated.
The BPP switch is connected to the instrument cluster via a CAN bus. In its rest state the switch is closed and sends a ground signal to the PCM .
The stop lamp switch is connected to the PCM and is open in its rest state. When the switch is closed it connects 12V to the PCM .
The signals from the BPP switch and the stop lamp switch are used in the event of failure of the APP sensor for the emergency operating mode.
In this instance, the PCM compares the signals of the BPP switch and brake light switch.
APP sensor
The PCM requires the pedal position from the APP sensor in order to regulate the power output of the engine according to the driver's request for power.
The APP sensor is a double contactless inductive sensor.
If a fault of the APP sensor occurs while driving then a trouble code is stored in the PCM.
If both sensors of the APP sensor fail then, after a single operation of the BPP switch and the stop lamp switch and a subsequent comparative plausibility test, the engine is regulated to a maximum engine speed of up to 4000 rev/min. The vehicle can be accelerated to a maximum speed of 56 km/h.
When the brake pedal is pressed again the engine speed drops to idle speed. When the brake pedal returns to its rest position the engine speed is increased again.
Error messages from the APP sensor
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Driver information system
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Malfunction Indicator Lamp (MIL)
If one of the sensors of the APP sensor fails then the engine runs with reduced power. However, it is still possible to reach top speed.
If the vehicle is equipped with a driver information system, the fault message: "REDUCED ACCELERATION" will be displayed.
If both sensors of the APP sensor fail, the driver information system displays the fault message: "LIMITED MAXIMUM SPEED".
In the event of failure of the electronic throttle flap the error message "LIMITED MAXIMUM SPEED" is also displayed.
