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::

. .


2014-2015

Damascus University
Faculty of Mechanical & Electrical
Engineering
Automobiles and Heavy Machines
Engineering Department

Design and implementation of test stand


for some of the sensors and actuators
used in modern cars
Graduation Project prepared to obtain Bachelor in Automobiles
and Heavy Machines Engineering

By Students:

Kinan Ahmed

Rami Shded
Supervised by:

Dr.Thaer Sallam

Academic Year
2014-2015

:
,
.
...



...





.



...




1......................................................................................
: 2........................................................... SENSORS
1.1 3................................................................................
2.1 4.....................................................................
3.1 5............................................................
4.1 6.........................................................
5.1 10................................................... KNOCK SENSOR
1.5.1 10...................................................................
2.5.1 12..........................................................
3.5.1 12........................................................................
4.5.1 13...............................................................
5.5.1 14..................................................
6.5.1 14...............................
7.5.1 15.................................
8.5.1 18..........................................
9.5.1 18...................................................
10.5.1 18........................................................
6.1 19.........................RPM and velocity sensors
1.6.1 19..........................................
2.6.1 19.............................
3.6.1 20.................................Inductive-type sensors
4.6.1 22.................................Magnetostatic sensors
5.6.1 23........................................................... Hall-effect
6.6.1 25....................................OPTICAL SENSORS
7.6.1 26.............Cam Shaft Position (CMP) Sensor
8.6.1 )/(28......
9.6.1 )29..................(Hall-effect
10.6.1 30............................

11.6.1 30.................................
12.6.1 ) (DTC 30.....
13.6.1 31........................................
14.6.1 33.................................................. Hall-Effect
15.6.1 36....................................................
7.1 37.......................................Temperature sensors
1.7.1 37................................................
2.7.1 ) (Thermistor 37......................................
3.7.1 38.............................................................
4.7.1 )41................................. (ECT
5.7.1 )42..............(ECT
6.7.1 43.....................
7.7.1 43.........................
8.7.1 44........................
9.7.1 44. . . .
10.7.1 45.................................................
11.7.1 45......
12.7.1 46....................
13.7.1 46.......................
: 48...................ELECTRONIC CONTROL UNIT
1.2 49...............................................................................
2.2 50.........................
3.2 51...........................................
4.2 52......................................................
1.4.2 52...................................................................
2.4.2 53..................................................................
3.4.2 54........................................................
4.4.2 54.........................................................................
5.2 )57......................................................... (PCM
1.5.2 58.....................................................

6.2 59............................................
1.6.2 59.................................................................... CAN
: 60..................................................... ACTUATORS
1.3 61...............................................................................
2.3 61....................................................................
3.3 62.......................................................
4.3 63..........................Solenoid actuators
5.3 64..............................Motorized actuators
6.3 65................................................. Stepper Motors
1.6.3 65.......................................................
2.6.3 65......................................................
3.6.3 66...................................................................
4.6.3 67.......................................................
5.6.3 67................................................
6.6.3 68.......................................
7.6.3 )( 70...................................................
7.3 71............................................ Synchronous motors
8.3 71.............................................. Thermal actuators
9.3 72.............................................. Oil Control Valve
1.9.3 73...................................................................
2.9.3 74....................................................... OCV
3.9.3 76................................................. OCV
4.9.3 77.................................................... OCV
5.9.3 78............................................OCV
6.9.3 78..................................................... OCV
7.9.3 79....................................................... OCV
8.9.3 80.................................................... OCV
10.3 81............IDLE AIR CONTROL VALVE
1.10.3 IAC 82..................................................
2.10.3 83............................................................. IAC

3.10.3 87................................................... IAC


4.10.3 87.................................IAC
5.10.3 87................................IAC
6.10.3 IAC 88..................................
7.10.3 89.................................................... IAC
8.10.3 89....................................................... IAC
: 90............................................
1.4 91...............................................................................
2.4 92..............................................................
3.4 92...............................................................
1.3.4 93....................................................................
2.3.4 94....................................................................
4.4 99.........................................
5.4 100................................................. KNOCK SENSOR
1.5.4 101.........................................
6.4 102.........................Cam Shaft Position Sensor
1.6.4 103..................
7.4 )105.................................... (ECT
1.7.4 106.......................
2.7.4 108....................
8.4 109......................................................... OCV
1.8.4 110................................................... OCV
2.8.4 112..................................................... OCV
9.4 112......................................... IAC
1.9.4 113.................................................... IAC
2.9.4 115....................................................... IAC
116.....................................................................................


) (1-1 3..........
) (2-1 4......................................
) (3-1 9....................................................
) (4-1 10..................................................................
) (5-1 11..............................................................
) (6-1 11............................................................
) (7-1 13..................................
) (8-1 15.......................................... on
) (9-1 15......................................... DLC
) (10-1 16.................................
) (11-1 16.............................
) (12-1 17..................................
) (13-1 18....................................................
) (14-1 18..........................................................
) (15-1 21...............................................
) (16-1 22.........................................
) (17-1 . 23..............
) (18-1 24....................................................... Hall-effect
) (19-1 25......Hall-effect
) (20-1 26..............................................................
) (21-1 Hall-effect 27...........
) (22-1 28.......................
) (23-1 )/(
29.......................................................................................
)(24-1 ) (Hall-effect 30....
) (25-1 32...................................
) (26-1 Hall-effect 35....

) (27-1
Hall-effect 36.......................................
) (28-1 Hall-effect 36.........
) (29-1 37.........................................................
) (30-1 39.............................
) (31-1 40........................................
) (32-1 41.........................
) (33-1 42.................................
) (34-1 44......
) (1-2 50.........................................................
) (2-2 52.................................................
) (3-2 54.................................................
) (4-2 58............................................
) (1-3 64...................................
) (2-3 65...........................................................
) (3-3 67..................................................
) (4-3 68................................................
) (5-3 69.........................
) (6-3 69....................................
) (7-3 69................................................
) (8-3 70........................
) (9-3 70....................................
) (10-3 71...........................................................
) (11-3 71....................................
) (12-3 72..............................................................
) (13-3 72..............................................................
) (14-3 73.............................................. VVT
) (15-3 74................................................ OCV
) (16-3 75......................................OCV
) (17-3 75.......................................OCV

) (18-3 )( 76.......................OCV
) (19-3 77.....................................OCV
) (20-3 78.................................................. OCV
) (21-3 80................................................
) (22-3 80................................................
) (23-3 OCV 81.........................
) (24-3 82...............................................
) (25-3 IAC 83........................................
) (26-3 84.................................................................... IAC
) (27-3 84................................IAC
) (28-3 IAC
85.......................................................................................
) (29-3 IAC
86.......................................................................................
) (30-3 IAC 87. . .
) (31-3 89...............IAC
) (1-4 92............................................. .
) (2-4 93................................................
) (3-4 94.............................................................
) (4-4 96...................................................
) (5-4 97...............................................
) (6-4 98..................................................
) (7-4 99............................................................
) (8-4 101.....................................
) (9-4 101...........................................................
) (10-4 102........................
) (11-4 103.................................
) (12-4 104....................
) (13-4 104..........................................
) (14-4 105.........

) (15-4 Hall-effect 106.................


) (16-4 Hall-effect

106.....................................................................................
) (17-4 107...............................
) (18-4 107.........
) (19-4 108.......
) (20-4 110. . .
) (21-4 OCV 111......................
) (22-4 110............................................. OCV
) (23-4 OCV 112...................
) (24-4 OCV 113.....................
) (25-4 IAC 114......................................
) (26-4 114............................................................ IAC
) (27-4 IAC 115..................................
) (28-4 IAC 116.....


) (1-1 14..............................
) (2-1 ) (DTC 31......
) (3-1 ) (DTC
46......................................................................................
) (1-3 79................................OCV
) (2-3 OCV 80...........
) (3-3 88.................................IAC
) (4-3 IAC 90............
) (1-4 103.....................................................
) (2-4 109...........................
) (3-4 112...........................OCV
) (4-4 115...........................OCV

Glossary

ABS

Anti-lock Braking System

ESP

Electronic Stability
Programme

OBD

On-board Diagnostics

MAP Sensor

Manifold Absolute Pressure


Sensor

BP Sensor

Barometric Pressure Sensor

O2 Sensor

Oxygen Sensor

ECT Sensor

Engine Coolant Temperature


Sensor

CKP Sensor

Crankshaft Position Sensor

CMP Sensor

Camshaft Position Sensor

IAT Sensor

Intake air temperature


Sensor

TP Sensor

Throttle Position Sensor

KS

Knock Sensor

MAF Sensor

Mass Air Flow Sensor

DLC

Data Link Connector

Harness

DTC

Diagnostic Trouble Code

NTC

Negative Temperature
Coefficient

PTC

Positive Temperature
Coefficient

VVT

Variable Valve Timing

EGR

Exhaust Gas Recirculation

EVAP

Evaporative Emission

ECU

Electronic Control Unit

ECM

Engine Control Module

TCM

Transmission Control
Module

PCM

Powertrain Control Module

BCM

Brake Control Module

SCM

Suspension Control Module

CCM

Central Control Module

DCU

Door control unit

PSCU

Electric Power Steering


Control Unit

SCU

Speed control unit

AMP

Amplifier

ROM

Read Only Memory

RAM

Random Access Memory

KAM

Keep Alive Memory

PROM

Programmable Read Only


Memory

EPROM

Erasable PROM

EEPROM

Electrically Erasable PROM

NVRAM

Nonvolatile RAM

Local Interconnect Network

LIN

pulse width modulation

PWM

Oil Control Valve

OCV

IDLE AIR CONTROL

IAC

Idle Speed Acuator

ISA

Electronic Air Control

EAC

:
.
) (
) .(ABS


. .

.
. .

.
.
bus .

.

. .

.

SENSORS

SENSORS

1.1:
)
(... .
.
) (1-1 .

) (1-1


) ,
(
.
, , , .


,
,

.

SENSORS

2.1 :
, ,
, :
.1


) (
) : (ESP , ) (
) ,OBD
(

.2

:
:) (a 2-1 )(
.
.
) (b 2-1
.
):(c 2-1
.
) (d 2-1
.

a
S

S .
X .

d
S

) (2-1
4

.3

SENSORS

.1 Digital Sensor
: on
off .
.2 Analog Sensor

.

3.1 :
.1 :Resistive Sensors





.

.
,

.

SENSORS

.2 :Voltage-generating sensors
.

) ( ,

.

.

.

4.1 :
.1 Manifold Absolute Pressure Sensor
):(MAP


.

.2 :Barometric Pressure Sensor



,
.

SENSORS

.3 :Oxygen Sensors
.

.

.4 :Coolant Temperature Sensors



) (ECT .
.
.

.5 :Crankshaft Position Sensor


.
.
.
.

.
.6 :Intake air temperature (IAT) Sensor



.
7

SENSORS

.7 :Throttle Position Sensor


.



.

.8 Camshaft Position (CMP) Sensor


) (CMP .
CMP CKP 1
.
, .
.9 :Knock Sensor
.
) (ECU

.
.10 ):Mass Air Flow Sensor (MAF
.
) (3-1 .

SENSORS

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)

( 3-1)

SENSORS

5.1 :KNOCK SENSOR


.

.
. .


.

- .
, .

1.5.1 :
) (
) (
) (4-1
) (5-1 .




.

) (4-1
10

SENSORS

.1 .

.2 .F

.3 .

.4 .

.5 .

.6 .
.7 .
.8

mc 1

) (5-1


.
.
)(6-1

b
c

(a
(b

(c

b
c

) (6-1
11

SENSORS


,
.
.

2.5.1 :
:
. .
:
.1 .inductive resonant sensors
.2 .piezoelectric resonant sensors
.3 .piezoelectric non-resonant sensors
.

.

) .(5kHz 15kHz

.

3.5.1:

.
12

SENSORS

.
.
. 5 6
. 8 12 .

4.5.1 :

) (7-1 :
2 .ECU
1 3.

KS

Sensor side connector


3 2 1

Signal

Harness side connector


Sensor
Signal

1 2 3

ECU

Signal

) (7-1

13

SENSORS

5.5.1 :

.
.
.
.

.
.
) (Check engine
. .
.

6.5.1 :

. ) (1-1 .
) (1-1

P0325

P0326

/ 1

P0327

P0328

P0329

P0330

2
14

SENSORS

P0331

/ 2

P0332

P0333

P0334

7.5.1 :


.
. .
.

Resonance piezo electric


.
:
.1
.2

) on ( ).(8-1
DLC).(9-1

) (8-1
on

) (9-1
DLC
15

SENSORS

.3

).(10-1

.4


).(11-1

.5

1500
. ).(12-1

) (11-1

) (10-1

) (12-1

16

.6

SENSORS

.
).(13-1

.7

ECU .
.
).(14-1

) (14-1

) (13-1


. .

.

17

SENSORS

8.5.1 :

.1 on .
.2 :
) (.
.3
.2.5V
.4 .

9.5.1 :

.1 .on
.2 :
.
.3 .
.4 )
( .

10.5.1 :


.
.
)( .

.
.
.
18

SENSORS

6.1 :RPM and velocity sensors



.
.

.
.

1.6.1 :
.1 .

.2 .
.3 .Hall-effect
.4 .

2.6.1
.1 .
.2 .
.3 .

19

SENSORS

3.6.1 :Inductive-type sensors

) ( .

.
).(15-1


) (16-1 .

. 30
.
.

. .
4
.
.

.


.



.

2 cm

4
5

6
7

) (15-1

) (
20

SENSORS

Output voltage

Time

) (16-1

:
.1 .
.2 :
.
.3 .
:
.1 .
.2 .
.3 .

21

SENSORS

4.6.1 :Magnetostatic sensors


. .

) .(17-1
.

. .

)(
.

) (17-1 . .

22

SENSORS

5.6.1 :Hall-effect

, .
) ( Hall-effect
.DC
"
.
.
Hall-effect ) (18-1:
.1 Hall
.2
.3 .
a
1
2

2 cm

3
4
S

a
Z
L

b
L

High

Low
Angle of rotation

) (18-1 Hall-effect
23

SENSORS

) (
.
.
.
) (19-1 .Hall-effect

Hall-effect

Hall-effect

) (19-1 Hall-effect

24

SENSORS

6.6.1 :OPTICAL SENSORS

LED .
LED
LED ) .(20-1
.
360
,


6 1200 .1800
1 .
180

)(b

)(a


180

) (20-1
)(b

) (a

25

SENSORS

7.6.1 :Cam Shaft Position (CMP) Sensor


.

1
.
, .
.

Hall-effect) .(21-1
. . Hall-
effect .
180

360

Hall-effect
:


)(on


360

)(off

) (21-1 Hall-effect

26

SENSORS

) (Hall-effect ).(22-1
.
.
. .

) (22-1

27

SENSORS

8.6.1 )/(:

) (23-1
.
1 3
2 .

Sensor side connector

CMP

3 2 1
1

Signal
Harness side connector
Sensor
ground

Sensor
Signal

1 2 3

ECU

Signal

) (23-1 )/(

28

SENSORS

9.6.1 ):(Hall-effect

) (24-1 Hall-effect

.
1.
2 .
3 .

Sensor side connector

TPS

3 2 1
1

Signal

Harness side connector


Sensor
ground

Power Sensor
Supply Signal

1 2 3

ECU

Signal

)(24-1 ) (Hall-effect

29

SENSORS

10.6.1 :

) (CHECK ENGINE

:
.DTC
.
.

11.6.1 :

CMP CKP
CMP .DTC

.

. .

12.6.1 ) (DTC :


. ).(2-1
) (2-1 ) (DTC

P0340

P0341

P0342

P0343

P0344


30

SENSORS

13.6.1 :

.
:
:
.1 .
.2 .
.3 .
.
:
.1 .
.2 .
AC .
.3 .
.
:

) (.

+2V

.1

0V

-2V

.2

) (25-1

).(25-1


.
31

SENSORS

:

.

.
) (
.
.
.
.

32

SENSORS

14.6.1 :Hall-Effect

Hall-Effect
.
:
.1 DC :
.
.2
5V
.0v
:
0v
.
0v
.

Hall-effect

.
.1 .
.2 .
.3
5 12 ) (
).(26-1

33

SENSORS

:
5 12 0 .
.

).(27-1
).(28-1

Voltage
Time
) (26-1 Hall-effect

34

SENSORS

Voltage
Time
) (27-1
Hall-effect

Voltage
Time
) (28-1 Hall-effect

35

SENSORS

15.6.1 :

.1 .
LED
.
.2 .
.3 ) (29-1
.

) (29-1
(a A .

(b A B

36

SENSORS

7.1 :Temperature sensors


.

. .
.
.
.

1.7.1 :

.1 .Coolant temperature sensor


.2 .Intake air temperature sensor
.3 .Engine oil temperature sensor
.4 .Fuel-temperature sensor
.5 .Exhaust-gas temperature sensor

2.7.1 ) (Thermistor :

.

. ) 5(
.


) .(30-1
.
37

SENSORS

ECU

5V

) (30-1

3.7.1 :

.1 ) : (PTC
.
.2 ) : (NTC
.

NTC .

38

SENSORS

) (
).(31-1
ECU

5V

12V

Voltage
regulator

10K
Temperature
sensor

1K

Grounds

Voltage-sensing
circuit

) (31-1


) (microprocessor .
) 1.25v ( 1K
.10K
1.25v 1K 909
. ) .(32-1
.

39

SENSORS

4.80
4.48
4.16

ECT VOLTAGE
ABOVE 120

3.84
3.52
3.20
2.88
2.56

DC
VOLTS

2.24
1.92
1.60
1.28
0.96
ECT VOLTAGE
BELOW 120

0.64
0.32
0.00

235 255 275

215

195

175

135 155

105

85

65

45

25

-18

-40

DEGREES F

) (32-1
. 1
3.6.

40

SENSORS

4.7.1 ENGINE COOLANT


TEMPERATURE (ECT) SENSOR
) (ECT
.
.NTC
.
) 5( .
.

. .
) (33-1 .

.1
.2
.3
.4
.5
.6
1 cm

) (33-1

41

SENSORS

5.7.1 ):(ECT

,
:
.1

.2

.3

.VVT

.4

.5

.EGR

.6

.EVAP

.7

).Idle air control (IAC

.8

.closed-loop

.9

42

SENSORS

6.7.1 :

) (34-1 .
1 .
2 5v .

Sensor side connector

ECT

3 2 1
1

+
3
Harness side connector

1 2 3

5v

ECU

) (34-1

7.7.1 :

check engine
:
43

SENSORS

.1 .
.2 .
.3 .
.4 .
.5 .
.6 - .
.7 .
.8 .
.9 .
,
.

8.7.1 :

.DTC
.

. .
) 4.0(
.

.
. .

9.7.1 ) (DTC
:


44

SENSORS

.
).(3-1
) (3-1 ) (DTC

P0115

P0116

P0117

P0118

P0119

10.7.1 :

.1 .
.2 .
.3 .

11.7.1 :

.

) ( . :
.1
.on
.2 Live Data .
.3 )

(ECT ) (IAT

45

SENSORS

.
.4
.

12.7.1 :

.1 .on
.2 .
.3 .
.4 .
2V .3V
.5 .
.6 .
) .(NTS

:
) (
.
ECU .
.

13.7.1 :

.
46

SENSORS

:
.1 .OFF
.2 .
.3 .
.4 ) (20C
5C .
.5
.
:
.1 , .
.2 .
.3
.
.4
.
.5
.

47

:

ELECTRONIC CONTROL
UNIT

1.2:
) (ECU
.
.
.


.

.
.
DTC .
.
.
) (1-2 .

) (1-2
49

2.2 :
control unit control module
:
.1 ).engine Control Module (ECM
.2 ).Powertrain Control Module (PCM
.3 ).Transmission Control Module (TCM
.4 ).Brake Control Module (BCM or EBCM
.5 ).Central Control Module (CCM
.6 ).Body Control Module (BCM
.7 ).Suspension Control Module (SCM
.8 ).Door control unit (DCU
.9 ).Electric Power Steering Control Unit (PSCU
.10 .Seat Control Unit
.11 ).Speed control unit (SCU
.12 .Battery management system

50

3.2 :
)(.
) (2-2:
.1 :

.
.2 :

.
.3 : .
.
.4 :
.
.
.

PROM

RAM

ROM

) (2-2
51

4.2 :

, .

,
.
) (3-2:
.1 ).(input unit
.2 ).(output unit
.3 ).(CPU
.4 ).(Memories

1.4.2 :

.
:
.1 ) :(A/D .

.
.2 ) :(AMP )(
. 1
. .
.3 : .

52

UCE


/D A

ffO

nO


D/A

) (3-2

2.4.2 :

53

3.4.2 :

. :
.
.
.
.

microprocessor .
.



.

4.4.2:

.
.
.

.
:
.1

):ROM (Read only memory


,
,
.
:
54

, :
:Calibration Tables
, .
:Look up Tables
,
.
.2

):RAM (Random access memory


,
.

.

.3

):KAM (Keep alive memory


.RAM KAM
.
. .

.4

):PROM (Programmable read only memory


,

.

.5

):EPROM (Erasable PROM


PROM
55

.

.
.6

EEPROM (Electrically erasable


):PROM
EPROM
.

EEPROM ) (DLC
.
.

.7

):NVRAM (Nonvolatile RAM


RAM EEPROM .

.
EEPROM .
EEPROM .

56

5.2 ):(PCM


) (lookup tables . )(4-2
.
Outputs

Inputs

Fuel injectors

Engine coolant sensor

)Ignition coil(s

Mass airflow sensor

or A/F heater control

Intake air temperature

Fuel pump

MAP sensor

Idle air control

EGR vacuum valve


EVAP vacuum valve

Crankshaft position

P
C
M

Camshaft position
Vehicle speed
2 or A/F ratio

Park/Neutral switch

MIL

Throttle position

EFI relay

Knock sensor
EVAP pressure

DLC

Power steering pressure

Battery

) (4-2

57

1.5.2 :

.1 -:
) (ECU
.

MAF ECU
.

" .
.2 :
.
) ( .

.
.3 :


.
.
.4 :
.
.
.5 :

.
58

6.2 :
) (CABLES
. ) CAN-Bus (controller area network

Bosch CAN-Bus
,
CAN-BUS
.
CAN-Bus
LIN-Bus .MOST

1.6.2 :CAN
:CAN A .1


.
33.33Kbs 83.33Kbs .
.
:CAN B .2
.
.95.2Kbs
:CAN C .3
.500Kbs

59

ACTUATORS

ACTUATORS

1.3:
.
.

.
.
) (Solenoid
. .

%20 %80 . .

)) (pulse width modulation (PWM
.

.
.

.

2.3 :
:
.1 .Solenoid actuators
.2 .Motorized actuators
.3 :Steper motors
61

ACTUATORS

.4 .Synchronous motors
.5 .

3.3 :
.1 :Air Management Solenoid valves
)
( ) (.
.2 Evaporative Emission (EVAP) Canister
:Purge Valve
,
.
)
(.
.3 :EGR Flow Solenoids

,
.
.4 :Fuel Injectors
.
.5 .Idle Speed Controls

62

ACTUATORS

4.3 :Solenoid actuators


" solenoid .
.
) (1-3 .
.
.

) (1-3

).(2-3

.
.0.1mm )
1.5 10 ( .
.

63

ACTUATORS

PLUNGER

) (2-3

5.3 :Motorized actuators


.
. )

( .
:
.1

.7

.2

.8

.3

.9

.4

.10

.5

.11

.6

.12

64

ACTUATORS

6.3 :Stepper Motors


.
.
,
.
,
.

.
. 7.5 3.5
.. .

1.6.3 :
.1 .
.2 .
.3 .

2.6.3 :

65

ACTUATORS

3.6.3 :

) (stator
) (rotor .





.
.
.) (3-3
.
.
) 360(

200 ) 360(
1.8 1.8.

) (3-3

66

ACTUATORS

4.6.3 :

:
.1 ).(Permanent Magnet Stepper
.2 ).(Variable Reluctance Stepper
.3 ).(Hybrid stepper

5.6.3 :

.
,

) (4-3 .

) (4-3

) ,

, )
( .

. ) (5-3
.

67

ACTUATORS

) (5-3

,
).(6-3

) (6-3

6.6.3 :





) (7-3
.

.

) (7-3
68

ACTUATORS

)
.
, .
) (8-3 .

) (8-3

,
).(9-3

) (9-3

69

ACTUATORS

7.6.3 )(:


.

.

) (10-3 .

) (10-3

,
.
.
) (11-3 .

) (11-3
70

ACTUATORS

7.3 :Synchronous motors



) (12-3
.


.

) (12-3

8.3 :Thermal actuators



.


. ) (13-3
.

) (13-3

71

ACTUATORS

9.3 :Oil Control Valve


) (Oil Control Valve
) .Variable Valve Timing (VVT

.

) (NOX HC
.
VVT .
) , ,
, , ( .

:
) (14-3 .VVT
ENGINE OIL
PRESSURE
OIL CONTROL
)VALVE (OCV
PADDLE

SPROCKET

CAVITY
RETARD
ADVANCE

CAMSHAFT
PADDLE

SPROCKET

) (14-3 VVT

72

ACTUATORS

1.9.3 :

) (15-3:
.1 .return spring
.2 :spool valve
.
.3 .coil
.4 .plunger

) (15-3 OCV

OCV

VVT .

73

ACTUATORS

2.9.3 :OCV

OCV:
:

).(16-3

) (16-3 OCV

:

).(17-3

) (17-3 OCV
74

ACTUATORS

)(:
)(
VVT
. ).(18-3

) (18-3 )( OCV

75

ACTUATORS

3.9.3 :OCV

) (19-3 OCV :
1.
2.

OCV side connector

OCV

2
2

+
Harness side connector
12v

ECU

) (19-3 OCV

76

ACTUATORS

4.9.3 :OCV

OCV , OCV
.
) (20-3 .OCV
:
.
OCV .

R=0 /

OK



.
OCV
12V
NO

NO




YES

,
.
) (20-3 OCV

77

ACTUATORS

5.9.3 :OCV

) (1-3 OCV

.
) (1-3 OCV


P0011
P0014

P0021
P0012
P0015

P0022
P0016

P0300

P0018

6.9.3 :OCV

OCV :
.1 .
.2 .
.3 .

78

ACTUATORS

) (2-3 OCV .
) (2-3 OCV

OCV

OCV

OCV

7.9.3 :OCV
OCV ) 12V
( ).(21-3
) (21-3 .12V
) (22-3 .12V

) (21-3

) (22-3

79

ACTUATORS


) (23-3 .

.

) (23-3 OCV

8.9.3 :OCV

OCV
.1 .
.2 .
.3 .
80

ACTUATORS

10.3 IDLE AIR


:CONTROL VALVE
) |
(Idle speed) .(24-3
.
.
.

.
)IDLE AIR CONTROL (IAC

) (24-3

.
)
( .
.
: ) (auxiliary air valves
).(IAC
81

ACTUATORS

1.10.3 IAC :

IAC ,
) (Solinoid .
)Electronic Air Control -

(EAC ).(Idle Speed Acuator - ISA



) (25-3 .

)IDLE AIR CONTROL (IAC

.IAC

.


.

.

IAC


,

.

) (25-3 IAC

82

ACTUATORS


,

.

2.10.3 :IAC

.1 ):(Rotary Solenoid Type


. ,
.
.
, )(26-3
.

.
) (27-3 .

12V

0V
12V

) (26-3 IAC

0V

) (27-3 IAC
83

ACTUATORS


.
IAC
) (28-3 :
1 .
2 .
3 .
4 .

IAC
M

IAC side connector

1 2 3 4
2

+
Harness side connector

4 3 2 1
+

ECU

) (28-3 IAC
84

ACTUATORS

.2 :
, .

.
IAC
) (29-3 :
1.
2.

IAC side connector

IAC

Harness side connector

1
+

ECU

) (29-3 IAC

85

ACTUATORS

.3 :

.
.
.
IAC )(30-3
6 ,
.
:
4 5.
1 3 4 6.

IAC

IAC side connector


1 2 3
4 5 6

Relay

+
Harness side connector
1
4

ECU

3 2
6 5

) (30-3 IAC
86

ACTUATORS

3.10.3 :IAC

IAC .
.IAC

.

4.10.3 :IAC

.1 .
.2
.
.3
.
.4 .

5.10.3 :IAC

) (3-3 IAC
IAC
OBD-II
DTCS .IAC

) (3-3 IAC

P0505

P0506


87

ACTUATORS

P0507

P0500-P0599

6.10.3 IAC :

,
. .

) (31-3 %60
, .%60 %60
%60 . %40
.

12V

0V
12V

0V
) (31-3 IAC

88

ACTUATORS

7.10.3 :IAC

IAC
:
.1 .
.2 .
.3 .
) (4-3 IAC .
) (4-3 IAC

IAC

IAC

IAC

8.10.3 :IAC

, ON

.

89

1.4:


.


:
.
:

.
.
,

) (12

.
) (1-4

,)(2-4

.

) (1-4 .
91

) (2-4

2.4 :
.1 .
.2 .
.3 .
.4
.
.5 ) (.

3.4 :
:
.1 .
.2 .
92

.3 .
.4 .

1.3.4 :

.
) (3-4:
.1 .
.2 .
.3 .
:
190 [cm] :
120 [cm] :

) (3-4

93

2.3.4 :

220V AC DC ,
:
5V.
12V.
.
:
.1 :
12-5.
.2 :


)
(.
.3 :

.
:
.1 :


) (4-4
.

94


O
1

8.8.8


12V


5V

) (4-4

.2 :
:
*36
.12
.36*30
.30*12
.3 :
) (5-4:
12-220 60.
.
.
95

.
.
.
.
.
.

) (5-4

:
) (6-4
220
) (s1 ) (LED1
) (L1
) (L2 12v 5A
)(D1,D2

96

) (V1,V2,V3 5v ) (j2
) (V4,V5,V6 9v
) (U1 ) ,(HEF1
12v ).(j1
) (j3


, ).(D3,D4.D5,D6

, ) (j4,j5,j6
.

U1

2 1

+ Power
- Plug

S1

3
3

5 4
4

6
6

8 7
7

11

16 15 14 13

10

11

12

220 v

STROBE

DATA

CLOCK

Q1

Q2

Q3

Q4

Vss

GND

Transformer
220-12v

V1

GND

Voltage IN
Regulator
5V

Voltage IN
Regulator
9V
V6

OUT

15

14

13

12

11

Vdd16

OE

Q5

Q6

Q7

OUT

Voltage
Regulators
9v

GND

Voltage IN V2
Regulator
5V

Q8

M1
D2

GND

Q's 10

Voltage IN V5
Regulator
9V

OUT

Qs

L2

Voltage IN
Regulator
9V

D1
L1

GND
OUT

V4

HEF1

LED1

OUT

GND

R2

Voltage IN
Regulator
5V
V3

10K

J6

J5

Rotary
Potentiometer
Plugs

OUT

Voltage
Regulators
5v

R1

D3

D6 D5 D4

J4
J1

12v Output

J2

5v Output

) (6-4
97

J3

Mesuring input

13

14

:

.
) (7-4
) (L1-L2 )(R1 R2 R3 R4

)(a

R2
10K

L1

)(b
L2

R1
220

R3
220

+
-

R4
220

) (7-4

)(b-7-4 R4 L2
:
VL2=(R4/R3+R4)*V
R4

) (a-7-4 R2 L1
R2 L1
.

.

98

4.4 :
:
.1 ) (.
.2 ) ,
, (.
.3 ) (
.
.4 .
:
.1 .
.2 .
.3 .
.4 .

99

5.4 :KNOCK SENSOR



.

,
.
) (8-4
,) (9-4
,

) (8-4

) (9-4
100

1.5.4 :


,
) (10-4 :
.1 .
.2 AC


.
.3 .
.4 .
.5 .

O
1
DIGITAL MULTIMETER

000.0

AUTO

0 1 2 3 4 5 6 7 8 9 0

mV
mA
A

COM

mA A

) (10-4
101

8.8.8

.6
. .
.

2.5.4 :

) (11-4 :
.1 .
.2 ) (1-4

.
) (1-4

4.87M 20%

DIGITAL MULTIMETER

4.92M

AUTO

0 1 2 3 4 5 6 7 8 9 0

mV
mA
A

COM

mA A

) (11-4

.3 )
( .
102

6.4 :Cam Shaft Position Sensor


.
1
.
, .
.Hall-effect
.
.
.

.

S
N

.
) (12-4
,
) (13-4
,

) (12-4

) (13-4


103

1.6.4 :

, ) (14-4 :
.1 5V
.
.2 DC

.
.3
5V
0v .

O
1

8.8.8

S
N

DIGITAL MULTIMETER

005.0V

AUTO

0 1 2 3 4 5 6 7 8 9 0

mV
mA
A

COM

mA A

) (14-4

104

:
5V 0v
.

.
5V
,
5V


) (14-4 .
5
) ,(15-4 :
5 0 .
.
) (16-4
.

Voltage

Voltage

Time

Time
) (16-4

) (15-4 Hall-effect

Hall-effect
105

7.4 ENGINE COOLANT


:TEMPERATURE SENSOR
.
.NTC
.
5
.
.

.



.
) (17-4
,
) (18-4
.

) (18-4

) (17-4

106

1.7.4 :

) (19-4
:
.1 .
.2 )( .12V
.3 .

O
1

0.0

DIGITAL MULTIMETER

0.83K

AUTO

0 1 2 3 4 5 6 7 8 9 0

mV
mA
A

COM

mA A

) (19-4

:
) (2-4
.

.
107

) (2-4

) (K

-40C

-40F

48.14K

-20C

-4F

14.14-16.83K

0C

32F

5.79K

20C

68F

2.31-2.59K

40C

104F

1.15K

60C

140F

0.59K

80C

176F

0.32K

2.7.4 :

) (20-4
:
.1 5V .
.2 .
.3 .
.4
.
.5 )( .12V
.6 .

108

O
1

2.0

DIGITAL MULTIMETER

00.72

AUTO

0 1 2 3 4 5 6 7 8 9 0

mV
mA
A

COM

mA A

) (20-4

:

.

109

8.4 :Oil Control Valve


Variable Valve Timing
).(VVT
VVT


VVT .
) (21-4
,) (22-4
.

) (21-4 OCV

) (22-4 OCV
110

1.8.4 :OCV

) (23-4
:
.1 .
.2
).(3-4

DIGITAL MULTIMETER
AUTO

008.0

0 1 2 3 4 5 6 7 8 9 0

mV
mA
A

COM

mA A

) (23-4 OCV
) (3-4 OCV

6.9-7.9

20C

111

:
.
.

2.8.4 :OCV
OCV 12V
, ) (24-4 OCV .

.

O
1

8.8.8

) (24-4 OCV

112

9.4 IDLE AIR CONTROL


:VALVE
.
.
IAC .
) (25-4 IAC ,) (26-4
IAC .

IDLE AIR
CONTROL VALVE

) (25-4 IAC

) (26-4 IAC


113

1.9.4 :IAC

) (27-4 IAC
:
.1 .
.2
).(4-4
.3
.
.4 .
IDLE AIR
CONTROL VALVE

IDLE AIR
CONTROL VALVE

DIGITAL MULTIMETER

DIGITAL MULTIMETER

AUTO

AUTO

11.9

9 0

15.3

9 0

0 1 2 3 4 5 6 7 8

0 1 2 3 4 5 6 7 8

mV
mA
A

mV
mA
A

COM

mA A

) (27-4 IAC
) (4-4 OCV

11.1-12.7 at 20C

14.6-16.2 at 20C

114

COM

mA A

:
.
.

2.9.4 :IAC

12V ,
) (28-4 IAC .
IDLE AIR
CONTROL VALVE

O
1

8.8.8

) (28-4 IAC

115


:
(1)

James D. Halderman, (2012), 'Automotive Technology - Principles, Diagnosis, and


Service', 4th ed, Pearson Education, Inc, 1 Lake Street, Upper Saddle River, New
Jersey 07458.

(2)

Robert Bosch GmbH (Ed.), (2013), 'Bosch Automotive Electrics and Automotive
Electronics', 5th ed, Springer Vieweg, Plochingen, Germany.

(3)

JACOB FRADEN, (2010), 'Handbook of Modern Sensors: Physics, Designs, and


Applications', 3rd ed, Springer-Verlag, New York Berlin Heidelberg.

(4)

Jack Erjavec, (2009), 'Automotive Technology: A Systems Approach', 5th ed,


Delmar, Clifton Park, NY.

(5)

Barry Hollembeak, (2010), 'Automotive Electricity and Electronics Classroom and


Shop Manual Pack', 5th ed, Delmar, Clifton Park, NY.

(6)

W Ribbens, (2012), 'Understanding Automotive Electronics', 7th ed, ButterworthHeinemann, USA.

(7)

Chonan Technical Service Training Center, Sensors and Troubleshooting.

:
(1)

http://www.kirmanual.com/downloads.php

(2)

http://www.aa1car.com/

(3)

http://troubleshootmyvehicle.com/

(4)

http://www.azosensors.com/

:
(1)

ALLDATA, 10.53

(2)

Autodata 3.40

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