Sensor

2011 Automobile Maintenance Advanced Course for the Industrial Technical Instructors

Class No. :

Instructor:

Hsiao, Sun-ching

Inspection of Sensors

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201109

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Syllabus • Practice of sensor inspection (trouble shooting) • How to guide students in a simple way

201109

1

Engine is not running?

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Why isn-' t it running? \

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Case 1 : Engine is not running ?

Three answers :

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The common signals for sensors • Analog signal- DCV / ACV • Digital signal- Square wave 1.0 2 v 137Hz

4 6.0 lS4

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-GENERAL SEliSORs "'lIP 0H!I~1~

SotYoIV

Throttle position 2~~~sor

Magnetic pickup wheel speed sensor 4

Hall effect type senso~_

How to measure the three signals below? • Analogy Signal - DCV / ACV • Digital Signal - Square wave

What kind of meters or simple ways can be used for measurement?

201109

Hall Effect Type sensor

4

voltage

To which sensors are applied to?

t

J\iO

1----1f---4----+-----l

Eg. :

Crankshaft position sensor (CKP) Camshaft position sensor (CMP ) Vehicle speed sensor (VSS)

t.. time _ _ t.

Wheel speed sensor Hall element and the waveform

Steering angle sensor

201109

5 ----- - - -

Hall Effect Type Sensor open '---.,.----l

5V

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6

(NTC)

4

2

•'::2

ECU

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THW " Signal voltage Signal wire

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0.8 0.6 0.4

0.2

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+5V I

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40 ' 60 80 100 120

Water temperature Sensor

Inspection of water temperature sensor Easy way for inspection: -Use lKO to replace the temperature meter -Check the temperature if it is at 40°C -Distinguish the problems from sensor, circuit and meter (Bfiu::mni: -The indicators of problems are i = i difficult t~ start th~ engine when ,:arming the car, high fuel con sump. no power m speedmg and generatIon of smoke ( " ", EngineECM

2011(

ECT

ECT circuit

22

;\11:£"i l ~.

How to check ECT Measure the resistance. Measure the resistance between each terminal with an ohmmeter.

about 2.32~2.59 k,Q at 20°C about O.31~O.326 kf! at 80°C

Resistance:

rill

L_· _. •.

Note: when inspecting the water temp. sensor in the water, do not get the terminals wet, and wipe the sensor clean afterwards. voltage: ,--

water tern. °CCF)

Voltage V

2CX68}

-

0.5"'3.·1 0.2"'1.0

6((140} EngineEGU

Water Temp. Sensor R

2

1 SR

E1

Junction Connector

TFT transmission fluid temperature sensor PCM

peM harness side connector

201109

23

Inspection of transmission fluid temperature (TFT) sensor ATF temperature Resistance(k [2 ) Measure the resistance between The terminal E and H

0C {OF})

- -{-_4-}----+--2-3-6-3-24----l 2O

1---_

TRANSAXLE CONNECTOR ~

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B3E0517W064

o {32}

84.3-110

20 {68}

33.5 -42.0

40 {104}

14.7-17.9

60 {140}

7.08-8.17

80 {176}

3.61-4.15

100 {212}

1.96-2.24

120 {248}

1.13-1.28

130 {266}

0.87 -0.98 r::.-' r

201109

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.:::..~~~ ECT sensor will affect the following control system

1. Idle speed air control (lAC) 2. Fuel injection control 3. Advanced electronic ignition control 4. EEC scavenging control (the carbon can magnetic valve control for the air evaporation from fuel tank) 5. EGR control (gas recycle) 6. AlC off control 7. Coolant electronic fan control 8. Alternator control 9 . AT gear shift and TCC control ~ ., ~

201109 24

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Throttle position sensor TPS

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Crankshaft: Position Sensor

Junction , Connector

SR

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Timing Rotor

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Magnetic induction coil type

CA)- --l

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Camshaft Position Sensor

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Magnetic induction type sensor

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Two-track waveform of magnetic induction type CMPS and CKPS

201109

Hall effect type sensor P CM CKP / CMP Sensor

+5V +5V

MRE Type is

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the same

201109

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Optical type sensor lvLAX= 4.94 V

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201109

Fig. normal waveform of photoelectric type CKPS

The difference between two-wire type and three-wire type • How to measure # two-wire type - measure resistance ... etc. # three-wire type - measure voltage ... etc. • What will happen if CKP/CMP get problems?

201109 33

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201109

Types of vehicle speed sensor VSS •

Magnetic Type

•

Hall Effect Type

What kinds of signals are generated?

•

Optical Type

How to check?

•

MRE Type No.1 Vehicle Speed sensor

~ulse

4-Pulse

Jlf1IlJL Combination Meter

Engine ECU

201109 34

VEHICLE SPEED SENSOR 2 ELECTROMAGNETIC PICKUP TYPE (Magnetic Type) OPERATION Magnet Core \ Magnet

ELECTRICAL CIRCUITRY

Generated

Engine ECU

SP2

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Speed sensor

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SP2E1

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VEHICLE SPEED SENSOR 3 MRE TYPE

(Magnetic Resistance Element)

OPERATION Transmission

output shaft

20-POlE TYPE SPEED SENSOR

Driven gear Speed sensor

Magnetic ring (rotating) MRE

Comparator Speed

sensor

12 V,

oV

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Mass Air Flow sensor MAF

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201109

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The type of fuel injection system corresponding to air inspection • D type- intake manifold absolute pressure sensor (MAP) • L type- air flow sensor .a. Vane type b. Karman vortex type - Ultrasonic /optical / pressure c. Hot wire type, hot membrane type

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201109

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BASIC CONSTRUCTION OF EFI O-TYPE EFI Pressure regulator Fuel filt er

l!::===:=!l

Fuel tank (with built-in fuel p ump )

L-TYPE EFI

Air flow meter

2011 09

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High speed

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Air flow meter (Vane type)

SI ider - ..------;c----~II)

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Return spri ng

Intake air temp. sensor

Form air c leaner

To air intake chamber

via throttle valve

How to check?

*

Idl e mix ture adjusting screw

Fuel pump switch

Potentiometer

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To air intake chamber via

Fe

/throttle valve

VB

Ve Vs THA

AIR FLOWMETER OPTICAL KARMAN VORTEX TYPE Mirror

LED

OPERATION AND FUNCTION

Leaf spring

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From air • creaner

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Pillar (vortex generator) KARMAN VORTEX

Vortex generator

LED

Phototransistor

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ELECTRICAL CIRCUITRY

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Engine EeU Air flow meter

sv

vc

Phototransistor

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Mirtor Pressure directing aperture

~enerator

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Phototransistor

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-----------High Intake air volume

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Hot wire air flow meter B++12V Power Transistor

__~... Output

Voltage Signal voltage

Platinum Het Wire N

+12V

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Air mass meter (hot wire) 1/2

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Hot-wire

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Thermistor Intake Air ./ Temp. / ' , .• Sensor

Thermistor

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L ,l IL;;..-Platinum electrode ____ Solid electrode (Zr02 element) Pl at inum electrode

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Air-fuel ratio

Coat ing (ceramic)

Exhaust gas

Leaner

OHP 66

-The inside and outsitle of ZrOi (lipe hascoate,d~ thin layer of platinum, to maktdhe electricalpole and Electronic Motive Force to produce the amplification. The outside of Zr02 pipe 'explores in the em,i ssionof low,oxygtm andth~ inside is with atmosphere. The thickness difference of oxygen will produce Electronic Motive Force.

201109

02 Sensor circuit Eell

5V

O2 sensor

What methods can be used for testing? 201109

48

02 Sensor (includes heater) PCM

+12V

201109

02 Sensor connector • • • •

One wire type Two wires type Three wires type Four wires type

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201109 49

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Idle speed, first acceleration, then

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Keep low voltage :~:::;::d (decrease injection or off-injection, lean mixture)

2 slOiv

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·2.00.

In 1200rpm

mV

In idle speed

o· .400!!J ' . ". 56 $

Air-fuel ratio sensor • The advantage of air-fuel ratio sensor is that the voltage is variable according to the different mixture ratio, so we can get airfuel ratio more accurately_

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Air fuel ratio (AIF)

201109

Voltage and AIF

Current and AIF

50

Air-fuel ratio sensor and 02 sensor •

The output of Air-fue) ratio sensor and 02 sensor

1.2

1.0

0 2 sensor

0.8

: 0

Air-fuel ratio sensor

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The basic concept of testing for 02 sensor • The test for O2 sensor: 1. The engine must reach normal working temperature and computer must be close wiring circuit control system. 2. The temperature of O2 sensor must reach 600°F(300°C) 3. The heater of heat type O2 sensor must be operated normally. 4. If the over-rich signal of O2 sensor last over 5 seconds, then the wave will be unstable and not easy to be analyzed. So must take care of the wave difference. 5. If the over-lean signal of O2 sensor last over 10 seconds, then the wave will be unstable and not easy to be analyzed. So must take care of the wave difference. 6. If the catalyst converter is overheat of malfunction, then stop testing. 0

0

201109

51

Basic measurement Concept of 02 Sensor :MAX= +O.87V

MDT = +O.09V VPP =+O.78V

tiThe crossing variables of 02 sensor should be more than 5 times in normal idle speed within 10 minutes. More variables means 02 sensor 201%Ylore active. Less variables means 02 sensor is not active.

02 Sensor Test Simulation method: • Disconnect the 02 sensor. Use a wire to connect to the ground and make the signal to be 0, PCM will judge 02 quantity is high, then the mixture ratio will correct from lean to rich (wave correction). • Acceleration up completely and the voltage will be OV. If the voltage is not OV, that means one cylinder might not be ignited. • Acceleration up to 2500rpm. Loose the acceleration pedal suddenly to cut off the fuel. The voltage should be OV. • Make the spark plug short circuit or injectors not inject, the 02 voltage will react slowly. It means O2 sensor is under malfunction. • Add the fuel. In normal situation, the output voltage of 02 sensor . will be up (become rich). • Connect 02 sensor, measure the 02 voltage. If the number varied rapidly between O.1r--JO.9V, means the 02 sensor has no problems. 201109 52

- - ------------------------------------------------~

02 Sensor Test • Test 02 sensor by sudden acceleration. • Warm the engine in 2500rpm and 02 sensor for 2-6 minutes, allow the engine in idle speed for 20 seconds ; a. Accelerate suddenly several times to produce a rich mixture ratio, the 02 signal should be bigger than 0.8V. If it is smaller than O. 7V, that means 02 sensor is under malfunction. b. Accelerate to 3500rpm and loose suddenly to cut off the fuel. If 02 voltage is smaller than 0.2, it means the 02 sensor has no problems. 201109

How to find out the problems by using LONGFT/SHORTFT fuel trim ~

l-+--~~--~~~:~~~--;­

g , 02 sensor signal

Computer judge signal

*t Feedback correction signal

SHORTFT ~Mi?&nB~lE L£~MFT ~Mi?&nB{~lE

Mixture ratio feedback control 53

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Test two 02 sensor

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Knock Sensor KS

201109

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To Engine ECU

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Low -

Frequency

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ELECTRICAL CIRCUITRY Engine ECU

Knock sensor K "-' H-_ _ _ _..:..c N:.:... K'-¢----11---j I--

Piezoelectric element .

Knock Sensor

.

Resistance

EeM Voltage alternator

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Knock sensor

201109

Knock sensor circuit (from ASE) 55

Voltage meter

Knock sensor test

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REPEAT TEST 201109

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K nock sensor test

How to test if knock sensor is good ? I What methods can be used?

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201109

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possible malfunction for sensor and circuit

• Sensor has no power, broken circuit, short circuit or poor ground conditions. • ECU ground is not connected, for example, water temperature sensor ground • Main relay within ECU power has malfunction -ECU has no power and can't read trouble code? • Sensor connector is poorly connected, power or oxidized ground is poorly connected - intermittent malfunction, e.g. MAP ... • Sensor interior is aging, causing intermittent Inalfunction, e.g. crankshaft/ camshaft sensor. • Dirty sensor will bring intermittent malfunction, e.g. Hot wire air sensor, ABS wheel speed sensor • Two neighboring wires of one sensor are connected to each other. 2CJ11109fhe wiring circuit of engine warning light has malfunction r .~ and the bulb burned-out. ~ '===="'-:~-...,~::,===="9I

BAiTERY

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IGNITION COIL

PRIMA!W IGNITION WINDINGS MODULE CONOENSOR (CAPACITOR)

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Water temperature

output duty

Coolant water temperature control

Low (Duty 10%)

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< 98°C

EEC/ EGR Solenoid

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Exhaust Gas Recirculation (EGR) @Two EGR system : • EGR-Vacuum type ECM control vacuum ' switch EGR solenoid valve to ON or OFF. • EGR- Step motor type The step motor installed in EGR quantity control valve will change the steps of step motor according to ECM signal wave. 201109

98 - --

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ON/OFF Control type EEC/EGR Solenoid ~ Air dea nef

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Purge control solenoid

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EGRcontrol solenoid ...a!....e

201109

Solenoid Control Duty Ratio control type +12V

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Solenoid valve

EGR Valve Step Motor

a

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PCM Control EGR Valve ( 1 ) Not in the starting engine (2) Not at idle speed (3) Not in heavy load increasing area (fuel injection control) (4) Speed is faster than 3.8 kmlh {2.4 MPH} (5) After car warm up EGR only operates in warming up, driving, and non-instant acceleration. 201109

100 , - - - ------------ - - - - - - -

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EEC

Fuel Tank Cover

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Throttle Valve

Fuel Tank

Main Relay

Solenoid Valve

Sensor Signal

ECM

Active carbon can, ~'n:,1C..

-

exterior Air - - - ------ -. _ - - - - - - _ . _ . _-_.

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Evaporation (EVAP) Fuel Emission Control System

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-- - -

- - - - - - -- -- - - - - -

1

Fuel Tank cap

2

Check valve

3

Active carbon can

4

Scavenging Solenoid

-PCM Control EEC • Under these four situations, PCM will activate EEC solenoid (carbon can solenoid) 0

(1)

When the shift lever is on D, 1 or 2 position

(2)

EeT is above 60°C {140°F}

(3)

RPM is over 1000 rpm

(4) In close wiring circuit operation or high intake efficiency, engine is during heavy load. I

201109

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-=====--.===-._-----.._ . _..---==-_ ...-.. . -. --~ . --. --

I

Possible reasons for actuator malfunction • Actuator fault- e.g. Solenoid valve( EEC/EGR) • Relay has malfunction (connection point/coil)- fuel pump/injector/step motor/ignition Coil/fan motor/compressor • ECD control module - power/ground • Poor connecting point/connector • Dirtiness- Idle Speed Air Control (IAC)/(ISC), carbon accumulation in injectors. • Leaking electricity- e.g. intermittent misfire within ignition system (Coil/ignition module/high tension cord/spark plug) 201109 102

--_.--

Q&A

201109

103

Introduction to Electrical Wiring Diagram

& Trouble shooting for electrical circuit 1/2 201109 - -- - - - - - - - - -

Integral wiring circuit

Voltage

4,Q

I+

source lftj{

load

-T'--__--o~o___---'

12V

switch

•

•

201 104

--

Light Etnitted Diode • LED circuit design

[_.-

._....._._.... --"\;\;'\.,;--- _._--_._--- - --

Test stick (probe)

330 n

LED

Useful detection light - Resistance can decide LED current ( related to the brightness)

-

- -- - - - - - - _ . _ - - - - - - - - - - -. -

r-~----I

I

1_000

-- - - - - - - - --- -

---- --------

- - --_._-

- ---- --- - - - -

P==IV

I~ 1---------..

Power (W)= current (A) x voltage (V) 12W= ?Ax 12V _

V1

How Inuch current does a headlight need ? I Fuse current I how lTIuch current is in your shop?

12V

Hybrid 50KWI energy saving bulbi 220V 7000

V==IR

.---V'/v---. 1= 12mA

I + 12V -=-

!

Voltage (V)= Current (A) x Resistance (n )

Load 3000

1

201109

=

12v

700n + 300n

= 0.012(A) =

What is the influence if resistance changes? Take examples: 105

12(mA)

The influence of resistance changes in the injector -H---Io---o+12V

Injector(resistance Rc)

/~,

Transistor as a control switch for injector 201109 --

...- ..

- ~--

---_.

-~

The influence of resistance short circuit in step motor

Idle speed servo motor

-4

6

LG

V '

R-G 29

-

.-

"--~

..Q\aI:

~ ~~~

15 .

---- -

i

Y --L, l

' 28 -----

201109 - --- -- -- - --

-

- -- --

5V - -- -_ . _

-

- - - -- ------

Think about what will happen in the following situations? • The bulb and lamp holder are rusty? - poor ground for lighting. • Terminal B of the alternator is not locked tightly? • The ground is not locked tightly? - Why not? For example: Ground of the engine and the body o

Ground of the sensors

00

Ground of the actuators

It's all because an integral wiring circuit is not formed.

201109 --- -_._---

-- - - --- - - - - -

;~;o6t,:-gtound .

_._- -

- -- ---- _. _-

-- --------- -

----

9V

12V

fo~Alg1iting +

3D

3D

(a)

(b)

201109 107 -------- - - - - - -- ---- ---

- -----------

RESISTORS . 'f( .

. "

.

. "

• • "' , ",'

-"'.

.

.

"

.• ••

/



Vs Signal voltage

-l-

Water temperature sensor

Resistance is big at low temperature 110

~----------------------------------------------

General Circuit Failure • Electrical components failure - damaged, burned, electronic components breakdown, aging, diminished performance • Line failure - broken circuit, short circuit (three short circuit conditions- short to ground, short to power, coil short circuit), loose wiring, moisture, oxidative corrosion causing poor contact, poor insulation or poor ground (no integral circuit) 201109 -

- - - - _.. _

.. - .. ----

- - _ . - -------- ....

--- ~

---

Broken Circuit • For example, fuse burning out, loose connectors, wire harness shrinl
-

- ----

--------_ ._-- - -------------- _._._ - _

120

. _ - - - - - - - - -- - -- - - - - - - -

Introduction to Electrical Wiring Diagram

& Trouble shooting for electrical circuit 2/2

201109

----~--- . _----- --_._--

- - - - - _ ._- -- -- - -

1

2

lIT

4

~

o

LOCK ACC

I

ON

II

START

(a)

201109

3

AM ACC IG

ST

A. ~

,...

'" (b)

""

-!

~

~--------------------------------------------------

(switch diagram)

(switch form) Wiper switch

'"

OFF INT LO

HI

Q

1

2 3

4 5 6

WASH

10 Q 0 10 0

-§ )

0

() 0

fNT .

LO H -e.. I

. . "WASH

OFF

()

•

T

INT /

Wiper switch

OFF

Turn on the two switches

T

Wiper switch conduction circuit Switch position

II

Conduction circuit

OFF

3-4

'I NT LO HI WASH

3-4. 5·-6 3-6 2 -6 1-6·

1-75 .

201109

__________________________~\)~\S5~~'~)C~~~~ 11 -~ ----------.----- ---------.-..

-

____________

---- ~----.--~---.- - ~-

. --.~-----

,

~~ _-~~-~~

General circuit repair method • Visual way- smoke / heat / sparks / odor • Broken circuit - like the speaker keeps homing • Short circuit 2- screwdriver / jumper (be careful not to cross 12V-line on 5V sensors / not cross + to -) • Test lamp - LED electronic pen / 12V test lamp (do not test computer control systems) • Substitution 20~atch meter

-

7' .: " 122

'--~-~--

----------~---

~'-;rJ

--- ~-------.--~--- --- -- -- ----

General circuit repair method • Instrument method * Do not use spark test method (unless loading, but ... ) / Do not use pointer meter to test computer control systems (internal resistance needs to be > lOMQ) / as IG sw ON, do not dismantle elements (self-inductance voltage) / no wiring / no static electricity at work place or on maintenance personnel/as welding, disassemble peM and battery 201109

• If you don't get the action and principle of each circuit contact clearly, do not arbitrarily process short circuit with jumpers, or it can cause serious results. A given example as below: if you use the jumper to connect A and B, the transistor inside the computer will burn out immediately.

Jumper

~ ~ ~

r---------. computer

..

B -----~t__

~

actuator 201109

Computer-controlled ground terminal

- - - - -- - - - - -

--

Circuit Protection Devices • Fuse - short-circuit protection • Fusible link - Overload Protection • Circuit Breaker - Overload Protection

* The real failure point needs to be found and then be replaced by a new onel replacement specifications need to be the same I Note that poor Insert type Glass tube type contact point cause pressure drop and heat

~ Card connector type

1

2

3

Fusible link

4

- ------------------- - - - - - - - - - - -- - - -

Meter use - short circuit measurement •

• When measuring short-circuit or broken circuit, circuit power should be turned off. • Electric meter should be cut to the lowest level of resistance or short-circuit test level. • Note that the circuit to be measured can not have parallel circuit. • Place probe at both ends of the circuit to be measured; if the resistance is small (short circuit), meter will beep. If it's broken circuit or the resistance is large, it will not beep. 201109 124

-------------------------------------------------------------------------~

Wrong measurement easy to make - 1 1"Conduction tester" measurement If the power is wrongly introduced into module control ground terminal, it's often easy to burn the module. 2"Ohm level" Measurement F or any levels, before each measurement, it should go back to zero first. F or measuring components, there must be one end to be removed from the circuit. Do not measure as electrifying. Do not touch the point with both hands.

~~

----------------- ~~

Wrong measurement easy to make - 2 3. "Voltage level" measurement By measuring the voltage decrease, the contact resistance of platinum contacts from the relay can be ascertained; But because the switch is open and broken circuit has no current, voltage decrease caused by contact resistance ca~ot be measured. R I Tum Oft' Relay

c,-,-

tum ()B'the switch

• e ay contact resIstance ---------;

The correct measurements are used when the circuit is functioning (circulating current), and there will be contact resistance.

201109

125

011

---------------------------------------------------------------------------

Wrong measurement easy to make - 3 Because of the same potentials, when measurement point is on the same side of circuit, people may think voltage doesn't work on bulb.

Bulb

+

®r

+

cutthe line

~~~~~~~~~~!'I~, Body ground

First, understand the circuit, and then fmd out the correct measuring point. 201109 -

----------- - .------- ~~

-----

~-

- ---

Wrong measurement easy to make - 4 4. "Current level" measurement The internal resistance of electric equipments may increase due to failure, but the voltage measured from the connector won't change. If channel current can be detected, the malfunction of components can be detected and then correctly find out the failure. The current file of analog multimeter usually can be used to detect rnA, it is not useful and is easily burned up. The current file of digital multimeter, l OA or 20A gears, it is more convenient for the test.

* *

The current direction of circuit must be understood first, or ammeter is easily burned up. As measuring current, the circuit needs to be in series connection. (As measuring voltage, the circuit needs to be in parallel connection.) 201109 126

--------

~-------------------------------------------------------~

Wrong measurement easy to make - 5 5. "Oscilloscope" measurement AC signal voltage, pulse signal voltage, injector signal voltage, ignition coil negative pole voltage, etc., generated by vehicle speed sensor(VSS) must use oscilloscope to be correctly measured and conduct correct troubleshooting.

201109

Circuit check procedure -1 [113

Open check • Resistance (conduct) test ECM (61)

(82)

(A)

ECM

o 127 - - - - - - - - - - - - - - - -----

--- -----------~- ---

--

---------~----

- - - - - - ---- - - --

--

-

Circuit check procedure -2 Open check · Voltage test

[[11 4 I

o

v

ECM

-- -.-

-- ~-

----

- ~.~ ~- ~--.---------

-

- - -

---~

--.~--.--

--_ ._. __ .

-

-

llill 6 I Circuit check procedure -2 ECM

Ground check

o

• Resistance test

1IJ5

I [ill I ECM

ECM (C)

(Al

(61)

~9:D~

[3

201109

o

128 --------

~~

----

-_._

-

--

-_ .

Tips for testing interlllittent malfunction • First, eliminate fault code. • Check if connectors / terminals are in a bad connection - loose wiring / bended or deformed / damaged or corroded terminals / connectors are not firm. • Shake connectors and harness slightly with vertical / horizontal direction. • Resistance measurement needs to be conducted under room temperature (200C). 201109 ~~

--~-~-~---------.--~-~---~--.-

Vibration simulation Sensors and actuators: Use fingers to slightly vibrate sensors, actuators, or relay. Caution: Strong vibration will damage sensors, actuators, or relay. ). connectors and harness: Shake connectors and harness slightly in vertical and horizontal direction.

l.

*

201109

--~---- ~ ~---~ -- --

---

----

~

• Temperature simulation a. Use a hair dryer or other heating devices to heat the possible breakdown components.

*Caution: Don't heat the components to damage. Don't heat ECM directly.

201109 ------

- --------

~~

Sprinkling simulation a. Sprinkle water over a car to simulate the situations of rainy days or high humidity.

*Caution:

Don't directly sprinkle water to engine room or electronic components.

Circuit load simulation a. Turn on all the electrical systems to simulate circuit overload (stereo, fan, light, etc.) 201109

a. When separating the connectors, don't pull and drag harness.

201109 - --

- -- - - - - - - - - - - - - - - - - - - - - --- - - - - - - - - - -

b. As opening the connectors with locks, press down or pull up lock -pieces.

201109

c. As connecting the connectors, a crack sound must be heard. The sound means the connectors are connected firmly. 131 -

- -- - -- - -- -- --- --

-

d. As using a meter to test conduction or voltage, a probe must be inserted from the harness side.

201109 ._ ._._.

__ ..

- - - ----- - - - _ . _ -

e. Check waterproof connector terminal from the connector side. Waterproof connector cannot be checked from the harness side.

201109 _

L

-Use thin wires to prevent terminals from damage. -Don't damage terminals as inserting probes.

_ _ _ _ _ _ _ _ _ _

-

_._--- - - - - - - -

~ 132

_ _ _ _ _ _ _ _

~'I

- - - -- - - -- -- ------- - -- - - -----

How to test current leakage (J/0

~

o

• Test method : Hood iK switch offl connect the current meter first, then oped negative terminal • In sleep situation • Leaking standard: 30",50mA(O.03",O.05A) (little difference in cars)

Battery negative cable Current meter

Battery positive cable 201109

9

~l

~

....s'

Relay

~ :: : ~

201109

~>~~ -- - --

- - - - - - --- --- --

- --- -

-

-

-

-

- - - - --- - -- - -

Relay Function

Fuse

Switch Relay

Speaker relay circuit

201109 -- - - --

-

-- - - - -

r----------------------------------------------------------------,

Which are most frequently used?

~50

--

-

~----------- ~-

87 = =87a

=

asO 8£ 0

000

Ow

DStl

- - - _ ..__. _ - - - - - -- _._- -

-

87

-----. ~

-

..

-----~

Type of Relay NO NC

r------------, 86 871 .

,

I

·

,

1

I

l'

--

i

. .

I

i

L. _. _____ _ 3 ___ , __85 0..J'

ic2j6 .87r87j

r-------------., 87

87 186

851 130

~

!L

-

. ..

--- -

-

____________ 30 ..J!

r-~ - -·~-

,

,i I I

20111

.I

86

__ ·=-;:;t I

87rffl.

l'i

--

I

85 30 ..J L. __________

8....6.. .

I .

I ...

.

_

.

I

i.

IJ:

.L--- ____ 85 . ______ 30' ~

87 18687a8s1

130

r--------------,

r--·-:-·--_· .... ·;t

1-

J..... ~~7a 1

'. ~. 1....

I

87 87851

130

~ 86 ~7a .187 i . . . . . . ... .. I .i

... .. .

. .• . ... . .

-

.

iI

······ 85 ____3 0' L--- ___ ___ I

.

.

~

~

r--- -- -- -

-~-.

87 \86878sl 130 .

if i.

!~ . . . . .8. 6 _~ 87f I ...... I

I

.

135

. .

130

- -,

!

8530 L--- ________

I

186 87a 851

I, I

'

._.~

87 186-851

130

Inspection of relay • Two pins with coil in relay must has resistance and follow the regulations. The other two pins no need to be conducted. But after coil be magnetic, this two pins must be conduct and on • In circuit, relay has two pins connect to the power. The other two pins is OV After control coil be magnetic, two connect pins must be same potential. 0

CONTINUITY

o

0

201109 -----~ .

-- --~ ---- ~- --

CONTIN U ITY

o

"3"-

'T' -

+

201109

-- -

---------

~~

--

-------

--- - - ---- --- -- - - - -- - ---- - -

---

+ Battery

137

ETCS -- Electrical Throttle Control System ETB -- Electronic Throttle Body

201109

ETC S-i (Electrical Throttle Control System-intelligent)

EngineECU

201109

138

Electrical throttle control

201109

ETCS (No-cable type electrical throttle control sytem) There are two sets of sliding resistance in accelerator pedal position sensor and throttle position sensor Injector

201109

Intelligent electrical throttle control system (No-cable type) • No need to use ACC valve because it has idle speed control. Accelerator position sensor

Throttle position sensor

Throttle control motor

Air mass meter 1--...... Brake control ECU

Ignition coil

Engine ECU (ECM)

Injectors

Accelerator pedal position sensor

Accelerator Pedal Position · Sensor

EP2 VPA2 VCP2

EFt

"'FA

v 5.0

Output Voltage

o ·Tr~~djer

Close

the accelerator pedal to output signal reliability •There are two sets of si which calluincrease the re

Open

VCPI

Types of Accelerator pedal position sensor & Throttle position sensor • Sliding resistance type • Hall type Functions of ETCS

201109

"'"

~"A~~~

Sliding resistance type 'jfn{~*li!

;..~

,,

M~*St

+:-v wt~1l{m

I

M

/;N'--r----?---

I

-l-

I I I

,

'~a5!~

U-

wt~~

M

~~~

=='----+--------'

f i ..__ _ 7ic'''~

8-3.EPSI EPAS ~ T ,}rD" rOJ Electronic Power Steering (EPS)

:

Electronic power steering (EPS)

Torque sensor unit

EPS module EPS motor

201109 159

Electronic power steering EPS structure

EPS CM

PCM EPS warning light

Steering column and linkage

201109

Electronic power steering EPS structure "'" ""--- _... ._......,_............. .,. ,

Turning angle signal

,

. . . . . . . . . . ,-------------:

_ . ._

power

L _r - - - - - - - - ,

Torque

• .• r L..-.._s_en_s_o_r_--"

~

Driving signal ~--- - - ---------------- -

'\ .

'

EPS motor position ~ignal ,

,

I

'...

~-~*---~-~--* - ----- - --~'

'

~

Situatin ,, signal

______________ _ _________________ _ _____ J

I

"t

i li~ ()

, :, Speed ,, ,

,

•:;Hiiil~ t "", 1

(CAN ,

~ ~I

... .;}.'

:

--- B

~",-------I----

j'-~':,:::::i_._ ~:':I- j I 1 :"

\ ,.... ,... ___ ..

EPS Control module

intermediate axle

Steering column and linkage

160

IG

PCM and ICM

Electronic power steering (EPS) Torque sensor

201109

2

EPS problem manifestation Code

manifestation

1

When the ignition switch is ON, EPS warning light is not ON.

2

Even engine is running, EPS warning light keeps lightening.

3

EPS warning light flashes.

4

The force of power assist is different in turning left and turning right.

201109

162

On-board diagnosis of CAN bus 1/2

201109

In Car Communication Network Protocols m~j)JfJ~

{hitts)

10M

Byte/ligltt

FlexRay

D2B

lZSk

10k

---------+------r------+------r------;. rr. 2000 2 05 2010 1995 ]990 163

400M

22M Bit

rate

10M

[bp s14.2M

125k 20k

201109

Network structure ~

Bus~

~

Star 201109

164

Ring

BMW network r::-:-l

~

~

L.-......l

K-CAN-Sys

Byte Flight

Penprteral,trunk,kHY

System,air cond

InstrumHnt,disp,...

Si-Bus, Airbag",

Powertmin

100 kl)ps

100 kbps

22.5 Mbps

10 Mbps

500 kbps

U ne ar, 2-wire

Unear, 2-wire

Ring,Fiber-Optical

Star,Fiber-Optic.al

linear,2-wire

Ref- Arl)ei;sl)ericht ....on Michael Jani, P,axissemester Informatik! Bachelor cler HS Kartsru he, Fachbe reicli Informatik, Matrik.eJNr: 016359,03.10.2005 Belte 1 von 51 , (Sec.tion 3.1.3)

E65 Bus system detail

Data

IIK/P bus

CAN

9.6

500

linear

linear

kBd

rate Bus structure

Data rate Bus structure

kBd MBd

D

bus

9.6

Sub-

K-CAN

K-CAN

byte...

0

P

S

PT CAN

MOST

,bus

bus

flight

bus

9,6

100

100

500

22.5

10

115

linear

linear

linear

Hnear

ring

star pT

201109

165

~

~ ...~~

~------------------------------------------------~ -~

MOST • MOST (Media Oriented Systems Transport) for Multimedia and control networking technology • The MOST bus is designed to handle the large volume of digital audio and video signals and graphics as well as other data services required for increasingly high-quality entertainment services such as: Telephone/ Navigation services/ Telematic and ASSIST, Internet services/ TV /Audio functions (radio, music cassettes, compact discs, CD changers)/ Video ~ :: ..,

201109

~~7'~

E65 Bus Network Optical fibre technology MOST Ring structure

Separate sender and receiver Large amount of data Audio-Data and Video-Data Frame network Data transmission: 22.5 Mbit/s iid!t, iDl11

siutamoblle

201109

EtrijiIi .... -' _ ft ..... lUltim ·VtoIce A~i.!tar

tape.,.

1ft.

166C'.QA'-4-TI.".O~N'· - -........... .

SOF

: 1 : 1 : 1:

EOF

11

... ARBITRATION.....

Duration in Data Bit

CRC

ID

: 1 :

....

I• .III... . . ..

I""!""!"'.......

DATA

:

--r1~1lI~1 l!S

_.,I"'--....,......

411 CIRL

EOF

End of Frame

RTR

Remote Transmission Request

eRe Cyclic Redundancy Code

IFS

Inter Frame Spacing

SRR

Substitute Remote Request

del

10

Identifier

RBO/1

Reserved bits

IDE

Identifier ExtenSion

Ole

Data length Code

Delimiter

ACK Acknowledge

J-1939 CAN 2.08 29-bit Identifier-extended data frame (J~1939CAN2.08 29-111: ~J5U~~1$fl§) ' PGN 2 2 2 2 ,2 2 2 2 2 1 1 1 1 l ' I 1 1 1 1 0 0 0 0 0 0 0 0 0 0 8 7 6 . 54 3 2 1 0 9 8 7 6 5 4 3 ? 1 0 9 'H' 7 6 5 4 3 L...... 1 0 4-

'~

p p •. p '

PPP,.

", .:j~;

r d F

' .

~,

F -.F , F F F F F S S S S

S

S~

S S A A A A A A A A

.... 3 bit message Priority {~,,~.3i)t , ,,'.

Lowest) r ,

1

.,

..

~.

.(,

dentifier (1*m~.)ju+) (0)

.

"

d

,';:"

"

1 bit Datal~q.g~ ( ~M][ ) '.' (0)

~,8 ~rS~SSSS.. ~ . 8

FFFFFFFF • :' ..")'

.~.

'~

~. .,.

~iJ~MH~l.It) ,;, ;.·u J;

bit · p~u

.~;rmat ( t;5EJi*·l~JGm~) (PFl bit : ;PDU fpp~c: ifiC . (ta~~~t.J-ctfffi(1) (PS) .. ··.'f' ', ..'"

~,.

'.'

'. ,

,.... .

' b~b' ·sou~6~'·:~~dress . oftfa.nsmitt i ng ·,

I ..

180

devi,ce

(~j~

. '.. '."

SAE J1939 - Parameter Group Number I

Arb:trction field

B U.3 [dlc

! C ontro l

! i

"

'.",~ -~ "~";,~,",:

Dntn Field

End of

Frome Field

g

Bus Idle l i -bit Base 1:1 domonant·--- - - - L" '----------'

e Re F,eld

field

' - -_ _ _-+->-............_---'-_ _ __

....1_5_-b_i_tC _R_C--,f

I

Source.

Ada-ess

, , 3 bits

'I bit

1 bit

Priority

Reserved

Data Page

8 bits

PDU

PDU

Format

Specific

Opel CAN H:s.c.A.N. ....... . ._ ..

ECC

TMS

201109

181 ...

_ _

._._--

_ .. _. - -- . ---. - - . - - -

8 bits

BuA JiC {MO) jf.

~ .. . ~~v

i

I·

•

.1 ~RIL¢4{t .

DiV · ' tmtDMtCH2 •

•

. ..~ ,,1j ••'

CAN_H average voltage

~t'r'~-

~ .,/ ,/

v "\

nec,.A·

CAN_L average voltage

CAN L waveform 201109

I

~-.------------------------------------~

tc

CAN H waveform

CAN L waveform

~ : "~

201109

190

~",,-_-+ 0 _ _ _ _ "'iORHX'''''J

0{13,.,,," ASS WHEEt.·$P€EO SENSOR LA (~ rCCACi

FllvlG 11"G I"R I'. I"v ''ire I". 1M-IVv I'. 11." IB", I1'. If i:ljl.~ trw I', I'. r. 1'. 1',,1'. I', rA I', I', U'S H: ,..