2011 Automobile Maintenance

Advanced Course for the

Industrial Technical
Instructors

Class No. :

Instructor:

Hsiao, Sun-ching

Inspection of Sensors

f'":

201109

=.,

~",,:-,~

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

201109

Engine is not running?

(]

Why isn-' t it
running?
\

201109

H>- ~~ "'W" 'WW W ~""" ~ _' '''~4:''''''

. " ~"~~" """''''''''' '''''''''''''''''''''""N~'''''''_'''

" "

"

~.""'" .'

III
3

Case 1 : Engine is not running ?

Three answers :

i- -:f"ue\
L-

V'-l"'"'f +- \ VI Jeutoy

'5 fG\.'r'(.. ~\0)

J - CovY'. fv-e

+- \':)

V\\

-hoV)

+\ v-r.iV\6

ssuve .

'-, ~
...

201109

~'r:"~

The common signals for sensors

Analog signal- DCV / ACV
Digital signal- Square wave
1.0 2 v
137Hz

4 6.0
lS4

Pfll(..j>EAi(

FREQlIEtll:v

~ Mv CYa.

IllS

11

PILSEIJIOllt Ir

... ' .... "" .... ~ .... .... ,... ... -i.... ..--

-I

.v

-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

voltage

To which sensors
are applied to?

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

Bn<.h

RI
(h'("t!lll)tJ

! hAkl

c~

Hall effect device

ECM

Fig. Function of Hall effect device

201109

Hall element
\

tttt
field

without voltage output

Hall Effect

201109

with voltage output

How to test Hall Effect Type sensor

CKP / CMP Sensor

or+12V

PCM
+5V
+5V

IWhat are the six ways?

I

201109

--2

- 4V '

lms/O IV

Vehicle Speed Sensor (VSS)

(?)

PCM

:~=nruL

CAN

(~)

Sensor

meter
DPE5I7ZT1005

201109

How to check?
peM

Hall effect type sensor

LED

DCV

""'sv

power
signal
ground

Hz/ %/ RPM
Scan tool(Data list
or Datalogger)
Scope
.
-

-.
..
..... ;-.. .. : ....
'"

:'., ':

"

...

;'"''

.. . ...

201109

Magnetic induction sensor

,1
/
" (SIC"

<~

-{GNDi

10

At Hight Speed
Coil

Rotor~
"""
\

I I
!

+Vi
i

o.

liO::OOl lN/si," S:

./j \_ =-~~~~~==
I ...

//

/ ..permanent Magnet

OUtpllt

-V

. (\

,H

' , --

() ()

L"r~
I

~//

"~~

At Low Speed

,"""

.........

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

How to check it?

e

LED

ACV

II' ,.,.

..I ... J_1. .... L~...

.1_.1._
ttl

.J_l..~I._I ,

II

eQ
e

e
e

Hz/ RPM

ACV?fRm
ACV Waveform

Scan tool(Data list or Datalogger)

Scope

201109

Basic circuit and inspection of sensor

Basic circuit of the sensor
How to calculate Vs==? (Voltage divider)

lR1

~2ohm

V2
5V

30hm

Divided voltage applied to sensor

Sensor

PCM
R1

R1

-_._.

-../'I\r-

20hm

+5V

i V2

-Lsv
;,R2

+ ,------.,

Vs

R2

3.000

IV

30hm

201109

Divided Voltage
R1

R2

1.000

70hm

V1

IA

50hm

5.000

Iv

12V

201109

10
-.-~----~--~.-~- - -.----. ~- -- ~

---~----

,-------------------------------------------------------~

Calculation?
R3

R4

~
40hm

R5

50hm

30hm

-1"1'

Iv

12V

IA

I
+

V3

Iv

~ ... , ~
201109

t.:: .<~

Circuit types of the sensor

Sensor

PCM
R1

,tvv

PCM

Sensor
R1

+5V

+5V

R2

>

1.R2

Vs

Vs
R3

>-<

1-

~,
""
~

11

..:::.-.~~~

Application of throttle position

sensor Sensor
PCM
PCl\I

TPS

R1

+5'"

~~1tm

l~

..- +5V

<

Vs
p,R3

f
~

) VI'"

.\ ,...! \ ;i

-';"

~ ..'.,.....-'--. .

.~

Close
completely

20

Throttle valve
open

-,.-----"".~'''--''-''.-"''''-~ .. ~

K2+

F3

How to check it?

Open
completely

The influence of poor ground in

water temperature sensor
PCM

PCM

Sensor

THW Signal voltage

Signal wire
R1

->NY-

THW

+5V

+5V

R2

Vs
Signal voltage

Water temperature sensor

When temperature is low, signal voltage is big

12

How does sensor make PCM

produce trouble code?
When break circuit of the sensor happens ' V s=?
When short circuit of the sensor occurs to ground or
break circuit of reference voltage happens' Vs=?
peM

Sensor

Sensor

PCM

R1

R1

01\r-

/v'v-+5V

+5V

lR2
<-

R2
~"-

Vs

Vs

fRl
1-

2011ut1

PRINCIPLE OF DIAGNOSTIC
SSTEM

"CHECK ENGINE"
lamp
..

~
.;,,.;. ~.~"~
'-'~----"~-,,*",,---

04--~~o~~-------7.1~~
' ,.--(~8)

(282}

Coolant temperature "C (OF)

201109

13

If there are abnormal signals

in sensor, the engine warning
light will be on in dashboard.

In dashboard
ECM

Check tenninal T

Self diagnosis presentation

The order is "no trouble"

and trouble code
"1","3","14","24"

ON

orr

Different ways of engine

warning light

201109

Myth of trouble code?

ECU
THW

Signal wire

Tr-iW

tA

TPS

'--0

.E2

Signal
voltage

y+5V

High

+5V

Powcr

specd
position

TH W

Signal

E2

Idlc

-~

Ground

speed
position

Water tEtmp.e rature

sensor

IDon't celebrate too early?

201109

14

'::

Rcler-cncc
voltage

Decoding of faultcodes
according to SAE J2012
:-

POXXX

--

1_..

,-~

Faultcode
1-Fuel-air measurement
2-lnjection nozzles
3-lgnition dropouts
4-Aggregate emissions
5-ldling and speed control
6-Vehicle computer
7-Gear
8-Gear
0- SAE J2012 defined
1- manufacturer defined
P- Powertrain

2o{'0BD II . P-Powertrain /C-

chassis

IB-

Car body

U-

Three requirements for sensor to work

Reference Voltage : 5V / 12V
sent by the modes, fix voltage
Signal Voltage : variable voltage ' send back to the modes
(sometimes reference voltage and signal voltage use the same
pin)
Ground
PCl\I

ITS
High speed
position

+5V

Power

~.

Signal

Reference
voltage

\~~---~~---------~~
Idle speed
position

' . . ,T

Ground

" - - -- - - . f - - - - - {

201109

15

Power supply for car engine computer

There are two types of power supply connecting to
the computer, one is direct power supply (from
battery to the computer through the fuse), the other is
controlled by ignition switch (power comes when
ignition is on).
There are two kinds of voltage operated by the
computer, 5V and 12V. It includes 5V reference
voltage used by sensor (12V induction switch signal)
and 12V drive voltage (control actuator)
201109

How to inspect whether the power supply

circuit of the computer is normal?

GJC-~---l"'"

detect intake quantity

~. .

Air flow meter

Basic injection
volume
.

detect engine
RPM

Injector

Crankshaft position sensor

Basic injection quantity is decided by intake
quantity and engine RPM.

Basic injection quantity

201109

16

Air flow meter

Injector is installed
into the intake pipe in
front of intake valve.

Airvalve

Multi-injection injectors position (1)

Injector is installed on the top of
cylinder head, inject the fuel to the
combustion chamber directly.
GDIIFSI

Spark plug

Combustion chamber
High pressure
injector

Multi-injection injectors position

Shallow piston ---ji---llofl

~
""'

Hid'Hxessute
pJrnp "

MAP , ",,-.ora .

Fuer ll!n~
It,jrtitiOil 6:).il
{

iclt(~lr{)n\r::

o:::rltml !..mit

lfli-t;& fit( mootrl'e

mell):,2!ng ifif':-

lUql. SuW[1 ,p..!mp

GDI- Gasoline Direct Injection

201109

FSI- Fuel Stratified Injection

17

BASIC CONSTRUCTION OF EFI

O-TVPE EFt

Fuel filter

Fuel ta.nk
(W'ith built-in
l!==::=:!J

fuel pump)

L-TVPE EFI

Air flow meter

201109

The type of fuel injection system

according to air inspection
D type-intake manifold absolute pressure
sensor (MAP)
L type-air flow sensor
a. Vane type

c)

\\ '.(0

b. Karman vortex type - ~yersonic

/optical / pressure
c. Hot wire type, hot diaphragm type
201109

18

l-Jetronic

Bosch 1972

Tt-li:; i:=: an electro nic ally controlled fuel in.iection S\,::::tern "Nrliell injects fuel interrnittentl'~l into
U-,e inta~;:e manifol d. It combines H-Ie advantages of direct air-flo',.",., sensing and electronic
prec isi on - \,vithout the need for any form of dri'.,e.

__ , . N N

1. Electric fllel pump.

6. Thermo-time sVlitch.

2. FtJel filter.

7. .8.uxiliary-air regulator .

3. Fuel-pressure regulator

8. Throttle-valve s\'vitch.

4. In.iector.

g. Lambda sensor.

5 . .l.,ir -flol'. sensor.

10. ECU .

lH-Jetronic

, .

'~~~ ~ ~

.....

~'

.. N "

,.< ... ~,. ,~,. )

Bosch 1981

The LH-.Jetronic i:=; an advance on L-.Jetronic, "/olith a HoPl,lire air-mass meter vvhi n,
rneasures Uie air inducted by Uie engine. Trle result of this measurement is independent of
U-Ie air densitv . . . ,'t-lich is itself clependent upon temperature and pressure.

1. Electric fuel pump.

6. Engine-temperature sensor.

2. Fuel filter.

7. Rotary idle actuator.

3. Fuel-pressure regulator

8. Throttle-valve switcrl.

4 Injector .

g. Lambda sensor.

5. Hot-"Nire air-mass sensor.

10. ECU .

19

K-Jetronic

Bosch 1967

Tlii:3 is a rnecrlanical fuel injection sv:=;tem "Nhich constantl '~l rneasures the fuel in accordance
"il/itb Hie amount of air being dra\,vn in b'~l the engine.
<

~. - -""

11<;~]
"Ii

iaT

m4'
r.:::=r__

1. Electric fuel pump.

E;. Electric statt .alve.

2. Fuel accumulator.

7 . Fuel distributor.

3. Fuel filter.

8. Air-flo"N sensor.

4. VVartTl-up regulator.

9. Thermo-time switch.

5. In.iector.

-1

o. /1,uxiliary -air regulator.

KE-Jetronic

VE-Jetronic is simil ar to Hie K-.Jetronic , vI,I'ith a mechanical hydraulic injection s'y'sten1 .

Ho'I,'V eve r, it 'was an additional electronic control unit w'hich increases tlexibility and enab les
other petforrnance entiancernents.

1. Electric fuel pump.

8. .l'.,ir-flo\,(,,1 sensor.

2. Fuel accumulator.

8.

:3. Fuel filter.

-10. Auxiliary-air regulator.

4 _ System pressure regulator

1 -1 _Engine-temperature sensor.

5 _ Injedor.

1 2. Throttle-valve svvitch_

6. Cold-start valve.

-1

Thenno~titne

s\!vttch.

3 _Lambda sensor _

20

Mono Jetronic lMono Motronic

(BOSCH)

r'llono Jetronic is an electronically controlled 10'11," pres,;u re, single-point injection s\lstem for 4
cylinder engines. It features a s ingle ce ntrally m ounted solenoid controlled injector for U1e
entire eng in e The rlea tt of thi s system is the central inje ction unit. ,A, ',,0' ari et\' of sens ors are
used to rnonitor en~line operati on and furnist1 tl-Ie essentia l control pararneters for optimum
mj},ture adaptation. Mon o r'll otronic is as per rnono-jetro nic but also includes ign ition fu nctions
into trl e electro nic contro l unit.

MPI
(Multi Point Injection)

SPI (Single Point Injection)

TBI- GM 1980
(Throttle Body Injection)
Mono Jetronic- Bosch 1983
Mono

2. Fuel fi~er.

Motronic (Injection and

3d . Connector plug v"rtt; irdake-air temperffiure sensj,gn iti 0 n CO n tro I at th e sa me
3e . Throttle-valve idle actlJffior
ti me)

38. Throttle-valve poterdiometer

9 . Engine temperature sen:;:or.

3b . Pressure regulator

9. Lambda sensor.

1. Electric fuel pump .

20

3c . Injector

9 . ECU.
-- ----

- - - -_ ._._ - -

----_._"-

- - - - - - - - --

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

Engine coolant temperature sensor

ECT

201109

21

::'

....
,

~'';7::'

- -

Water temperature
& air temperature sensor

Thermistor

40

20

'
Connector (green)

r->

'-"

OHP 59

'"
c:

....'"

(NTC)

'::2

ECU

'"'"
a:

THW " Signal voltage

Signal wire

10
8

T HW

0.8
0.6
0.4

0.2

+5V
I

- 20 0

20

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 40C
-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 20C

about O.31~O.326 kf! at 80C

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

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 ~

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

..
r'

.:::..~~~
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

~ "~~~

--~=====================-====================~~~-

Throttle position sensor

TPS

r-::",

201109

~>'"~

Throttle position sensor

LinearTPS

""'....

""II" .... ...

~
".

Eel)

'1./V\r<J) j v 1
.....
~

signal

VoJ./"

..

EC'U

Throttle position
sensor

.L

E:

(a) Three wire type of TPS

(b) Four wire type ofTPS

Throttle position sensor circuit

201109

25

THROTTLE POSITION SENSOR

LINEAR TYPE
ELECTRICAL CIRCUITRY

Slider (contact for

IDL signal)
~~~~'--_ E2

Engine ECU

Throttle position
sensor

IOL
............-VTA

VC

.-------~----------~~~5V

VC

VTA R1

IDL R2

~----r-----~--~Wr+B

Slider (contact for

Resistor

E2

VTA signal)

E1

(Closed)
(v)
5-12'-~----------------~

To other ECU{s)

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

....::l

....Q.
::l

2
1

o t
Idling

Fully open

Closed ~ Throttle valve-t Open

2(

Practice again
VTA=?

VTA=?
ECU

ECU

TPS

TPS

E2

Throttle valve position sensor (Toyota)

Throttle valve position sensor (Toyota)

201109

26

How to check TPS

Engine ECU

Throttle Po sition Sen.SQr

Junction

5V
VC

VTA 3

L
Junction

E2

SR

E1

201109

VTAE2 VC

How to check?
Check lamp is on
Read trouble code---TPS
Measure TPS connector--signal pressure DCV is
normal

I Dev . l
TPS
High
speed
position

r----+-lil-'-'-'-'-'--()-~-.J

Idle
I ground
speed ! ~~-+'--''---'...:..:-{'"}-..--,
position '

L. ___ _ _ _ _ _

201109

27

Reference
voltage

Throttle position sensor

r

4.72

:ivL!"..XllilUM

680

mV

?-.1INIMUM

HOLD

1
--------r------T-----,------T------, ------,-------r------T--------------.

e.g. The amplitude of vibration of a poor TPS is

beyond the permitted range for testing.
SV -------t------~------+------~-----_lI

I~'!I'!!!'!!!"'!

-------+----~------+------~I

-------t-----i------t----- I
I
I
I
!
!
-------+-----1----- _. _
I

OV -------+----+-----+--1v I

~OO

ilS

~-- ---

~------

_____Jj___
!~

!!II_jill- - - -

:::

~------ -----~------+------f-------------1
I
I
I
I
I
I

!!

_.:.. __________ ...! ______ ...!.. ______ L ______ !. _____ J ______l.. _____ .!. _____________ J

Normal TPS waveform

The downward surge indicates a possible

short circuit or intermittent open.

201109

Throttle position sensor

I TPS wave in acceleration and deceleration - poor working wave
If TPS is in poor condition, it will lead to unstable idle

speed or without low vehicle speed, insufficient horse

power, or stall when decelerating.

Poor working point

L - - - - ")

20110'

it

Key points for judgment:

1. Start the engine and turn on Ale to make the
compressor clutch connected.
2. Accelerating at low speed and observe Ale clutch,
only when the connection of Ale clutch shows normal
funct.ion wit~ 3500 RPM acceler~jpn indicates that

PoorTPS

Logoff when
decelerating

Function of Oscilloscope
Broken circuit
Short circuit
Poor ground
intermittent
malfunction

~ -it tit lI! ~ :if, f(l l'i.\.

F'I

*-

fll!

-:---...

~e1'"i!!t~;r:mi;
~ .!
11. ~ fi' ~ J;<i
(j/i

.m

r~

IJ/I lifl qo )

-- - -- - - -

201109

TPS will effect the following control

1. Idle speed air control (lAC)
2. Inspection control
3. Advanced electronic ignition control
4. EEC control
5. EGR control
6. AIC off control
7. Coolant electronic fan control
8. AT shift lever and TCC control

201109

29
---- ~

Crankshaft Position Sensor

& Camshaft Position Sensor
CKP/CMP

201109

Crankshaft position sensor

& Camshaft position sensor
'---

f--

( a ) Hall effect type

I-

;--

;--

I--

(b) Optical type

201109
( c ) M)tgnetic type

I-

Camshaft Positior'l Sensor

1

1r'l9i('tt:) ECU

(Shielded)

,- -a- - -,

G2

. =~,
~
. 'Vt.">ri

-~--.- ...,

I
I
I

11

(Shielded)'
-----1

,I
.L.

Crankshaft: Position Sensor

Junction
, Connector

SR

2(

Timing Rotor

.
..d..tSH:::::P-(
Signal alternator -+.JJ tt9tJ:):\j .
I _Timing Rota, (7200

Magnetic induction
coil type

CA)- --l

f\Nr1M--. ---~
. . ----~
10 CA

i
i

2-Teeth Missing

20

Camshaft Position Sensor

31

Magnetic induction type sensor

-- -- --- ~ --- - -,-- -----r--- - --r------T - - - -

II

;I

II

II

~------~---~------~------~------L-----I
I
I
I
I

II

;
:
:I
I
I

I1

+ 5V 'j---jIl---!-J__ ---:JIl---~I.+--I'ol_--

+ 5V r-----!-----~-_IIl_-+_------

ov ~....I!Ik~.i----t"...,...+f----T..._.._::_Hr-----

!!

~\' 1---

: .l:\
I

-~

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

'l

~.. ------~.-------_l------..J

I:
I

_____J____ l ______ L____

l_~2_~~

_L _ ____. __ L __. _____ 1 ______

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

. - .: -.
-

the same

201109

32

- -.. - .. ..

..-:. . ...

Optical type sensor

lvLAX= 4.94 V

)'HN=OOOV
-------T------'-------r------T------,------,-------r------r------.------.

I
:

I
:
l

:
I
I

:
I

I
:
I

I
:

:
I

:
I
I

:
I
I

:
I
I

r------t------1------II------t------1------1-------i---- --1 --- ---1------~

:
I

I
I

I
I

I
I

:
I

r ----- -t------i ---- -- -r------t- -- ---i------l-------j------~------i----- -i

I

6\i L______+_____ ~-----_-:----_--~---_--~---_--~----_--~------~------4------~

!
~

. I

i'

I
I
I

,
:

I
I
I

I
I
I

: :

-.I

r=

r1

"

I
I

I:

:::

0\' ~------,------,-..:--..:..:~ ------,------ ;---..:..:- ,-------, ---..:.-...:, -- ---,---..:.--~

:

I
I

~------+------i------~-------}------i------~-------~------~------i ------l

: ?"'f.;
I -

L_~_~~~L_____ L____

J _____1___J _____J _____1______ l____?j?_~?:j

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

G
>~ I

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

.-L~

Speed
sensor

-v

,
I

To other ECU Is)

SP2E1

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

.---J
~
r
L-.--J
L---.-J

L---.-J

COMPARATOR
OUTPUT

'8
i

i
!
i

A>B

A< B

Hi(1)

--Lo------
-l
(0)

3 - ---- - '

o1J1~~

Mass Air Flow sensor

MAF

~ :,: ~.

201109

"
,.,.
~,,-,~

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

; .'"

201109

36

t.:>-~~

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

Analogy/digital air flow sensor

tr\f Ir------T------T------,,------r-----~-----,-----~-----r-----r------
J.
I
I
f
I
I
I
,
I
f
I
'I
:
"
i
:
I
:
I
f
'.
I
I ,
I
I
I
I
l
I"
I
I
J
I
f
4\11\'" I~--- ...... lI . .-----J,E.... ---.l...I ...
..J._
.. ___ ...I __ .. __ ... ~_
. . ---,I
I
I

I
"J

-""-.-J,...-----J---...

I.

; ____ .. _
_.L

__.

I .

~;

: : _ _ __ ._

_,..;L. _ _ _ _ _ L

_ _ _ _ "1

'

i
i '!
I
I
,
I'
:
,I
II
II
" I
I
o ~-----j.----~---t---~----4-----~--- -- -+---~----i -____.J
I
fit
I
1
f
:
!
fit
!
!!
!!
!
I.

,I

II'

Low speed

fli

Output ttl
voltage

201109

---

High speed

-~
_ _

...:

37

Air flow meter

(Vane type)

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

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

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

f=O.2 x . l

From
air

creaner

~~

...."",---,r=

Pillar (vortex generator)

KARMAN VORTEX

Vortex
generator

LED

Phototransistor

~
o 10__

ELECTRICAL CIRCUITRY

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

Engine EeU
Air flow meter

sv

vc

Phototransistor

Mirtor
Pressure
directing aperture

~enerator

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

KS

E2
E.1

~;,:r:ow

Hi9h_

Phototransistor

II I

........ .........

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

2011~~

38

Hot wire air flow meter

B++12V
Power Transistor

__~... Output

Voltage
Signal
voltage

Platinum Het Wire

N

+12V

2011~------------~~-------

Air mass meter (hot wire) 1/2

..... ,.....

, / / "/

Hot-wire

\VI

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

Thermistor

"i

~~.~""" .

.//

<",?t:.YI

::t'

0-

O~

Pl atinum fl ot-wire

201108

40

____________________________

Air mass meter (hot wire type) 2/2

Engin e
ECU

Air flow rnet er

Ra (thermistor),

.l

Op,e ratio nal

uif"I" :Ii
0. m'" p
" Wi
v r
201109

Engine ECU

r----"'B;;....
. ';;';;
W---i~~1l1J

B-W: . .

21

UE4 Kt-----"B-"--'w---{ E7

- rJ

Engine Room

How to read
the circuit?

RIB and JIB

EEl.
Relay

.\-,

,('

, (:;

.(

\(

'f. /r
~

W- 8

'\"

yV

Air Flow Meter

MREL

L-W

'\,

11

/0"'1

VG

EVG

(a) Start the engine.

(b) Measure the voltage between terminal VG and
terminal E2 of engine ECU connector E8 at idle speed.

Battery

LUllU\::I

Voltage: 0.5----3.0 V
Hint: gear position should be P or N, and AlC switch is
off.
41

How to check MAF

(a) Check the output voltage.

E2
VG
+B
\ TIIA E2G I

\'

I /

(1) Supply the battery voltage to terminal 1(+B) and terminal

2(E2G).
(2) Use the voltmeter, connect positive probe to terminal VG,
and connect negative probe to terminal EG2.
(3) Make the air flow into MAF meter and measure the
voltage change.

(b) Check the resistance

(1) Use an ohmmeter to measure the resistance between
terminal 4 (THA) and terminal 5 (E2).

Resistance:
g~':f

Ii&: ~J:l
13.6-18.4k {1
221-2.69kO
OA9-0.67k n

THA-E2
THA-E2
THA-E2

..'(.9

'-11ft

Jfl.
.~ .

-20C (-.{ 'F)

20 "C(68"F)

6iJ"C (1 '10 "F)

Does dirty hot wire affect the engine?

,0,2 .
0,1
~,,, ....., ., ~ _L~ ........ ~),, ....

,,_,,,s...,.._,_....l,,, ....,,.

. l ..

A . . .. ....

"""1

-20 0 20 40 60 '180 100

(-4) (32)(80)('104)('140) (176)(212)
TEi\IPE1~ ATl'R E'ttF)
A;~:17j

How to simulate a loaded engine?

Air temperature sensor

Engine ECU

fntake Air Temp. Sensor

(Inside air flow meter)

Y-8

E1

(a) Switch the Ignition switch to 'on' position

(b) Measure the voltage between terminal THA
and terminal E2 of engine ECU E8 connector.
'llt~:

i~fUftt it "c CF)

20 (68)

05""'3.4

60 (140)

0.2--1.0

1rt~ V

42

+B

E2G

VG

THA

E2

Intake manifold absolute

pressure sensor
MAP

MANIFOLD PRESSURE SENSOR (VACUUM SENSOR) -

Vacuum

chamber

Vacuum chamber

Intake manifold pressure

Intake manifold pressure

(V)

1 kg/cm2 =0.98 bar =14.2 psi

1 bar =100 Kpa = 0.1 Mpa

ELECTRICA.L CIRCUITRY

Manifold pressure
sensor

Engine ECU
VC

r-----~--------~~-5 V

PIM
E2

El

o
20
60
100
kPa labs)
(760,29.9) {610. 24.01 (31O, 12.2) (10, OAllmmHg,
in .Hg
Intake manifold pressure

__~-' To intake manifold

Silicon chip

[vacuumH

43

Pressure sensor

The type of pressure sensor are

Capacitive type, Piezoresistive
type, Piezoelectric type.

The pressure measurement comes from the

diaphragm deforming or actuation force.
There are many positions in car that need
to measure the pressure. For example:
Intake manifold pressure
Pressure of air suspension system
Tire pressure
ABS . . oil pressure of fuel storage chamber
for power auxiliary steering system
The refrigerant pressure in air-con system
The adjust pressure in automatic
transmission
Combustion chamber pressure for knock
testing
Turbocharger pressure
Common rail type electronic control diesel
injection system

201109

Capacitive type MAP sensor

~1!iU.i!J'M fl.ll

c: ;' -'.:; . -~
1~

',<' '.

:>> ~Hlm~~fl

"

1i:~iii!w.

Df"!i~~
,

. "" ,

!m

ilRt)jJf

.n

Jj{~~~liU:;I
MAP~miiliJ

}!$fit

iJI

~
~

Piezoelectric type
MAP sensor

IHow to test MAP? I

201109
-

- - - - _.-- -

How to test MAP

When the engine is not running- IG switch is ON '

use vacuum gun to simulate vacuum situation, connect
vacuum gun to MAP vacuum input pin. When vacuum
situation changes, voltage will change as well.
When engine is running - observe the signal from idle
speed to acceleration gradually.
1. Use multi-meter - observe the voltage in Dev position,
pressure/voltage will change during acceleration
2. Use oscilloscope - load is fix but wave is not stable
(voltage signal not stable), then MAP might got
problem if no leaking situation.
0

201109

02 Sensor

45
. ---~ ~---

- -

The close circuit in mix ratio

feedback control
Engine
Three elements
Catalyst converter

Air flow meter

02sensor

Injector

ECM

201108

Feedback signal

O 2 sensor

Engine

ECM

ldI:.

Injector

Exhaust O 2
quantity
02 sensor feedback
control

201109
46

Feedback of 02 sensor
The following situation is not included in Close
wiring circuit control :
1. When the engine is starting
2. Quantity increase after starting the engine or the
coolant water temperature is lower (some better car still
can do Close wiring circuit control)
3. Acceleration or deceleration
4. The lean signal lasts for a while
5. Output increasing quantity is changing
6. When the fuel is off
7. When the engine got problem or in limb mode
f :" "

201109

'\

~" ' ~" ~

02 Sensor
Type:
1. Zr0 2 type
2. Ti02type
02 Sensor is used in feedback system for
computer control injection engine, to sense
the oxygen quantity in gas emission and
judge the air flow ratio, then use the ratio of
14.7:1 to be a monitor to send signal back to
PCM.
201109

47

(f\

'J

C\,. (((l1r---~
..
',10'~
,i

1 "

When AlF ratio is lean (high O 2 )

voltage is low(O.l V)

02 Sensor

Theoretical
ai r-fuel ratio

-'-.

\ I '
---.:::--"
\
.j"
;

>

Atmosphere

~--F!ange

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

o J
Richer -

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

~ ,~ ~

201109
49

t.::'''':i'-~

Input A

1416 ..

.~

1216
1016 '

;:.

Idle speed, first acceleration, then

..,

. j:~\ . f\ jJ\Jf. ...

..-1

' 1;:~ ~~' . "~ ~+"-,-;: .~,,,,,,,,,,-c~S

-2.00 s

Keep low voltage :~:::;::d

(decrease injection or off-injection, lean mixture)

2 slOiv

0.072
.0.272~

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_

;>

.E.

2500 I"" """""" "" """!"""""" " '" .. j-.------ +

~:::

-""F~

. .. :;;.;Ooo__

.-"'-;
'
:

i:

i:

~~C. . .I.::.:.::.[...:::l::::::.::I::::.::..[:..::.:.:

':.v1 tiJiiil
o

10

,I:

12

Ip

0- ...

: : ! : : ! ! :

14

16

18

20

22

24

26

28

30

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

I~

I
I

- - -I

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 600F(300C)
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

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

- ~-~=-==
---==========================~=-~
--=
---===-~~~-~
--~
---

Test two 02 sensor

Good catalyst converter ,

Knock Sensor
KS

201109

54

Knock Sensor
.c:

rr,

Ol

Ii ,

: !

Knock sensor

,,

\
\

To Engine ECU

Low -

Frequency

,
-

High

ELECTRICAL CIRCUITRY
Engine ECU

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

Piezoelectric element .

Knock Sensor

Resistance

EeM
Voltage
alternator

:)'--_ _..l

Knock sensor

201109

Knock sensor circuit

(from ASE)
55

Voltage meter

Knock sensor test

3.84
1 5.6

HOLD

PEAK-PEAK

kHz FREQUENCY

3V

----r--j

-- -- 2

i
-- -- -2 __ L_
0-1

.-3V !

REPEAT
TEST
201109

~~~Keys

'"

121loM'

K nock sensor test

How to test if knock sensor is good ?

I What methods can be used?

~ 'A. '"
,

201109

56

~>~

l~he

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.
~ <~

Q&A

201109
57

Inspection of Actuators

201109
. --

_.. - ._-

---.-----

~~~-

Actuator control circuit

fuse
fuse

Computercontrolled power
supply terminal

relay

battery
computer

actuator

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

Duty cycle 0/0

Actuator control circuit, some use the transistor
inside the computer to control continuity of collector
and emitter. It is called pulse width modulation
(PWM), which can control pulse width, and also it is
a control for the duty cycle % variation.
Computercontrolled power
supply terminal

computer

computer

actuator

actuator

Computercontrolled
~_o~ld ter min a l

201

Duty cycle 0/0

The figure below is the definition of duty cycle 0/0.
Note that this figure is a computer design based on
ground terminal control, so the ON pulse width must
be calculated as OV potential. The duty cycle % is
75% as an given example.

OSY'

12V

Duty 0/0

ON pulse width

- - -- x 1000/0
cycle

15 1\0

ov -

75 '0

I...

...

ON pulse width

...
....

cycle

201109

59
- - --

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

Relationship between Duty cycle and

Pulse width
Duty cycle: %
Pulse width: illS
I illS =1000 Jls
1 s=1000 ms

~I

Duty Cycle

Q,Xp

=a +

~ll==

b :P

20m!

Duty Cycle

---

T=a+b

Duty cycle= afT

=TonfT

b= 30ms
20

20

30

20

50

= 40 %
Q

~.

Ratio and calculation of duty cycle

2_011_09_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
- - . - - - - - - - - - -- -- - - -

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

.- - - - - - -

Duty cycle 0/0

Duty cycle == (ON pulse width/cycle) X 100%

o:h

I 40%!

D D D

60%! 40%! 60% ! 40%! 60% ! 40%! 60%

(a) Duty cycle

70% !30o/i

=40%

70% ~oo/i 70%

!30o/i

70% !30%1

(b) Duty cycle = 70%

201109

60

.-_._--

Hz
Frequency refers to the number of cycles per second,
and the unit is hertz (Hz). For example, there are two
cycles within one second in the left figure, of which
frequency is 2Hz. Whereas in the right figure, the
period is 20ms (millisecond), same as 0.020s
(second), frequency is 1/0.02, which means 50Hz
(generating 50 signals per second).

<'11.-

ltp

.l-tP -

' : ~I

'

.
,

- U. "." . :...lJ_ -. ,U._. _. : J~~

u

,. . .

1..---------1
period

20ms

201109

-~-----,~--- . ,- -

---- -,---..- ---------_ ____~I

Relationship between Duty cycle,

Frequency and RPM

[f= liT [

T : time (s)
f : Hz (times/s)
Duty cycle: %

[f= nx/60

I
12V _ _ OFF ON OFF ON

f : Hz (times/s)
OV -----.....I

n:

RPM (turn/m)

x : signal times

I...

-I

Duty Cycle is the ratio of ON time in a period

..........

~ ,,- ~

20110'one turn
61

~'"7<~

~----,------------------------ --------,---

0--0

+12V

+12V

HIIIJ
R

12V

--

i"

ON-time

OFF-time

12V

t-

OFF-time

OV

--

ov

!"'""'-

ON-time
(b) Ground terminal control

(a) Power supply terminal control

This way is used to control AT Measure the voltage signal This way is used
of point A
the most often.
201109
-

_ ...

_-

~~.

----~--

0140-2

CONTROL SYSTEM (L3: INCLUDES AUTOMATIC TRANSAXLE CONTROL I NFtJRMATI ON)

(-

- .\

t ===~tc:-oe
alLJ~
"I
=

'-

./

OATA Ut.K Ctlt'H:C1't:A-2

ClECTlflN

PC!I

101-<0-2091

00<>-2)

~i6'f~~ ~O(E)()

Oi40-EOB
e<ISSIflN 1&0 -'I'RAHSJol<LE !lHmT COR>

0*

0140-209

S1.&DIO

~!HJrrrou

:r

I...

ffi: i
B

62

----

VAi....VE~

SH:lR'i CCKJo)

mm~

[DmcD

c:- - - - -PCM Output Signal

-------------------,

+12V

1 reM
2 Electronic switch
3 Actuator Solenoid valve
4 Switch output signa l

-------------------~
7834/33/ESG

12V
peM control sign,ft--f---4

Adjust of PWM (Pulse width)

(Duty%)
0~
12V

'

6V ----- - ---- - ------ ------ ---- -- - --

~--~--~----~--~--~~~~
Al

12V-

3V --- ----- -- ----- --- -- -- - -------

~~~~--~~--~--I~~
~

r-

A: Higher average
vo ltage (ground time is
shorter)
B: Lower average
voltage (ground time is
longer)

c:

Typical
output signal

PWM

..--

1 Pulse width
2 Average voltage

7834/34/ESG

3 Time

201109

63
------------

._--- - - - - -

Adjust ofPWM (Pulse width)

(Duty %)

-1s

(Off 50%

and control 50%)

B 75% actuation

1s

....

A 50% actuation

(Off 25%

and control 75%)

C 25% actuation

(Off 75%

and control 25% )

...

-I ~

1s

...

7834/35/ESG

201109

- - -

- -

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

Application of Electrical
Induction (Coil)

109

64

--- -- - ------ -------'I

Application of Electrical Induction

TRANSFORMER
(COIL)

Figure 93
+ 12V

IGNITION
COIL

P'H",ARY
IGNITION WINDINGS
MODULE

SWITCHING
TRANSISTOR

COMPRESSION EXI-1AUST
STROKE
STROKE

Figure 99

Application of Electrical Induction

FIXED
OPENING

FLOW THRU VALVE

Fi ure 106

~===--=~

VALVE CLOSEO
NO FLUle SPRAY

Figure 107

AI--+-----o+1 2V

Injector (resistance Rc)

2011 09

Transistor as a control s'6gch for injector

VALVE OPEN
FLUIO FLOWS
THROUGI-1 NOZZLE

Cont rol re la y

OR<M,O

Figure 92
I dle speed
con tro l servo

Application of Electrical Iudu

Engine
control, uni t

r - - - - - - - ----- -- - - ----------- ------------- ----------- - - ---- - - - - ---- ---- -

ISC
(Idle Speed Control)
( Duty Ratio) control/ Step Motor
201109

66
- ----- - - - --

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

BASIC CONSTRUCTION OF ISC

ISC valve

(ldleSpeedConlrol)

Air
intake

cleaner

Throttle valve

Cranks haft position sensor;

Wate r temperature sensor

Vehicle speed sensor

Throttle va Ive

POStTIon

I
,

sensor JI
I

Sta rt signal

A C alternator signal

Ai r-con signal

ECM

---" lAC valve

Electri cal load check signal

I I
AC gear position signal

Brake switch signal

PIS oil pressure signal

l

201109

1
I

Sensors and Signals for Idle Speed Control

67
--- -- -- - - - -- - - - - - -

Starter

Neutral start switch

Vehicle speed sensor

Electric load

Water
temperature
sensor

NC amplifier
Crankshaft position sensor

Type for Idle Speed Control Valve

IrJ

W-i!Ii;~-3:i't

Step motor type

Jltlt{l ffi *w.J~th1iitm. 79i~HI~~~

;i:.
Jltlt{lnEB~*iT*~~m:lr~*~
fii':tt1Wl ' ~JIt ' t~~*iT1Ei1f~[J~

OUT

mt;~

IN

, Ell6ftt1WH:i~;i:

m
IN

c. Linear move
magnetic valve
o

m:lr~ Valve ~ *iT Rotor ~ !@(lCoil I9 li~~ Magnet ~ Bimetal

68
---

-- - -- - - -

-- --

~--- -~-----

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

-- --- -- - - -

Linear Move Solenoid Valve

Computer
PCM

Linear move solenoid valve type

lAC valve
Computercontrolled ground
terminal

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

_._-

- - ..

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

DUTY-CONTROL ACV TYPE

---

--

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

ON-OFF CONTROL VSV TYPE

From air cleaner

-+

From air cleaner

..

. . To air jntakt):

chamber

i-

Solenoid coil

To air intake cnamber

DUTVRATtO

10ft)

LOW DUTY RATIO

, --"-.1

(01'11

Duty ratio ('Yo)

o
B

=A

A
+

: JlJUUL : J1flJlJL

B x 100

{Off}

1 cycle

A: Current flows (on)

B: Current does not flow (off)

69
- ---- - - -- -- - - - _. _-

HIGH DUTY RATIO

(On.

(Off)

Regulation for l AC Pulse Width

DUTY Ratio

201109

---~

-- ~ -----

~---.

~~.

ROTARY SOLENOID TYPE

CONSTRUCTION
Bypass air pa.s sage
Throttle valve

Bimetal
element 'Sl;m>:~

Sensors---r

Coil:T,

EngineECU

A-----<ftsC1
JSC2

From air

To air intake

cleaner
J}

chamber

o
~~L--

Sensors

Bypass port

'A----4-+-- +8

Valve

To PIS idle-up air

control valve inlet
Cross-section A-A'

L ___________

70
-------

--~-----

---- ----.

---

Rotary Solenoid valve ISCV- 1 coil

Permanent magnet

to Air intake
chamber

from Air cleaner

A-A cross section

Coil

ROTARY SOLENOID TYPE ISC VALVE

- 2 coil

Engine ECU
ISC1
(RSC) V

EFI main relay

lSC2

ISC valve
L

UU

(RSQ)

'-----'

+B

BATT

El

201109

----Sensors

Rotary Solenoid valve ISCV

Engine ECU

8
4
21
'--_S-:_W
_ _-J~t--_-=B-,-W~-( E7 MREL

Engine Room
RIBand JIB

E.EI,

Relay

+9 (+) RSO

EOl

ISC VQlv~
DUTY 1

l----",B,---=2=-t vise GNO' 3

FL
MAIN

,.,

201'

B-L

W-B

- . Junctlon

W-B

Battery

-'-

- - --..-

.. _ -

--1

Longer ground time

indicates faster idle
When AlC is on,
ground time will
longer.

...--------,
computer

PCl\I
Linear move solenoid
valve type
lAC valve

-72

tepper Motor Type Idle Speed Control Valve

be rotation of stepper motor will increase or decrease the
gap between valve and valve mount, to adjust the bypass air
ow.
The amount of bypass air flow adjusted by step motor is a mass,
so it can be used to control high idle speed and don't have to be
used together with other air valves.
Idle specd
adjustment screw
MAFmeter

Throttle valve

From air cleaner

Air intake chamber
sensor

ISC
valve
To cylinder

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

--

STEPPER MOTOR TYPE

ISCV
Air flow meter

ti
IL_ _ _

Sensors -----..l

____

Small _

_ _ _ __

________

Number of steps _

Large

CONSTRUCTION

Valve

" To air intake

,

'chamber
Coils
Valve seat
Valve shaft

Stoppel' plate
~-' .\

2.

From air

~~w meter
73
- ~---- - ----- --- -- - -

STEPPER MOTOR TYPE

Sensors

Engine ECU

ISC1

BATT
Microprocessor

ISC2

+8

M-REL
Main relay

lGSW

control circuit

E1

E01orE02

l...-..~";';;;";;'"

201109
- - ----I

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

The influence of short circuit fo

step motor resistanc
Control relay !

(j

How,to test j

1.25
R-

00 - 1 is)
Idle speed
control selVO

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

LG

y i

R-G
1G

Engine
control unit

74

'1

' 4

Y-f...

' 25

, 14

'\K-- .

Injectors
i

I
I
!

i
_____ I

~ <~<;: ~, I

201109

~""'~

--------------------------------------------------------------------~--~~~ I

- -- - --.-- --- ---- - -- - - - - -1

----------------------------------------------------------------------, 1

+12Vo--+-.....

Measure the wave

ape at this point

12v

ov

H
ON

ON means the on-tllne for injectors

.)fall ON/OFF 119&iIU!

(b) Jlf,;lJ;'J

Illilllll~*.lIi

( 01109

75

The influence of poor ground for PCM

-tt--+----o+12V

Injector (resistance Rc)

5VJUUL
H

!fv-,,,,,''''--'I"""''I

OV

Sms

..-------G+12V

I
IIE

What does the poor

ground cause?

The influence of inJ

resistance chan

Transistor as a control switch for injector

How to check it ?
Case 1 . How to confirm the injection of injector?
.

No.1

ECM

Main relay

socket

What are the eight ways?

Four ways each in both
Chinese and Western
Medicine

injector

(a) appearance

(b)

How to check it ?
What ways? Which way is faster?
What tools or instruments are used?
Case 1 : How to confinn the injection of injector?

>- What are the reasons that point A

and B can not be touched?

>- The way to test injector is

working properly or not :

socket

II
-

::

1\1

+l2V

Injector control
circuit

+12V

x:.
77

The standard wave for injectors

M

Back Electro Motive

Force (around 7 xlO V)

50

tInjectors drive time

t'

tVoltage

.
,
, Time
1------11----7FU1202

2CJllU!:I

- - - - - - - --

-- - _._-

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

-_.

- -

_._-- -----

-_.

Wave Analysis of Injectors

If there is messy wave
here, it means the
elasticity might be
weaken or broken'
the injectors need to
changed. _- - -- j

Batte
Voltage

Ground should be a linear wave and close to OV ' if there is variable

messy wave, it means other electronic signals interference exists or th
transistor has malfunction inside the computer to drive the injectors
201109

.
a poor ground In the cOInputer.
78

Fuel injector

3.20 ms
7a4 v

IN.JECTION PULSE

HOLD

MAXIMUM

'180";
;

-80

Self-induced voltage of nozzle

edge of the circle

-~8

jector driving time

48

INJECTION

i~~Keys.

VEHICLE

~ 12'l1@:J '
MOVE

DATA

Fig. Fuel injector

c-- -

----

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

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

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

Time of injector driving

"

1\

"

; I
,

..
I

When engine accelerate

suddenly, injector driving time
will be longer at the beginning
and then will be adjusted
according to RPM.

.---

---

-- .. -

Idle Speed
Acceleration

2.Sms-7 >8ms -7 2.Sms

IThfthe injection time doesn't increase suddenly and cause the engine vibrati~n:e probability is the breakdown in TPS sensor or in air flow sensor (MAP "'
MAF)
I~ ~f the injection time increase suddenly in normal situation, but the engine still
tho~e~n'~ ~ork. The probability is the breakdown in oil pressure regulator or in
20 JQ9"' IgmtlOn system,

7 ::: ",

I'---

~ ,~

79

__

t:-:--------------------~------~~---~----------~~~~~~~~~~~~==============-=-=-_ -=_-=_-=_-=--..J~~~_. .:.:.

...A
___- _
. _

Wave analysis of injectors

Procedure for injector test :
I .Start the engine' stay 2-3 minutes in 2500RPM ' until the en
is really hot and the fuel feedback control system become close
wiring circuit, then observe the signals of oxygen sensor in
oscilloscope.
2. Tum off air-con and all auxiliary electric equipment, put the s
lever to P or N, accelerate slowly and observe the corresponding
increase for the time of injection driver injects.
201109

Wave analysis of injectors

3.Add Propane from the intake pipe to make the mixture rich. If
system works normally, injection time will be shorten to adjust
rich mixture. (the high voltage of 02 sensor will be varied accor
to different car company)
0

4.The vacuum leakage make the mixture lean. If system works

normally, injection time will be longer to compensate the lean
mixture. (the low voltage of 02 sensor will be varied according to
different car company)
0

201109
80
~--------------~--~~~ -- -----~ - ~---~ - ~--- -~~-~ -~ -

Wave analysis of injectors

~.Increase

the engine to 2500prm and stay stable. In

most fuel injection systems, when the system control
air-fuel ratio, the injection driver time could be
adjusted (changed), from slightly longer to shorter.
Usually injection driver time, from completely rich
(high voltage of0 2 sensor) to completely lean (low
voltage of O2 sensor) , the time range just between
Oms to 5ms
0

; .. ~
~.~._:./~

2011 09
. __ ... . _- -._----

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

I
I

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

Wave analysis of injectors

~

Observation of injection timing

O~servation of injector wave in the oscilloscope, the most important
pOInt is in injection time and the judge of air flow ratio feedback control
Below are the observations of wave shape :
I.Become rich after starting the engine in cold
2.Become rich after warming up (fast increasing)
3.Become rich after starting the engine
4.Basic injection amount at idle speed
5.Become rich rapidly
6.Become rich in full load
7.Stop the fuel in decreasing speed or lean control
8.Injection correction in close wiring circuit control

~ ::: ~

201109

81

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

Check the fuel dripping in injectors

Stop inj ectors actuation
and check the fuel
dripping in inj ectors.
Standard valve : no
more than one drop in
5,...,12 minutes ( Altis)

IrIlICtur
,~-...
'

201109

------ --~

~ - .-

Carbon Deposit in Injectors

Why there is carbon deposit?
How do we know there is carbon deposit?
How do we clean carbon deposit in injectors?
What is the influence of engine from carbon deposit
/aged coil/short circuit?
How do we clean carbon depsit in combustion
chamber? (the wrong way commonly be used)
201109

82
-

- -- -- ~-- -

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

Fuel pump circuit

Fuse

Fuel pump

Fuse

IG S.W.

Relay

Battery

How to check?
201109

I~~.'W

<>----0

.mlIHi~JIllili

~l"tilli~
~
D...

NO>

-- .~ --~ -- .

201109

83

20

What is the function of vacuum tube?

What will happen if it blocks or breaks?

injector

Pulse buffer

t
Pressure regulato

Fuel cleaner

Integral fuel
pump assembly
Fuel pump

201109

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

Ignition System

.:

, .,

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

~ -

201109

----~~~~---

-----

--~---

- ~ -

- -

History for car ignition system

Platinum ignition system (with distributor and advanced vacuum
mechanic eccentric equipment)

Transistor ignition system (with distributor and advanced vacuum

mechanic eccentric equipment)

Microcomputer ignition system

- with distributor : but without advanced vacuum mechanic eccentric
equipment ' ignition time is controlled according to the signals by the computer

- without distributor
1. without distributor ignition system DIS
(with high pressure coil- 1 coil control 2 plug or 1 coil control 4 plug)
2.Direct ignition system DI (without high pressure coilignition coil is installed in the top of spark plug)
~ -- ~

201109

85

~--~~:;;.

RPM and piston position

Crankshaft position sensor

t
I

Air flow sensor

Intake quantity

-.-- .--...-------..-------------. - Engine coolant water temperature

- Engine coolant temperature sensor

Throttle valve position sensor

,

Throttle valve position

1 Start signal

r Ignition switch

I igniter

Neutral position

!
I

ECM

Neutral position INeutral start switch

I Battery voltage

I Battery

I
I Vehicle speed

Vehicle speed sensor

_

.. ....

... ... ........ "' 1 Engine knock

Knock sensor

Sensors for controlling ignition timing

~ .,.

201109

..

"

"

~ ,--;.('
-----

_._.

...

....

Microcomputer Ignition Control System

~
MAFsensor~
IAT sensor

TP sensor
CMPsensor
CKP sensor

;~

PCM

'\

Advanced
electronic
ignition control
(ESA)

ECTsensor~
KS knock
201109

Ignition coil
PCM control 1st
circuit

sensor~

.... -~

'

86
-_._-

F~g~ 1>'===="'-:~-...,~::,===="9I

BAiTERY

+12V

IGNITION
COIL

PRIMA!W
IGNITION WINDINGS
MODULE
CONOENSOR
(CAPACITOR)

cc
01

HR
RV

TC

BAm~~ <1'===~

01

LT

SECONDARY
CURRENT
Figure 95

SWITCHING
TRANSISTOR

COMPRESSION EXHAUST
STROKE
STROKE

Figure 99
+12V
. FROM
BATTERY

SWITCHING

t_~:NSISTOR
SECONDARY
CURRENT

iO

DISTRIBUTOR
CAP AND
ROTOR

BATTERY

201109 Figure 97

Figure 98

The influence of poor actuator ground

+ 12 "V
Spark plug

Ignition coil

What does poor

misfire cause?
How to
check?

Ignition module
(computer)

201109

87

Ignition System Application/Test

secondary coil
,f'

~OCPS)

Ignition coil
Primary coil

PC~l\I

i-

1<
:;arkPtUg

I How to check? I
Be careful! Do not connect to the
wrong pin, otherwise ...
201109
- -- --

---

Three wire type ignition coil

PCM
C

I How to check?

201109

Be careful! Do not connect to the

wrong pin, otherwise'
-

- - - -- -- -- - -

~*-MM(IG1)

28-)1

r---ii<-~r=1l ~ K~ 111(1 )

.--------;':-----;r==:tl xt *-.. mI (2)

<JE:Im

<lEIIID

B-G

I El.W

~
~~lL_=-====-=-=-=-=---~-----==f~~
. ~r-5V
____-____ ~~t~~cu

B-Y

I"'"

12

G-'tol

43

1.25B

17

L:21______=-====~(C~-~m~8}~~===~~~~~~~~~~~=-~=--~- i
J~

.~ ~ (1m3) 6 &....

Jr/jf--

+12V

#3

+t2V
89

Ii

Two wire type ignition coil

peM
Ignition transistor installed

I How to check? I

Ignition coil

Two-wire ignition coil

";'

IG1 -- --

--i

lii!
Spark plug

TOYOTA DIS (Direct Ignition System)

G2

CMP

+B

I!

... '

IGTI

~_NE_ _

CKP .... 11--

IGT2
JIoo-j
"' 1

IGT3
Other
sensors

Q------+-i

... 1

Q----t---+-i

IGT4
IGF

"
....

201109

~
,~.

90
-~-~- - ----------- ~-----------~------~-

TOYOTAJ~: *

Four-wire ignition coil

+ 12S

IG-F

IG-T l
R-L

B-\'.'

L-Y

2
3
4

It

~),

Sr

*JIi1

~.~

ECU IG-T2
Y-G

ALTIS

-.

..

r-

\>

... 8<

IGF lG T GND

Spark
pI ug
N 0.1

~, ~

'.

201109

-_.- _.-

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

..

----- - -

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

Ignition secondary wave

Key points for ignition waveform judgment

2011 09

91
.-------- ~ -----

--~ ~--. ---

- - - - _ ...

' 1

"..........

3613* .

5.

201109
----

- - -- -

---

- - -------

Ignition secondary parade

697

HOLD

RPM

25kY

28 1

15

18
5

VEHICLE
DATA

201109

1 *1

.;

.~.Keys

SINGLE

Secondary ignition Jlarallel waveform

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

----- - -

Wave analysis in malfunction situation

r--~'

20kV

-----r-----.-- ---,-----r ---,--- --r----....,----- 'T-----r-- --,-----...

j.
I
:
t
;
I
:
1
l'
I
:

1:
:.
:
:
r~==-w. i=~ ----~t--------:

..

------1-~,..

:
:
:
:
:
:
:
f
.. ~t~
... ~~i=-W
~~~ t ~- --- : ~-- -i-~ow=wwt~ ~~~1=~~~ . . 1

-i

:.

!r - - - - --c-r - - --t------t't
: -----i--1
: - - - - - -{-, ----f"I -----t---:
I
:
I
~
- -J
--t-----t-- - --_-t _____ J
t
~
f
:
:
!
:
:
:
I
l
~
:"

i- _. t
-;
1:'-- . -- -",... r."--- ;
_.- - , - - _ ..- , _.._. - -~
f
t
~
I:
I
f
I
I
~

-r _.. _,. - - -,.- _. _..- '1' _.. _.. _ .- -T" --- -

- .~-

-" - -T"' - _ .......- -)_._. ---"_. -t

I
I
J
:
I
~
J
I
I
I
I
I
I
:
r..----l- ..- _.___.L ____ __L ____ .~--- -_L____ J_.__.__ .1._. ____4 _____ J _____ 1.._ - -.-- J-----i
~
t
~
:
1
:
:
I
1
-I
I
:
I
tit
:
:
~
:
:
I
:
I
~
:
".' - ..~.-... - -..... -~ -.-..-.-... -:..- - .--.- ~-..,- ... -- .-.. ;..._._.. .- -.-...~-.. ~ - - .....~ .......... - -~----- ~-.- -.- .f.._.. ~....... -T" ._--'"_._- ~
10kV
:
:
:
!
!
:
:
:
1
!
:
:
;
t:
;
I
:
I
I
!
I
. I:
:
!
f

-1.-- ---f-----+----~--,--t-----+----+----+-- - --l----- f-- -~-+-----I

~
.

I
I

,1

'-.. ~ r'~

I \)

.J

' \.' ~

l'
v
I

,~.

... 1

,:

I
I
I
1:
t_- _ _ l-_--..-i .::;-'.-.-1---- ...--- -t-----'"1~ -- .. t..--:1::.1---'" 1------ t_- '"1
... ~
I
I
I \)
I
J

I
t) '" I
I
I
I
I:
:
!' _,/ }
:~
:
:
~
\ l
l
:
:
:
---- i:----i----.-----{---- ,...}------{----+----+-----t---"""- l
}-- ----i-----.:t
1_
~/
l
,
1
J
I
1\
i
l. j

OkV

~--

"

:.

,I

___ L _ ___ -L ____ J _____ 1... ____ .J_.,. ......

:
:J"
--..L----f-,

\-

:I .

" --!-----1r

:
I

f,.--- - -"'1- 1

f: _____
L

- - - , . _ ...... - - -1- - - - - - ( - - - -

-t-------;-- ---.. . . . . -----t>----- "'t--- --.:..----~1 . .---- j~

I ____ ...L
I ___ _ ...iI__ ...,,--_1..t _ ..... __ J J___ __.--.~
J I __ .-, _ ..... L[ ____ J f_____ ..l:1_____ lL __ ,..._J:_____ ..l

so

100

20

40

60

201109

Wave analysis in mulfunction situation

:--- --1-----;-- ----;-----T--- --;-----i----- r-----r--- --;-----r----1.-----,
I t !

I.

,I

.'

t-----i;-----t-----t-- ---i- ----r -----1--- -\t~-v:r~t- ----i--- - -t.... ----t- ----,

!r-

l'
I
I
t
~ -----1""'---I
: - --'1"I -;---

- - - - t-

t.

t:

I
I

I
-:

J
I

I
I

.!

!.

:-

I
::

\k

----I- - - - -

--1-- ......
1 ,,(

t;0
I
;
It.:
I
I
: - - - - ;r- - - - __ J I
.---T-----t---,:.--- - -'1'"'-

( !

I
I

I
I

I
I

I'
I

I
I
I

... -----I-----t-----+-----I-----I"-----1-----+ -----I"-----I-----t----+----~

:
;
;
: </~
: ::
:
,:
:-: ____ J-~ _____ L
__-_-1--~l_--
l:_'-__
-'i_____ l~ _____ :L____ J--__1-__ ~-L----_f

10kV

f:

- --" _ ..... __ .... r - - - - '--r--

I:

I
I

",

i ~ ', ) .i i i
-, :T~ --\.J - - r: - - - - -:, - - - - I
,->'"1

II ,''{t\.J

I
I

i.
:

T- - - - - r -

I
I

II,

I
I

'_

it:

!
1-

I'

[:

,I:

II

- - - -, - -_ .... - r - - - - , - - - --.....

II

---1:-----t-----t-- J--1-- --1----1--- -t-----I--- 1-----t----:----l

::
:
/t
:
:
:
:
:
:
:
~
I
~---- .... !--. L-t--- --~~-~~-"":--'-'
I------:--~ -: _____ !._,... __ L ___ ..... J
~
! rI!
l
~
~!!~:
:
l
I ~
I
I
l
I
I:
I
r
i
-~--~-~~- ---~- --~~---~~-------~--- ~ ---}---- ~-- --~
~
I
J
I
I
I
J
:
i
:
l .
l
~
-t
:
I
1:
:-----r----1----;--. - ----t------t---- ----l
I

OkV

t:

t- -1:-----r----T----1-----r----l-----r-----r----l ---:----T----l
::

l __ ~~J~ __ ~_L_~ __

100

80

I
'
JL ____ l~_~-_L~~_~~~~-_-l_~ __ L~ ___ J __ ~~_l~ ~_~j~~~~~~
I

60

40

20

201109

93

Control Circuit of Coolant Fan

201109

----

---

----- -- -- -

fuse

Coolant fan motor

IGSW

relay

Thermistor
tern. switch

battery

I-

fuse

Coolant fan motor

fuse
relay

I G SW

battery
...

PCM

20110
94
-

_ _ __ __ _ _-tL--_ - - '_ __ __ _ __ __ __ __ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ ___ _ _

Control Circuit of Coolant Fan

::tl*~#,f,tij~;g

::tRe1.-INJ 20A
~ (\Y.l'. ~t

Main relay

Fan Control Module

Coolant Fan Motor

M~ ~------------------------~_1 _~~
-

--- -

--

--~

----~--

--

-----~--~-

------

---~---

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

Control of Coolant Fan

-..

ECT SENSOR

PCM TEMPERATURE SENSOR

..

TP SENSOR

...

VEHICLE SPEED SIGNAL

INSTRUMENT CLUSTER
REFRIGERANT PRESSURE SWITCH
(LOW PRESSURE SWITCH,
HIGH PRESSURE SWITCH)

-....

If interior temperature of
PCM is higher than lO5 ( , ,
stop AIC compressor and
actuation fan.

...

REFRIGERANT PRESSURE SWITCH

(MEDIUM PRESSURE SWITCH)

BATIERY

PCM

.....

(AlC ON REQUEST SIGNAL)

FAN CONTROL MODULE

...

201109

95
~------~----

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

---~ -

-- -

Fan Control Module

+12V

12V

ovl.f1f

f!E
iti!1

Fan
~ motor
~

tI
5\7 "Jill"
.. . . .
Fan !

ov

.,

PCl\] .

B
Duty

trol

--

is used to control RPM of fan motor ~

Fan Control Module

Key off
DUTY%
DUTY%
DUTY%
DUTY%
DUTY%
DUTY%
DUTY%
DUTY%
DUTY%

0%
10%
20%
30%
40%
50%
60%
70%
80%

Voltage
Voltage
Voltage
Voltage
Voltage
Voltage
Voltage
Voltage
Voltage
Voltage

B+
B+
12.25V
10.8V
9.5V
8.1V
6.7V
5.3V
3.9V
2.6V

DUTY% Up
Voltage Down
Fan tum speed~
DUTY% Down
Voltage Up
Fan Tum speed Down

Measure the voltage of fan control module by using the gauge

201109
(ground terminal)
96
- - - - - --

,.~

6V

------ ,- ----- ------ ----- -

Average voltage

------1- - -

Shorter ground time, higher average voltage

12V I - - -

3,\1

---1------ - - -- --- -- --- ------

Average voltage

Longer ground time, lower average voltage

201109
--- -

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

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

PCM

Fan Control

90%

High (Duty 90%)

-Temperature

no!"

-Temperature

Jr ll~--------+--------------+------~
TW2
(1 DDOe)

97

or

.....

201109

> 100 C
/

TW1
(98e)

Water temperature

output duty

Coolant water temperature control

Low (Duty 10%)

- - --

< 98C

EEC/ EGR Solenoid

201109
- -- -

---- -

- -- -

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

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

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
- --

- -- - --

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

ON/OFF Control type EEC/EGR Solenoid

~
Air
dea nef

Canist.,

OFF

...

Oil!

Purge control
solenoid

"alve

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

201109

Solenoid Control
Duty Ratio control type
+12V

8fjijf;Rfiil

5V

ov

SV
5V

3.5V

OV

ov
ov

5V
5V

D/A ;M;,Q,!JI[ t-----1

_w

OlIfF

aMY

201109

99
~--.- .--

I _

EEC/EGR .

Solenoid valve

EGR Valve Step Motor

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

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

---------0----

___ _

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
, - - - ------------ - - - - - - -

- - - -----

EEC

Fuel
Tank
Cover

~.

\/

p"~

Throttle
Valve

Fuel
Tank

Main Relay

Solenoid
Valve

Sensor
Signal

ECM

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

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

._ - - - - _.

Evaporation (EVAP) Fuel Emission

Control System

,2

-- - -

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

Fuel Tank cap

Check valve

Active carbon
can

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 60C {140F}

(3)

RPM is over 1000 rpm

(4) In close wiring circuit operation or high intake

efficiency, engine is during heavy load.
I

201109

~.- ~
.- -_. _

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

. --. --

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

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

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

LG

V '

R-G
29

.-

"--~

..Q\aI:

~ ~~~

15
.

---- -

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(
.

.
"

.
"

"' , ",'

-"'.

"

<.

4(10)"

,"

" ') ~ Fi1l III tIle ,raInes'for the ':" .. ". '.'

. resi~~Ol;~RltoR3
r~a.d:the
.te'suits. forill'e difreren:t : .

and

-",

. ioniu~ctions . :
'.:OJ,,,,:,.,,,,,,,r':'''''i.~=:;'<;'''i

R2:4
R3:6

I.&.
.

.
's

.n.
.n.
.n.

R1: 2

".

'

,:::."'=.$=":""=""~~,""-~=,,,,=,,..a""'..1'';i:~~':.': :

.n. 1
1.091 .n. 1<.

: Serial res. =

12

Parallel res. =
'.The'. ~ralue

O.~~h~n1~d. like' all .' .

:hlte~ptirillat '~ffi'all~l: :'. ~ . .':' .' .. ~

. '. c.~im~ctioll:~ -': ',: '>:

- - - - . - - - - - - - - - . - .- - - - ..

-~

. ...

.'

-------

; ",---.- --,. I
. ohmmetern

Testing resistance

Testing resistance

120r~

120n

equal

r
ohmmeter .Q

-+
ohmmeter!1

~4.. 1?OO
- - ..a ..
>.,.

120f~

J
108

Human body
resistance
I .----------, I
ohmmetern

The application of resistor in series/ in

parallel on vehicles

CANH
CANL

CAN structure
201109

Divided Circuit
Sensor

PCM
>R1

R1

20hm

+5V

V2

<

_~5V

>R2

<-

-~

Vs
<

Signal
voltage

R2

Iv

3.000

30hm
;:-

l-=!:-

201109

~~~

109

-----

- --

- --- - - -

Divided Circuit
R2

R1

1.000

70hm

I
V1

IA

50hm

5.000

Iv

12V

201109
- - - - -- - - --

The influence of poor ground of sensor

PCM

PCM

Sensor

THW Signal voltage

1 signal

R1

+5V

<R2

"'>

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<ing, poor
switch junction,
filament burning
out, etc., will
cause the entire
circuit failed.

Fuse burns out

connectors are Filaments burn out

IOb~ .

Broken circuit

201109

111

Short circuit

I~

\
Shorted to ground (before load)
(0.)

Shorted to ground (after load)

Shorted to ground

(b) ~ Short circuit poor load work

(c) Shorted to power supply

Short circuit

201U

When switch is on but the bulb is not lightening,

how should we check?

Switch is on but the bulb is not lightening

bulb
5 6
4
3
8 9
fuse

switch Connector
A

SWON

Connector
B

battery

201109
112
-----------

--

- - - --

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

When switch is on but the bulb is not lightening,

and the fuse keeps burning out, how do you check?

~-2~~~:-

. ___4

~
.t

fuse

SWI C.h

6~

Conncctor
A
bulb Connector
B

S\VON

I
_

battery

201109
<
.:;:..?I.:

\ ','_ 1.:.

1...-"

t,,~

~ ... -

'-",.\

l"

-"

...

I " . ' ... .,."

. . . -"

..............'"

When switch is offbut the bulb keeps lightening

(can not tum off), how do you check?
2
r----4:T

.D-----c:::t'-. tI

__ ~se

sWItch

'-\1/
6~
Connector

Connector

bulb

S\VOFF

battery

7__

201109

-~

113

"\--

\-0

"I -,f'

i-'

. ,,_,/ "

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

I~

'L_

..... --------

Try shorted to ground by

Try break circuit by

uSIng tester

using tester

~01109

~;:

Reasons for poor ground ?

Poor ground screw (can not lock tightly)

Poor ground contact (rough, with paint ... )
Corrosive ground(rust ... )
Poor ground- copper wires cut off or resistance
become bigger due to copper wire aging
Cross sectional area of the ground strap is too
small

201109
114
-

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

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

How to test poor ground

-n
- Dev

scope

If------I----+---I-OV

r
~.

---..

.J...

~.~m~~D.~~~ov
-.-- ~

.---- - ------.

- .-- ~ -

'

------ -.-----..-- :l
r

~.

The influence of poor ground in actuators},

I
,:I
.

+ 12V

Howto
test?

What will
poor misfire
cause?
Ignition module

201109
115
- - - -- -

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

Circuit Diagralll skills

The switch or relay painted on general circuit diagram is at
that situation without power.
Car circuit is a single system, and every electrical
appliance (load) is in parallel, but switches and relays are
in series in the circuit.
Most electrical appliances (load) need protection from fuse.
Diagram system can be read respectively- power
(including alternators) / starter / ignition / lighting /
instrumentation / all the circuits within electronic control
device.
201109

Circuit Diagralll skills

After understanding the diagram, the principles of
the system should also be understood; do not
blindly dismantle or connect without concern.
As maintenance, the part of higher failure rate /
easier for checking should be checked first,
dismantle as less as possible or do not dismantle
parts.

~ :,:

201109
116

~>G

Wire line color code representation

Two-color wires are represented by double letters. The first

letter represents the basic color of wire; the second color
represents color belt.
F or example, WIR is white wire with red belt; BRIY is brown
wire with yellow belt.

Symbol (for example)

wire with color belt

wire with single line

I
I

I
I
1
i.

W /R
( IF )

fF)

white (basic
color)
red (color
belt)

( ) represents the symbol at wire harness position.

II

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

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

----=-""""~
I
I

European cars

Japanese car line and color

Color
BK black

Color

Color Code

Color

BN/BR brown

Color Code

WHJWT white

Black

Orange

White

Pink

Green

Red

Dark green

DG

Violet

Light green

LG

Yellow

Blue

Gray

GY/GR

Dark blue

DL

Brown

BR

Light blue

LB

Tan

Sky blue

SB

OIOR

YEIYL yellow
BU blue
GN green
GY/GR grey

...

PK pink
RD red
OG lOR orange
LG light green
NA nature
SR silver

~
"

201109

VT NI pUrplE
117
-

---- .. ---

---. -~---,------

..

--.---

:::.-~:;<~

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

----

Engine room fuse box

R-W

'-~~--7r------------~~----4MREL

Intake air temp. sensor

r -__-+_4~~~~ ~
.......I\I".IV\,-+--=:---1--:--4

E.EI.

E.F.1.

51

JIm

relay

W-8

battery

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

TPS

ICl\I
1

+5V

power
3

LG

signal
2

BR

ground

TPS connector

Light

ttl
fu

f*
fu

brown

Jfi yellow
fu

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

. ",\
I!"

TPS

\,. .\ 0 '

Engine ECU

Throttle Position Sensor

5V
vc

VTA

VC

VTA

Junction

E2

E2

SR

E1

201109

\
VTA E 2 VC

<F>28-W

<F)2B-W

(F)2Y-G

<F>2B-V

(F>2fFW

2
~
4

<F)2Y-G

1. 25B-W

(P)2Y-G

<F>2Y-G

B-L
(F}2Y-G
1

<&:5.5)

11lUtlt ~.fk

*41iJ.

20110

L:-c0

119
- - - - - - - - - -- -- - - - - -- - - - - - - - - - - - - -

7~

1.258

r--------------------------------------------------------------------------------------------------------------___

(p(Cl;J>7

l3l

.ere $SON

(L3)

rnot-! TER<!fIAL S!O!1;

I
._ - _ . _.- - - - - - -- -

- ----

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

120

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

Introduction to Electrical Wiring Diagram

&
Trouble shooting for electrical circuit
2/2

201109

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

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

lIT

LOCK
ACC

ON

II

START

(a)

201109

AM ACC IG

ST

A.
~

,...

'"
(b)

""

-!

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

(switch diagram)

(switch form)
Wiper switch

'"

OFF INT LO

HI

2
3

4
5
6

WASH

10 Q 0
10 0

-
)

() 0

fNT .

LO H
-e.. I

. .
"WASH

OFF

()

INT
/

Wiper switch

OFF

Turn on the two

switches

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

Fusible link

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

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

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

ECM

-- -.-

-- ~-

----

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

- - -

---~

--.~--.--

--_ ._. __ .

llill 6 I
Circuit check procedure -2
ECM

Ground check

Resistance test

1IJ5

I [ill I
ECM

ECM
(C)

(Al

(61)

~9:D~

[3

201109

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
_

-Use thin wires to prevent terminals from damage.

-Don't damage terminals as inserting probes.

_ _ _ _ _ _ _ _ _ _

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

~
132

_ _ _ _ _ _ _ _

~'I

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

How to test current leakage

(J/0

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

~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 .

l'

--

. .

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

--

85
30 ..J
L. __________

8....6.. .

I .

I ...

i.

IJ:

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

87
18687a8s1

130

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

r---:---_ .... ;t

1-

J..... ~~7a 1

'. ~. 1....

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

135

. .

130

- -,

8530
L--- ________

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

201109
-----~ .

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

CONTIN U ITY

"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

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

-l-

I
I
I

'~a5!~

U-

wt~~

~~~

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

f i ..__ _ <r---_m_~_~

1_

-+---1

. v-./' -v +~v

wt~~m

- -- --

Accelerator pedal position sensor

Throttle position sensor

2011 09

141

Hall type
PCM
PCl\I
,...-----o---l-()-----o +5V

+5V

lmlbJtUAPPl

.---0----o----i - ]

' - - - ( ) - - - - - - o - - - o +5V

Accelerator pedal position sensor

Throttle position sensor

201109

ETCS
Hall type throttle position sensor

Throttle valve open

201109

142

3 types of Accelerator pedal position sensor

& Throttle position sensor

A.
~

11

4 .

t.J

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

:.

L-L--L-..l---L-L
.' ......
\ ....,.,4 ......-L--

Accelerator pedal stroke

Three signal voltage designs

201109

How to inspect sliding resistance type

How to inspect hall type

Throttle
assembly

Throttle
control motor
-~

.6

iil8

r a'M
95'

1-

T
!

$V

201109

If ETCS has problems

(accelerator pedal/ throttle valve/motor)
Electronic

Decelerate gear

, _ motor (DC)
~

r- Throttle

~~~~
l\

Decelerate gear
~~--------

201109

Throttle
return spring

It%~~L!

Double signal
linear TPS

----------------,

If ETCS has problems

(accelerator pedal position sensor)
Single signal
malfunction

normal

double signal
malfunction

.----,...-_ accelerator pedal

. position sensor

I
I
'!I"

J
"

51~ I::CU

I.
:1

-~-I
5 i~ i::cu

'----r"'--,~

i.'

I'

'

Throttle motor
,t-

201109

Problems for electrical throttle valve

Not easy to start

Lazy acceleration or acceleration failed
Not steady in idle speed or engine stop intermittently (engine
stop easily if air-con is running
Gearshift locked in transmission

Possible reasons :
1. Throttle position sensor , how to do idle speed learning
procedure
2. Sensor has problem or poor connector
3. Actuator control motor has problem or move shift-fixed screw
4. Engine ECD has problem
5. Throttle valve is dirty or poor contact
201109

145
- -- -

--

ETB
Throttle

motor

Stopper
bolt,

Intermed iate
gear

Return
spring

Reasons for carbon deposit?

How to clean carbon deposit?

201109

146

Power assist steering system

Type of power assist steering system
- Hydraulic Power Assist Steering HP AS / HPS
- Electro Hydraulic Power Assist Steering EHPAS
- pure Electrically Powered Steering EPAS / EPS

~ .:
201109

~ .,~~

Power assist steering system

System actuate relationship
- steering wheel rudder angle vs. PS-Pump RPM
- Speed vs. PS-Pump RPM

1000
100

lMilifr~~~ 150

201109

(~ ~lIJ\HiJ)

147

250

B-1. Hydraulic power assist system

=15- rti] ~iJt
(Steering Wheel)

HPAS
jj!pJt1MJ:
~i] j] if!i.! fjJM~irl-Jm?ffi

(Steering Column)

(Power Steering Oi Pump)

i/ilcWiJ~al

(Steering Shaft

~'Plt@~fuJR~1'-T ~~~~~[
(Steering Gear and Linkage)

B-1. Hydraulic power assist system

HPAS

Pressure
line

20]
148

B-2. Electro hydraulic power assist system

Electro Hydraulic Power Assist Steering [EHPAS]
- driven by electro PS-Pump
decrease engine load" increase fuel efficiency
- Integral Pump" Motor and control modules
can make location space small and decrease
the load
- use CAN signal control to make inspection
easy

201109

B-2. Electro hydraulic power assist system

EHPAS

(Motor Pump Unit)

149

B-1. Hydraulic power assist system

j5rtiJ~ift

HPAS

(Steering Wheel)

lJW)]~!1Jr{iJt~l~lB1t?m

(Power Steering Oi Pump)

ifJl~lri]!I!Rl

(Steering Shaft

~'PJ~j!li:iliRB=;;'+

(Steering Gear and Linkage)

B-1. Hydraulic power assist system

HPAS

Pressure
line

201
148

-'-~

B-2. Electro hydraulic power assist system

Electro Hydraulic Power Assist Steering [EHPAS]
- driven by electro PS-Pump
decrease engine load" increase fuel efficiency
- Integral Pump" Motor and control modules
can make location space small and decrease
the load
- use CAN signal control to make inspection
easy

201109

B-2. Electro hydraulic power assist system

EHPAS

'til: [1)J);1t 3!nI.. il4J ~ )[;

(Motor Pump Unit)

149
------

B-2. Electro hydraulic power assist system

ERP AS system structure

~
..

PCM

::::::::===::;:::;::;:::;-

..... P/S ffjfJ!!~~~r@f

(Power Steering Angle Sensor)

201109

B-2. Electro hydraulic power assist system

EHPAS 80A

IEHPA$5A

!G

~~o kv~""_."';OJ
~loJfol )t}~i~ it6

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

B-2. Electro hydraulic power assist system

ERPAS system circuit
c:;.<)3

t l L - ! : d - - - - -.."'EI

-----~---.-...,.....""'O-_+-- BlfJ ---l!~~

.. -

.---_ _ _ _ _ _
HAA&o
_ 8(;f--<-VA.""<
.....
>---4_
~_o.
; );$.",.'""',.-2
"0_00_"'" + - - BtY'(f)

.............
....

~~ .
~~
2F20:26

!;e'i" 'fi[Biu~ (I)

'. .. "...

30~

'".

8{~ - - - - - ,

--41.----

..:~A.~f)
_~_~o(.())

........

B-2. Electro hydraulic power assist system

EHPAS system control module
... ~-(~~rPJ~l!tfJl~J1E)
PIS ANGLE
SENSOR

STEERING
SPEED SIGNAL

(l$iijirfj 3:@I~nlVi~~)
VEHICLE SPEED
SIGNAL (CAN)

PCM

ENGINE SPEED
SIGNAL (CAN)

( 5 1 ~~W.i~fJVJf}O

"

~....,.

pt'"

-.......
....

7"

__ (l\J9!~~ Pump Unit)

------- ~~,

" ... ...

... ...

... ...

'-

Ca1culatio
n

... "
\

-------

m:IJJJ%3M~~7G

.... 1

I'

MOTOA

-I

CONTAOL
CURRENT

EHPAS CONTROL
MODULE

... ... ...

... ...

--- --- - -

",

--

...
-... ...

.;

,. .-

- -: - - - - -.....-:JEHPAS WARNING
-ILIGHT

"

~ ~
ONBOARD DIAGNOSTIC
FUNCTION

~ ,~ ~

-,

201109
151
---

_ .-

-- -- -

B-2. Electro hydraulic power assist system

ERP AS actuate procedure:
a. Received signal ofMPU control modules:
- steering wheel turning angle speed (PIS Angle Sensor)
- vehicle speed signal (PCM I CAN)
- engine RPM signal (PCM I CAN)
b. MPU control module' send signal to inside
Motor
c. Motor drive Gear Pump to make steering oil to flow
out
0

d. Steering oil push steering gear and linkage to make

wheels turn
0

201109

B-2. Electro hydraulic power assist system

MPD ECD + Motor

Brushless Motor
-DC 12V

connector plate

- No Serviceable
(J!r;5lIW;T)

stator/ECU assembly
rotor

manifold

152

B-2. Electro hydraulic power assist system

MPU (Connector) -

CAN Connector
(CAN~~W:~[Fl5lj~)

- Ignition Signal (ION)

- CAN-Low
- CAN-High

(P/s f03r~t!~r,9;IJ ~[j.mj}D

- Supply Rate Sensor +

-S upply Rate Sensor OND

201109

*********

B-2. Electro hydraulic power assist system

Caution ...
no water in MPU! !
----- --------- _._ -----------I
~ When removing the connector
~ and MPU, put protection cover
on the MPU connector to avoid
i water into MPU motor through I
; the wire connector.

I ___________________________ )

201109
153

--

B-2. Electro hydraulic power assist system

PIS angle sensor (Power Steering Angle Sensor)

.""",...-=--=-----,.,.-------,

P/S f!J~~j!] (,ft

(Power Steering Angle Sensor)

Housing

Rack & Pinion

Cylinder

B-2. Electro hydraulic power assist system

PIS angle sensor-

20110

Steering Angle Sensor

Steering Angle Sensor
Front

"
'1.ICH:t'J

201109

PCM
r, 12V

Hall sensor
Power cord

Signal wire

+5V

~~----------------~--~~ CPU

Ground strap

201109

155

Steering Angle Sensor

H ow to test?

IG 12V

#........ ....................... Sensor

output

~~i~------~~

(ST1 )

5V

ECSCM

201109

B-2. Electro hydraulic power assist system

PIS angle sens r
(Hall Sensor)

MAGN~TIC ~
fIELD

lL-,!

!I HALl,

! SENSOR

(~iilillh)

MAGNETIC

PIS ANGLE SENSOR

fliNG

(HALL SEN SOR)

(li:lll'lSt)
OUTPUT WAVE PATTERN

SIGNAL)

...
ltrrO-r=L
.~

..
.
"

,
,,

,,
,

'

SIGt'Al2

, .
... .::.
, ..
~
..

PIS angle sensor install in steering gear and linkage or steering column
PIS angle sensor includes two Hall-Sensor' to sense the magnetic ring in
steering shaft The rotation of magnetic ring create Hall Effect and got 2
Offset Signal, then send to EHPAS control module.
According to the change of magnetic field ' EHPAS system can read t......_ _
rotation angle of steering wheel and the speed of steering angle
0

201109

156

....
I

....

-- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - ---- - - - - - - - - - _ = : : : : : :
. - - - - : -:-;-:-l~
. ,
,lI.~,,.;PJ/;,
~
.
,

( \1)'-,

..:
I. ., ;",,,x;.
.~

:;)~

"

not start et, turn the

.<...

>:

wheel

ORP M

OA
12.5

10

7.5

2.5

1 5

10

7.5

2.5

12.5

10

7.5

2.5

12.5

10

7.5

2.5

1 5

10

7.5

2.5

12.5

10

7.5

2.5

ORPM

ORPM
I

O-/s
I

12V

OKPH

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

Engine is starting, tum the steering wheel

ENGRPM

1440RPM

9A
1 5

10

7.5

12.5

10

12.5

2.5

7.5

2.5

10

7.5

2.5

12.5

10

7.5

2.5

12.5

10

7.5

2.5

12.5

10

7.5

2.5

2703.9RPM

2700RPM

O-/s
I

13.06V

OKPH

Installation of steering wheel angle sensor

IE403(;,1: _ __

--,-...,--,

_~

Use a suitable patch, put on the

outside housing when fixing
clock spring rotor.
20
n 40325

B-2. Electro hydraulic power assist system

C
. . aut'Ion ...
The situation of "steering wheel tum to the end" could
not more than 5 seconds.

,._._._._._._._._._._._._._._._._._._._---_._._-_._-,
i If the steering tilne is long, the temperature of engine oil will
~ too high. Then will damage the steering pUlnp.

i ---+ EHPAS system mIght show code ofDTC B1238

(ECU Over Temperature)
~ ---+

EHPAS system might stop operation (steering wheel power

~ , A '~

becomes big)

12Q.l.l.QQ ___ . _ . _ . _ . _ . _ . _ . _ . ___ . _ . _ . _ . _ . ___ . ___ . _ . _ _ .

158

_0': 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

,

'...

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

'

Situati<>n
,, signal

______________ _ _________________ _ _____ J

"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

EPS problem manifestation

Code

manifestation

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

ON.

Even engine is running, EPS warning light keeps lightening.

EPS warning light flashes.

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

bus

9.6

Sub-

K-CAN

K-CAN

byte...

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'<lIl.... iwit....

Inll!lAf'~

0\011.10.. ' .....

E65 Bus Network

Optical fibre technology

byteflight
Star structure

Integrated sender and receIver

~ High
d~mand
on safety data
transmISSIon

SIM

Satelli tes work separately

Data transmission: 10 Mbitls

,...,

..~

201109

~'~'~"'~

,
i

UN

{.

li;fl'H i

tJN
BUS ; ' ...'~~".'"
)i1~J;}J1!i.

11tt

lieu

/i;J'ji!1':f l'
ItCU
CAN

I""

'lUS ('2.. \ I('G", !

t tN

,~w_,

____

~ ,~ =_~~~,- -,

!. ~N

tms
EfT

~{i11irjtt

r1

ECtJ

201109

167

Gateway function

ll
K-CAN

oiagnoseBus

115 KBit/s
PT-CAN

..

bytef/ight

Diagnose-Bus
K-CAN

...

100 KBit/s

PT-CAN

!1

500 KBit/s

byteflight
10 Mbit/s

201109

Gateway
(~) ICM
(H~ . - - - -- - - - - - - . - --+-----M-S--C-AN-(-H)-------+------,

(l) '---_ _ _ _ _ _ _ _ _ _ _ _-

--M-S--C-AN-('---.:Ll-_---+-- -

(~) PCM

GEMC.~

(H) . - - - - - - - * - - - + - - - - - - 1 - - - + - - - -------,

HS-CAN (H)

I/_~~v
;

""\

J"-j1 ,
H

(l) ' - -_ _ _ _ _--.-_ _ _ _ _----+_---=-::H"'--S--=CA...o.:..N:....JCl:=L..-_---'

201',uv

168

What is CAN
CAN == Controller Area Network
For the transmit speed: 50r-v500 K Bit/s (1M)
1Mbps max. (one million bits/sec)
Meet regulation of ISO 11898

SAE J3919 (250 kbit/s) ,

I.:

~ ,. ~

201109

..::.:~,~,~~

CAN develop
The CAN protocol was created back in 1984
by Robert Bosch Corp. in anticipation of future
advances in onboard electronics. The first
production application was in 1992 to several
Mercedes-Benz models, but CAN is now being
used on more and more new vehicles.
By 2008, all new vehicles sold in the U.S will
be required to have a CAN-compliant onboard
diagnostic system.
~ ... ~... ..,
,"',

201109

169

~,~~

Milestones of CAN

1983

Siart of the Bosch internal project to develop an in-vehicle ne!'yIlolk

III

1986

Official introdu ction of CAN protocol

1987

First CAN controller ChlpS from Intel and Philips Sermconduclors

looJ
1991
1992

1992
1002

(,AN Kingdom CANbased higher-Iayel protocol introduced

CAN Application layer (CAL) protocol published by CiA.

First cars from Mercedes-Benz used CAN nelwork

ISO 11898 standard plJblished

19114

1sot internaHonal CAN Conference (iCC) organized by CiA

1004
J995

DeviceNet prolocat introduction hy .A.llen-Braclley

2fl00

by i<vS!ser

CAN in Aulomalion (CiA) international users lind manufacturers group

establishBd

1993

198fJ
201109

Bosch's CAN specification 2.0 published

ISO 11898 amendment (extended frame format) published

CANufJ,m PfUlu",,1 (Juul;:;h",Ll uy CiA

Development of the time-triggered co mmunication protocol for CAN (TTCAf\~

CAN in Vehicle (Example)

High-speed-CAN

PT-CAN 500 KBit/s

Low-speed-CAN

K-CAN 100 KBit/s

High speed network (also: High speed CAN or

HSCAN 500 KBit/s)
Mid speed network (also: Mid speed CAN or
MSCAN 95 KBit/s )
Low speed network (also: Low speed CAN or
LSCAN 33 KBit/s )
20110~MW PT--Powertrain

I K--car body
170

201 109

201109

171

201109

201109

172

Bus structure (two wires)

CAN
ECU

12 0

CANH

,- ,~

CANL

12 0

Two wires Bus

Terminal resistance (2 x 120Q)
201109
- _______________________
- .____ _______ ___ . _ _ _ _

~_.

__ ._ _ _ _ _ _ ._ _ _ _ _ _ _

".

_. ___

"_____ _

. ... ____

LIN
EC~l.T

201109

173

__ .. _ _

_ . __ .

. __ . _

- _

... __ 0_. _

- __ - - - - --

~!::!!'B

- - - - - - -.--

CAN 11

"r

"

1._

"

C, f .

' ~~ .

L=:;:-..-----

"'"\~. ,'

r---+"----.

~-=mI20n
I

CAN H

sf \ .--+------------- --.---+---.j ~

~\

-=
~

CAN L

14

. ' ...' ...' ...\1 .'... ~'.....

t ; t:,;t,;j;;f,it ;;j:,:t.f

W:1'f ~!ii 161}jn

201109

AlC amplifier AT computer

Combination
meter

V
CAN L
~

Diagnostic
connector

Engine ECU

Electric wire
connector

CAN H

ABS computer

~ :,~ ~

201109
174

~>~~

Terminal resistance

I
II:

C/U1
11 I!

I C/U4

ClU3

L_~---.J

L~~
... . ~
..... ~_:

r I ,,\-

.;-.)

t.

'{.,...

C/U1

C/U2

C/U3

ClU4

ABS

ECU

201109

175

INS

3,75 V

rs II . . . . . . . . . . . . . . . .. . . . . .
, II. . . . .. .

----

. . _. . . . . . . . . . . .I! _ _ .IIIt 'UI IUt

).

I II~. . . '

CAN-H

...................... ..........................................
....................................... .......................,....................
.
~

2,5 V~

.-

....._

1,25 v.............................

...................

CAN-L

...

SAE J3919
5

recessive Bit

> 4

;:::::.
Q)

>

Ul

;::3

o:l

CAN-H 2,5 V
CAN-L2,5 V
Difference OV

CAN H

---------~--=-~--------

r---~------------7----

- - - - -

~ - - -"----C-AN--L~ -

I
--j- - - - -

dominant Bit

recessive

dominant

CAN-H 3,5V
CAN-L 1,5V
Difference 2V

recessive

ISO 11898

Difference Voltage

CAN BUS Line "Hi"

: : ::::

---I

2.5Volt--;
CAN BUS Line "La"

1.5 Volt ...................

. L . . . -_ _- - - '

2 Volt

oiff. Voltage

o Volt

2 Volt

3.5 - 1.5 = 2 VOltL-1_O_"'_o_lt---,

2.5 - 2.5

201109

176

=0 Volt

o Volt

Advantages of differential signal?

CAN protocol generate digital signal according to
the voltage difference between CANH and CANL.
So CAN protocol will against noise.

Twisted pair line

-....,......-..~....

~~

Blue: CAN H line

Pink: CAN L line

201109

CAN use twisted pair line

CAN driven by different voltage

Hi

Hi

Twisted pair line

177

Why do we need CAN protocol?

CAN bus protocol .
The series of rules is set for:

Which computer has priority to send

signals?

What kind of information has priority to

be sent?

When is the information sent?

201 109

).'-CAN/
2.QA /2.0B~ Data Frame
J

..

..~ ;.
:. to.

<'

o"b"

sta rt
1 B it

Identifier RTR IDE ;-O

DLC
11 Blls
1 Bit 1 Bill Bit 4 B its

...........

Data
0 .. 8 B Bits

eRe

ACK

EOF+iFS

1G Bits

2 Bits

10 Blls

~ ' \(~0'(

CAN 2 .0 B~*4m~ (29{ft:n:; ~5jU~rf) l:; \ -\-

\ i l:)
\:

\~f\"

. 1

Start

Identifier SRR IDE

Identifier RrR r1

1 B it

11 Bits

18 Bit

1 B it

1 B it

rO

DLe

1 Bit 1 Bit 1 8il 4 Bits

201109

178

Data

CRC

0 . 8 8 Bi !

16 B its

ACK

EOF+IFS

2 Bits

10 Bits

CAN Oata Frame

MiI:nmum

m.m.t i/iIhgtIt ...... Jlof ~"121 bit,.

eRe
Oelimiler

sRi

BiI$ -it

o
F
"i

Identitier
,0

'1"' "

T , {) r
R, E ; 0
1
1

eRC

OLC
.. _.

"

,,;,

.: .....

. ,; J! .,. ,. 111

..

:!

+ .~~ . +*

III '" ""1\' .... wt . . .

15

0-64

ACK
Field
2

E.OF

w~*~.~

I
C.A.N 2.0A-ll bitsJWNV,.,L CAN 2.0B-29 bits ~

CAN Extendad Data FramtJ

u.xi.rrwm brmll ftQIJt" ~ .Jluiffng 1$0 b~!l

eRe

Control

."'....
',::_
,' ........_ -

~don n.~.. +-FlaId

32: 84m ,h

,-II< "" ' - ~tlI.......... '

Field

Delimiter
i .

CAN 2.0A /2.0B~ Data Frame

Standard Format (CAN 2.0A) : 11-bit Identifier
211::; 2048 (in reality only 2032) Identifiers possible
I

Arbltralion Freld

j - -- - - - - ,

II.

ConCrol
Field

Dala Field

eRC Field

Inl~

End of
Frame
Field

I'

14--~

I
0..64 Bit Data

Bus !dle

paCll'
:,...
....
. --

15-bit CRC

dominant- - - - L L - - - - - . . . L L - L L - - " - - - - - - - - L - - - - - - - - - - '

Extended Format (CAN 2.0B) : 29-bit Identifier

229

=536.,870.912 identifiers possible

I
II I
IJIooi

Bus, Idle

r8cessive-

Afbitration field

Conlroi
Freid

Data Field

CRC Field

Ac
Ie!

--

Field
~

Interj Bus ld!e

/Tam I

ppace

r-'"
I

" "",.~~_~~~~~l~ 11-MBase Id 1~1~1 18-bit Ext.ldl~ ~16IDLC 0_.64 Bit Data 'IS-bit CRCJ~: 7-bit EOF IFsrat~ Idle
EC E

dominant"""

End of
Frame

LKL

179
- -_

. _ - -- - - - - -

CAN 2.0A /2.0B~ Data Frame

..

Bit Stuffing

--1
Bus Frame
. glARBfTRATIONI
.
. .I

lit-

La.. ..- - -. . .- -..- _ ......

CTRL

Duration in Data. Bit

: 1:

CAN - V2.0A

1.. ~I..

Duration in Data Bit

12/32

0 ... 64

15

. 10[28.. 18]

: 1 :

11

CTRL

~3

r - -........
DATA

10[17..0]

.
: 1: 1 :
.,

...

.'

.....

Start of Frame

.:..

18

......1-. _~_...........,!;A~B awII..,I.JB>.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 A A A A A A A A

.... 3 bit message Priority {~,,~.3i)t

, ,,'.

Lowest)
r ,

.,

..

~.

.(,

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

"

,';:"

"

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

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

e Re F,eld

field

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

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

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

Bu<) Idle

pac4

i ( 7-bit EOF IFS

8 bits

21 bits PGN

~n!cr.J

~.m~

1:~ldle

CAN
r-C"4(")<:;ttDcDf'...U)

DDDDDDDD
DODDoooo
CbO

....

<N(')~~ro

l\IS-CAN Mid speed

;""""-;,---1 1""';';;"'.",...........1;

'--===--"
____---~-

//

Terminal
resistance

0'/

/
...

. \.

//

Gateway installed

Diagnostic connector 16pin

Terminal resistance (120 Q)

6/14 HS-CAN

Terminal resistance

\\ iII-~:-:---~E=:-:-C=1I=T~-;-;:-=:-:-~~-I. -I=I--:.-I-~:--"-'~-'-S-'-C_AN

High speed

201109

Jl04 '3'~T~~~ij!{~ EDL

VW2.0

ABS ~~E!'

ll;iJij!{9E**1t
J21 7 ~ !I7J~~;tiH~ilig~~
J2 3 4~It~iM1t~
.J2 49 ~5JB 1l1ii p~ij.1**1U~;M~~

r ~flj**1t J

J2 85 1fllii2Lc~itlJ~~OOMff-~
J519 !.IiJ::.~*~ili!j1t~
J5 3 3 jjU*I2I~11F~1fffii

Jl~j~:fi~H~~ ~ ~~~lM~!nX
(Mechatronics)

lOOk

r ~~flj:~~*~J CAN~f~~~~*~~5f,ttjH

,J527 1Jfi'iJ~tt~ilitJ~~
2(J743

CAN I~J:g-H~~j{:tGl-m5ftE~~

182

OOk

~..

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

- -- - - - - ,

Data transfer protocols

Standard OBD / EOBD protocols:
ISO 914 1-2 (Europe, imports for asia and
Chrysler)
KWP 2000 (Europe, imports for asia and
Chrysler)

SAE J1850 VPW (GM)-(VariablePulse Width)

SAE J1850 PWM(FORD, SCP)-(Pulse-Width
Modulation)
201109

CAN Frame

CANL

201109

183

OBD II (J1962 DLC)

16 pin

201109

Pin 2 - J1850 Bus+

Pin 3 - MS-CAN High
Pin 4 - Chassis Ground
Pin 5 - Signal Ground
Pin 6 - HS-CAN High
Pin 7 - ISO 9141-2 KLine
Pin 10 - J1850 Bus
Pin 11 - MS-CAN Low
Pin 14 - HS-CAN Low
Pin 15 - ISO 9141-2 L Line
Pin 16 - Battery Power

Possible CAN problems

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

CAN_H open
CAN_L open
CAN H shorted to GND
CAN L shorted to GND
CAN H shorted to CAN L
Remove termination between the CAN lines
CAN H shorted to VCC
CAN L shorted to VCC
ECU

CANH
CANL

201109

184

Pin 6/14=?
CAN_H open =? n
CAN_L open =? !!

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

i,
I

\,0

\"p

CAN L
CAN- H shorted to GND =?- n
CAN- L shorted to GND =?- n cP
CAN H shorted to CAN L = ? n (J)
Remove termination between the 6
CAN lines =? n \ LO
{ .\ J
~
CAN_H shorted to VCC = ? '''. '' '0'1- V..r'\;L...----+-, . . . vvv-t-- -----"o.J
CAN_ L shorted to VCC = ? / ~,.~ '_.~QI'. \,'(.,--.\'

14

.Q

7.
8.

110<t1m

C'-

201109

HSCAN
Ifwe can
measure III
DLC3?

1. When CAN H in break,

_i
measure in 6/14 pin = _ .\_tD
O(IG sw Off)

I,

s'~C"'\:<i EQi

. t :

.. .. 1 ......

TOC/oIi No. 1 BJ

I ~ ........ ....
'l ____

: C#i r; ~ Hie (~ 1l(f\.ar oft'" \'itl"" I

2. In normal, measure in
6/14 pin = (~ O 0

(calculation ??)

""...,
' ('Z).:

\\~. n "".S.. ;o\d.;II'.... F'cn~fl!;thl SJ"'"''')

('T):WlhSRSAl'l>1yS)'I!tIil)

I :
.

: I

I~......n.. ....

peM
...... .

.",1 5

3. Removing Ale amplifi....

le....r ""'Ineasure in 6/14 pin = Ck '
O(IG sw Off)

CAN NO. j SO!:

HSCAN
If the scanner
can be
connected in
DLC3??

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

1. DTC light IS good or not?

.... _ . _ . rTDCAt. MSB",

2. Engine can start or not?

L.

1-

HSCAN
0':-:'0

Measure

III

6114 pin =

(~O

Is it normal ?
lMeasure

Shor ed
to
grou d

III

n(I G sw Off)

6/4 pin = j'{ , n (IG sw Off)

r----r'/V'-I
--,-.. - -\t-v-

l --- .\<.1

C iJ

CAN 116,1 DU!:

_______~"~'b __ '~"

HSCAN

_ _ _ ,(.\!l'" ,;"'",n'l<.. ;:..,(~

ICM

i?)O I

--------- :fj; ~~. ~&rs~W~tJjl Ml

I
I

If the scanner
can be
connected in
DLC3??

:=~=_JOCAJ1MSlll1S

CA
CA

1. When CAN H and CAN L

in short, measure in 6/14 pin
I,/fl Q (I G sw Off)
2. When two wires of vicebus is in short, measure in
6/14 pin = <p Q (IG sw
Off)

Hand

, , " 1

""',,1

1 :
: em if. U'C(E41HRaar~n,.. 1M;;""}

'

,."i'Z):'tIJhIfS:"d',oIi('f'''''~''''!tt\lSf'larn).
.. ~
I : ~ : I PCM
12l)Q

, ni: \\\1h $P.$ N:.>; S,W"'l

(2./

..

t
Q..v...

C.J_fV

.........................................
Q /'

",'

()"(

n\

V-',
~.j

"

(j (

''. .'V~

\A'-~/;~ I~ r::: /

l,,,_

v , _, ,( ",,, .

.oj?

Jic,J'd"'-' -'

\...-......,.-J;L. :..QCl

HSCAN
If terminal resistor is
removed
(inside a ECU for some
cars)

'

: .-.--: _~J " iro CM MS Sus

I
: CAN!f>A JiC {MO) jf<<)1tof1hO\\l1iCl?)
r-if--';-'

---'----', -------t

r~CANNo,2Bj'

'-__--'-- 1 :

!om,c,
I:~ :I
I

r"w'~'
('2y.'tI1h IfS;M.iII1{~ Frm~r.,it'<>iSltl'm)
('}j: WIn SRS 1\i'~9 SW,;"'l

12:H1

' ~ ........ "",

.....

_ _ _ _ -.

H'C(8I1)(R"""W.. Wli:iej

PCM

........... ......................

cMeasure in 6/14 pin

n(IGs,~f)

/ \LD.JL

HSCAN
How do you check it?
,

1. DTC light is good or not?

2. Engine can start or not?

U" \\

\ui/

-\--

-rc-~

\ rjO

. \

(o"",A
0

If the scanner
can be
connected in
D C3??

Terminal resistance 120 n

(installed in computer)

Terminal resistance 120 n

ECU 5 r '\ ..-..._____---_-C--'--AN-H--_-+__.

ombination
..
meter

-$.

l:::I

CAN L

fR
6

2011vv

.A

AT computer

ABS computer

14

Diagnostic connector 16pin

200 !1 gear position

If measure in
6/14 pin = 60 n.
Don't celebrate
too early?

201109

188
I - -_ _ __ -- ~---.---.-- ---.--~------

,------------ ----------------------------------------------------

By the 6 / 14 pin measured 60n~ it

may have the following conditions:
/

', ,...

. 1\" ..

- - \.>

'/

. f ''0.+

s~ o~

rsJ'f 0,

'\o-~'-O

~c.. U .~

201109

1.
2.
3.
4.
5.

6.

-::-. . I , '!. , - . i. .:

KEY OFF, measure R between terminal 6 and l4, in normal is J..Q n

CAN_ H or CAN_Lin break, 6/14 = ~ n
CAN_H and CAN_L in short, 6/14= () n
CAN_H or CAN_L shorted to ground, 6/14 = ~ n
Measure positive voltage of the sixteenth (16) pin = Itt
V
measure R between the forth (4) pin and ground =
0
n
measure R between the fifth (5) pin and ground =
(>(...
n
Measure R and V of CAN network each pin in DLC, respectively,
measure R and V between CAN network each pin in DLC and ground :

PIN

Resistance

Voltage
Key Off

Key Off
Red connect terminal 6 ' black
to ground

Key ON

Red connect terminal 14 ' black

to ground

o
189

Why is the measure 2.SV?

CAN H waveform

..i(Wf~GHf .
1 ~j'.!H.QiJ

L
.."" ,.....
I u~;"r. .... ,
>.

~ .. . ~~v

.1 ~RIL4{t .

DiV ' tmtDMtCH2

. ..~ ,,1j
'

CAN_H average voltage

~t'r'~-

~ .,/
,/

v "\

nec,.A

CAN_L average voltage

CAN L
waveform
201109

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

tc

CAN H waveform

CAN L waveform

~ : "~

201109

190

~",,<~

-~~====================
-- ====================~~~

CAN wave
c.oWfi~, CHI .
CA",~ Rtol. all

1... . 3.56 V

US)'!

~~
Ll7' V

CNI-LCom. CH2

2.4 l V

CMj.HOOOl. ~1.
. C~Re~ Ojl
11~r:.a .ci1!

Normal wave

r-Mv

CN~t.RtZ.CH2

~v

I
OW .
< I ",. ' ;';~ 0.

cm~ Dom. CH2

Abnormal wave

201109

CAN trouble shooting procedure

Is it a problem if the code appears in the
scanner? What's wrong?
Correcting procedure
Step 1:
Step 2:
Step 3:
Why must you follow every step?
201109

191

2.2 V

192

Newly Brake System Inspection

sc

2011/9/19

New function for brake system

-ABS (Anti-Lock Brake System)
- BAS (Brake Assist System)
- EBD (Electronic Brake Force Distribution)
- TCS (Traction Control System)
- ESP (Electronic Stability Program)
/ ..... .

sc

2011/9/19

193

Different name in cars

ESP - Electronic stability program (FordlBenzlHyundai)
DSC - Dynamic Stability Control (Mazda/BMW)
VSC - Vehicle Stability Control (Toyota)
VDC ASC DDC PSM ASMS

Vehicle Dynamic Stability Control (Nissan)

Automatic Stability Control (Mitsubishi)
Driving Dynamic Control (Honda)
Porsche Stability Management (Porsche)
- Automatic Stability Management System
sc

2011/9/19

Deceleration

*~~!~m1tu

Turning

Turning

1Jo~~1tU

Acceleration

sc

2011/9/19

194

Active / passive security equipment

The difference between active and passive equipment
comes from the hit situation in car accident.
Active security refers to the equipment that can work
before the hit happens. Those equipment starts to work
when the car is going to lose control. They can intervent
driving operation and hope that the car is in control by
using machinery or electrical devices. Then can avoid
from car accident happening. These security equipment,
for example, ABS .. EBD .. ESP .. TCS .. BAS.

sc

2011/9/19

Active / passive security equipment

Passive security equipment, is to protect the
passenger when the car lose control. Hope to protect
the passenger in safety position through fix devices.
To absorb the impact force and provide passenger the
security by using the guide and crumple in
construction, for example, seat belt, SRS, WIL
cervical spine injuries ease design and cage shape
body structure.

sc

2011/9/19

195

Reminder
Vehicle security == 50% active security + 30%
passive security + 20% security awamess
Both active and passive security equipment are "assist"
devices. They will do the help when the car is over
control maximun. Those devices can not ensure 100%
of driving security. They just help to reduce the
opportunity of car accident and reduce the injuries.
The keep point for driving security is a good vehicle
maintenance, to make sure the normal operation and
safe driving.
sc

2011/9/19

Active / passive type security equipment

Active type

Passive type

Remark

SRS
ABS
EBD
BAS
TCS
ESP
Crumple steering column
Crumple brake pedal
Backing (parking) sensor
Cervical spine injuries protection
seat
Seat belt
Seat belt automatic tighten device
AFS head light steering system
..H ....

LUll/8118

196

Brake System Review

DUAL MASTER

CYUNDER

REAR

FRONT

sc

Vent ports

Reservoir

Piston
cup

cup
To
rear
brakes

Heservoii

To
front
brakes
MASTER CYLINDER UNAPPLIED

201

197

sc

Vacuum-assisted hydraulic brake

Dual loop brake assembly

Vacuum assistance
(Booster) sc

2011/9/19

Positioning

Brake drum

Shoe pin
-

Pull back spring

-- -

Regulator

Drum brake assembly construction

sc

2011/9/19

198

Splash
shield

sc

2011/9/19

How a Disc Brake Works

Cali ....."

::lr _ _

whee'l
aUaches
here

Hub

sc
199

Brake Rotor
Solid rotor

Inside ventilation rotor

Ventilation
Disc brake rotor

Ventilated disc is usually used in cars to increase the cooling area and get better
Coolant performance.

sc

2011/9/19

~- - --

-_.-

- -

---

- --

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

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

. -.- ~- -

The p.a.ds sepa.ratedu rrng:

~HJdd eo brak:ing

TheseparaUQn of
the pad hom Us
bactdng damages
the disc rotor

200

Brake Pad Wear Indicator

Normal

Worn

How to replace the brake pads

Use special tools to back the piston a little bit.
Will help to install the new brake pads.

Caliper housing

201 1/9/ 19

SC

Double loop brake system

GSQ16

Cross separation

Separate to front and rear

SC

2011/9/19

201

Disadvantage without ABS

When the driver push the brake urgently in damp
asphalt road, gravel road or snow road, though the tire
has stop rotating, the vehicle still slip on the road, we
call the situation "wheel lock" .
When "wheel Io ck"happ ens , the wheel will lose
lateral "grip"and cause below situation:

e1)

Decrease steering function : can not tum.

2) Decrease direction stability : wag tailor spin.
e3) The brake distance becomes longer.
4) The wheel got partial abrasion.

e
e

sc

2011/9/19

ABS
ABS is the abbreviation of Anti -lock Brake System.
By controlling brake oil pressure to keep the slip rate
between the tire and the ground in 0.15 0.30. The
brake power will reach the highest when slip ratio is
in 0.15 0.30 and can stop the car quick and steady.
r--J

r-J

vehicle speed - wheel speed

Slip ratio

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

x 100%

vehicle speed
1. Slip ratio 1000/0 means the tire is locked
201?!9,&~ip ratio 00/0 means no brake
202

sc

~~~

ASS slip tolerance

- - - - : Braking force
: Cornering force

Dry concrete

Q)

0
'-

Q)

"-

.g

0
......

C)

C)

.-c::"-

c
:.;(
co

Q)

c:
.....

co'-

Wet asphalt

Wet asphalt
" " .....

o
2011/9/19

20

40

Ice

80

60

100

sc

Slip ratio (%)

ABS

Rear brake
Disc / Solid disc

Front brake
Disc / ventilation
disc

______

fz.,,1$1., ','mi-'-I="k
""rr-.
" ...!..LiC;,p
, , ,,x.'I:ll~.
-ltl

~tx
I\ ~'

~i

(Brake Fluid Level Sensor)

(Reservoir)

20

~J:t: Disc
::/:-
P D
lix5\J:
rum

How ABS works?

sc

ABS
To prevent the tire being locked in brake

WithoutABS

~~~IIi&~--~~~-=~...j ~':!!~: : : : : : : :
1

Brake

204

The advantage of ABS

~

Good direction control

I-figh driving stability (the wheel won't lock

and keep correct direction)

Shorten brake distance ( especially for damp

road)

Decrease tire wear and tear

sc

2011/9/19

ABS Parts Location

C~) ABS Relay

sc

2011/9119

205

ABS Parts Location

fgnition Switch

ABS Warning Light

Rear Speed Sensor

ABS Actuator

Scrrul..:d RotOr
. Front Speed
. Sensor
1P"""-....---"1t--t-.

ABS
ECU

Dual-LSPV

Front Speed
St::nsor

Rcu!' Speed Sensor

Battery

Disc Brake Cylinder

Brake Master

Cylinder

Stop Ughl Switch

LUll/8118

0l.-

ABS Pipeline

206

Close type

Master cylinder

Pump motor
Inlet solenoid

Reservoir

Reservoir

ABS

2011/9/1

Assembly Cylinder

Buffer room

Reservoir

Pump motor

Motor

Inlet solenoid

outlet solenoid

sc

..._- -- -

,);

Outlet solenoid

RR

LF

Pump
motor ,
pump

I pressure
increase

OFFGif:J!2'f)

OFF(I#lH'l)

Stop

2 pressure
no change

ON(I#! Iof.!)

OFF (lmlof.!)

Stop

ON (~mlof.!)

ON(IfflJiilf)

Work

3 pressure
decreOO1

19/19

------- - - - - - - - - - - - - - - -- - . ,

ABS
ABS
System
circuit

.. ABSCM

. . t . .

ABSHu
..' , t .....
. ; Brake Caliper

...

-----

.....

PCM

"

,
I

' .... _--_ ...

OlC-2

2011/9/19

0413

ANTI LOCK BRAKE SYSTEM

~A. nEJl:\I'

[[]J__~____ e.:n\n __________'_"'...'~_ _ _ _ _~_or.-<""',,,Yl,.3"(>-_-+

0
_ _ _ _ "'<I----c;*';;,"-- S(!~ - - - - - - - ,

@J
r--

. , VACANT

DATA"-IXl'lNECTOA2
(S(CTJPNOOOl

RiA

.-.e$ i-IVOAAU:.tC UNrTr.;OtiT~OC MODULe-.

tASS H!.i."CU~

(7)

V(, C-o:!

YL_~

DAtI<, UNi( CONfi-EClOO2

rr

(~CT~QQP)

t.(FJ

,~

"tF)

__~~_ _____________
~~~~~~~~=l~R____________
RR
_ _~/
ASS WHEEI.SPEEC SENSOR

041:'''()2

Q4~SOO

A8S ~l~SFED SENSOf:t IF-

ASS ~HL-SPfEO SENS()A RF

(SHOA'lCORO)

(S>iORHX'''''J

0{13,.,,,"
ASS WHEEt.$PEO 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:
,..<,o~

e,(l :'H'!&

ASS WhEEt5PESO SENSOR R~

ASS OA! '" UNKCOtmcrOO!F)

!$HOfiTCQI'<O,

f!l
~

sc

ABS Wheel Speed Sensor

Permanent Magnet
Yoke

Coil

PermancntMagnct

sc

2011/9/19

ABS Wheel Speed Sensor

Hall effect type / MRE type wheel speed sensor is better than
magnetic induction style:
What are the method to measure Hall Effect Type / MRE type
wheel speed sensor?
When checking Hall Effect Type / MRE type wheel speed
sensor, don't use digital meter to check the resistance. The
voltage from digital meter might damage the semi-conductor
in ABS wheel speed sensor
When wheel speed sensor has malfunction, then :
- ABS will not work
- DTCs will be produced
- ABS warning light in the dashboard will be on
0

sc

2011/9/19

210

Hall effect type wheel speed sensor is better

than magnetic type
The voltage of output signal is not effected by car speed
(square wave)
Frequency is high ( can reach 20kHz=1000km/h)
Low Breakdown Rate
Not interfered easily by the magnetic wave
iiil ~~J5H!

ABSilfiij~~~*
.::.t:J~I!it:J'1![~

MREtype

sc

2011/8118

Disadvantage of magnetic type wheel

speed sensor
When speed is too low (output voltage< 1V) , ECU
might not inspect AC wave
Frequency Response not high - when the speed is fast,
Frequency Response can not follow
Effected by magnetic wave easily
At Hight Speed
Coil
,./\
(

R o t or

,
!

I
j

~ Q=:~_:~.==
I " ' ,c'~

! ',.

i .

2011/9/19

/ At Low Speed

Permanent Magnet

,".I'
,

_.\--_._.

Output

DriNen type

sc

Wheel rpm sensor test

OKPH

Right front wheel

OKPH

Left front wheel

OKPH

Means what unit?

lOKPH

Right rear wheel

lOKPH

OKPH

Left rear wheel

>;fiil:~f!ib~1W!f!ifii

>;tit1J~m!fi*mfiil:

Tum the tire by hand

How to test ABS is working or not?

sc

2011/9/19

213

Replace the Brake Fluid

Reasons for brake oil decreasing:
1.
2.
Steps to change brake oil :
1.
2.
3.
The way to up air:
1.
2.
3.
If the brake master cylinder is very dirty and the way
to up air is not correct, then what results will be

sc

2011etlused?

Do It Right--Replace the Brake Fluid

Often, used brake fluid looks like black coffee or coffee with
cream. Both conditions indicate contaminated or moisture-laden
brake fluid that should be replaced. The following steps will help
assure a complete brake fluid change:
Step 1. Remove the old brake fluid from the master cylinder using a
suction bulb. (Dispose of this old brake fluid properly.)
Step 2. Fill the master cylinder with new clean brake fluid from a
sealed container.
Step 3. Bleed each wheel brake until the fluid is clean.
sc

2011/9/19

214

The way to up air

OPEN BLEEDER
VALVE

ESCAPING
AIR BUBBLES

Fluid chamber

2011/9/19

sc

How to up the air after changing brake

master cylinder ?
Before installing in cars
Already in the car

---

A0020:M4 ----_

sc

2011/9/19

How to up the air after changing ABS HU/CM

1.

sc

2011/9/19

216

BAS
BAS - Brake Assist System
BA - Brake Assist
EBA - Emergency Brake Assist
Increase brake force in urgent brake.
BAS work or not, it depends on brake oil pressure and brake
pedal work speed
BAS has to be constructed with ABS system

sc

2011/9/19

With BA

Without BA

BAS
CROSS-SECTIONAL VIEW

OUTPUT CHARACTERISTICS

DURING BRAKE ASSIST OPERATION

t
DURING NORMAL BRAKING
OPERATION CHARACTERISTIC
(CHANGE ACCORDING TO PEDAL FORCE)
INPUT

- - - I......

sc

2011/9/19

BAS

0000
r:::::::::l

2011/9/1

sc

sc

2011/9/19

Brake pedal load sensing switch for new BA

function

sc

2011/9/19

219

ABS with BA & EBD system

Brake Fluid Level
Warning Switch

Stop Light Switch

Master Cylinder
Pressure Sensor

Speed

S peed

SensoIS

Sensors

Combinatiol1 Meter
Speedometer

ABSWaming Light

Skid

Control
ECU

DLe3

Parking Brake
Switch

EBD
EBD system design (Electronic Brake-force Distribution system)
- EBD system go with ABS system
- EBD system control front wheel and rear wheel separately.
- To prevent rear wheel from being locked earlier then front
wheel in braking.
~ use ABS wheel speed sensor to detect the slip rate of front/rear
wheel.
- Use ABS system to control (decrease) the brake oil pressure of
rear wheel
~ change brake-force distribution of front/rear wheel
~ distribution change depends on vehicle load, road situation
and speed.
sc
2011/9119
220

Benefit of EBD Comparison of stopping distance for the same brake pedal pressure

1. Light payload

2. Heavy payload
(without EBD)

3. Heavy payload
(with EBO)

..

.. .

EBD can increase the distribution of braking force to the rear wheelswhen there is aheavy payload.

c
front / rear brake force distribution

Left! right brake force distribution

EBD

Front Brake Force

sc

2011/9/19

EBD
EBD HU/CM actuation flowchart
ABSHU/CM
CM

HU

ABS WHEEL-SPEED
SENSOR (LF)

CALIPER PISTON (LF)

SOLENOID
VALVE

ASS WHEELSPEED
SENSOR (RF)

CALIPER PI.STON (RF)

CPU

ASS WHEEL-SPEED
SENSOR (LR)

. ASS WHEEL-SPEED
SENSOR (RA)

:
I
I
I
I
I
I
I

PUMP
MOTOR

CALIPER PISTON (LR)/

WHEEL CYLINDER (LR)

CALIPER PISTON (RR)I

WHEEL CYLINDER (RR)

l
B3A0413TOO5

sc

2011/9/19

222

TCS
TRC (Traction Control) ITCS/TRAC
ASR (Acceleration slip regulation)
To prevent from driving wheel slip (start to go , urgent acceleration, drive in
damp road)
Advantages : 1.

2.

Engine power will be decreased when TCS actuates (delay ignition timel
decrease injection quantityl control electronic throttle valvel control sub-throttle
valve) and the force of driving wheel (control wheel brake)
TCS must be constructed with ABS system

sc

2011/9/19

TCS

sc

2011/9/19

223

ESP
Electronic Stability Program

sc

2011/9/19

ESP
To prevent from slipping in turning (not under-steer or over-steer)
- tum in high speed/ damp mountain road / dodge for vehicle or people urgently
Engine power output and wheel driving force will be decreased in ESP actuation
ESP must be constructed with ABS system

sc

Steeled path (.vitl. . stabiliti

Gontrol)

/~=

\\
l~l

,-.j,
.

. .J

0, 0
..

2011/9/19

=-'"

Stability control: (a) unclersteer, (b) oversteer

IC

ESP
Control engine output
(engine brake)

More brake
forcer

More brake
. forcer

2011 /9/19

(Over Steer)

(Under Steer)

SC
226

vsc
... System Diagram -!III
Stop ug~t Switch

1-------1_
......

Sp(!ed SensOi'
>

SteefingAngle
Senwr ..... .

Engine EeU

Brake. Actuator

SUp Indicator
Light

Skid Control
ECU .

Yaw.lhte:SeflSor .

~ctid;tti1f;~~~,

....

VSCWarning

Light

:. . ~1~~te~CyUnder

VSCWaming

Buzzer

Pressure Sensor

sc

2011/9/19

ABS with EBD, BA, TRC, VSC

Brake Fluid Level
Warning Switch

Stop Light Switch

Master Cylinder
Pressure Sensor

Speed

Speed
Sensors

Ms___

Sensors

~g~l_

_V~C_W~r~n.8 ~g!:l

SI!}> IndiC<ltor Ught

EngineECU

Brnlce sYStem Warning ugti't

TRe 'OFF I;;di~iOr -

Skid
Control

ECU

sc

2011

227

Inputs & Outputs

Outputs

Inputs
FR,RL,RR)

'.~;
.

Ie sensor

"..

'."

ral G

;f

sor1EA

sc

2011/9/19

ESP Parts
Pressure Sensor
Master Cylinder
Rear Speed Sensor

Yaw & Lateral

G Sensor

Wheel Speed Sensor

Rear Speed Sensor

Front Speed Sensor

228

ESP
ESP systen1 design
- ESP system detect signal
~

vehicle speed, steering angle, (lateral grip force, yaw rate.

(Yaw rate o/S means the turning angel against vehicle body
axle)
~ Calculate the difference with "target yaw rate".
- ESP system control:
~ Engine RPM, brake system

sc

2011/9/19

Anti-Lock Control - Stability Assist - with adaptive front lighting

2008.25
Focu s

r------l

Am

I
fC';,l
I Adaptive front lighting
I
lS!ZI
I modulo
_ _ _ .II
IL. _ _~IG
1

C307 ESP

C838

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

I
I
t

GWA,A

$'1'11\.::0

",.p~

~p ~

l~c::[~::=f

S'/;.t.."
vee

S-CE8A

14

-----

;
I

A176

EI&Ctronl c . Stability
Program (ESP)
module

r==::: :::--=--====:=:---~====~ r=~::~ =:0

I

.5 GYfAO

4 EC12

16 , e111
~-- - --

H~kCAl'~

"i<:Hi CAti..

B-CE8 5 WltBU

:2

rRl
lSl2l

1-CF1A ,5 YEiRD

---,

_ _ _ !.

____ ~

C1I3

,35 WH'BU
1()..CEBA

.35 GY,Vf

7-CEBA.

~E88

7-CF67

.3S YEj8U

.35 WHIBU

5-EC12

,35 SU/RO

.3S GYiRO

4-EC12

stdng positlon

.:15 YE/AD

......-:vl:cc==";;.;;::E
=",,=,.'=H;''':'; :~C~.A.;.:826...:.:.,

8174
Yaw r~t. s.nsor

ceol
g..cF67
6

<>-CflA

..35 aN/AD
C113

.s BN:AD

15 ~'11
9-Cfl

2011 /9/19

.5_

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

r---=
1
-"'"
I~
I.
5

cal

sc
229

Yaw Rate Sensor

Uoul in V

i.
T

5
Upper limilation

4.5

(1.)=1)

+
ill

1.5

Output .
V(}\t.age

0.5
0.5

Lower limitation

r----+I-------OI+--------4--~
- 100

Yaw Rate

2011/9/19

... 100
(i)

in

-Is

How to check it ?

Yaw Rale
Left Turn .... ...
-

.. ,

RIght Thrn

Steering Angle Sensor

Steering Angle Sc,nsm'
Front

"
sc

2011/9/19

230

Steering Angle Sensor

How to check it ?

IG 12V
.... " .... """ ...... ,, ...... " .........

Sensor
output

,..---;......-----=-'V\tv- 5V
(ST1)

ECSCM

sc

2011/9/19

C307 ESP

7869/521ESG

1. Active rear wheel speed sensor

5.PCM engine control module

2. Brake booster and brake master cylinder 6. steering turning angle sensor
3. Active front wheel speed sensor

7. ABS and ESP warning indicator

4. Hydraulic unit and ABS/ESP module 2318. Yaw rate and lateral acceleration sensor

Hydraulic control unit

Under ESP control

General brake situation

TCS valve
motor

Inlet valve

Outlet valve

sc

2011/9/19

Front wheel speed

sensor

VDC/TCS/ABS control
microcomputer
component

VVDC close/slip indicator

VDC close button

Migration rate/lateral grip/G value

sensor for front & rear

Steering angle sensor

LUII/~/I~

232

Rear wheel speed

sensor

ESP light operation

When ESP and CAN in normal, and ignition switch in ON ' ESP indicator
light will be on for 3 seconds to test the light function. When system has
problem, ESP indicator will be ON.
When ESP and TCS is in operation, (ESP OFF switch is not pressed to
close the function) , ESP indicator as below :

Item

ESP indicator

TCS ' ESP not operate

No light

TCS in operation

1L8.
i LF--------------------------l
-,

~~1;

5~ ---

i,

Flash (every 0.5 second)

ESP in operation
TCS , ESP system has
problem

Light is ON

sc

2011/9/19

ESP Switch
ID
.
4WD

\. - 10
i l'

LOCK

ESP
OFF

0*
,."

..

ESP switch can removed the function of ESP and TCS.

ESP system only can be discharged in below situations:
1. When the vehicle stop or in low speed
2. When ESP is in actuation
sc

2011/9/19

233

ESP light operation

When ESP and CAN in normal, and ignition switch in ON ' ESP indicator
light will be on for 3 seconds to test the light function. When system has
problem, ESP indicator will be ON.
When ESP and TCS is in operation, (ESP OFF switch is not pressed to
close the function) , ESP indicator as below :

Item

ESP indicator

TCS ' ESP not operate

No light

TCS in operation
ESP in operation
TCS ' ESP system has
problem

Flash (every 0.5 second)

Light is ON

sc

2011/9/19

ESP Switch

ESP switch can removed the function of ESP and TCS.

ESP system only can be discharged in below situations:
1. When the vehicle stop or in low speed
2. When ESP is in actuation
sc

2011/9/19

233

Q&A

sc

2011/9/19

234