How do we carry out repairs?

Every ECU that arrives at our office for repair is first inspected for damage and then tested to confirm that the fault the customer is reporting is present and would cause the symptoms being mentioned.Once the fault has been established we use our Test Systems and our in house developed methods of diagnosis to determine which components have failed and whether is possible to carry out a reliable repair. The faulty components are then replaced using Surface Mount rework facilities that we have on site. The ECU is then tested again to determine that the fault has been rectified and to print out a diagnostic report showing correct operation of the ECU which is returned to the customer with the repaired ECU.

How do we test ECU?

ECU’s are tested on custom built Test Systems, this allows us to modify the test methods when new types of ECU’ or faults are seen so the process is an ongoing development. One of the problems of working in this industry is the huge variety of ECU’s that we may see for repair, this is handled by breaking the ECU’s down into family groups so for instance if we are looking at a Bosch ECU the type of ECU can be determined by entering the part number into the Bosch ESI software which might show that the ECU is an EDC16CP31 or an MEV9.2 etc. We have over a hundred configuration modules which are then used to configure the Test System to suit the ECU type, there could be a very large number of part numbers used in different vehicles all of which come from the same ECU family type. The Test System simulates the Crank and Cam Angle sensors in order to get the ECU to operate as it would on the vehicle, the other Sensors are also simulated and Diagnostic connections are established via CAN and K-Line to see the Live Data that the ECU is reading and the fault codes being reported by the ECU. In this way we can establish if there is a fault with a Sensor Reading or if an output Solenoid being driven by the ECU is incorrect in some way. Fly by wire Throttle Control can be tested dynamically on an emulator which is also part of the Test System. Test results are compared with the reported faults to determine if the ECU is the cause of the problem.