Automotive Sensors PDF

Automotive sensors
Automotive sensors
UniTrain-I course
"Automotive engineering 6: Automotive sensors"
Course number: SO4204-7F Version 1.0
Author: Hermann Kircheis
Lucas-Nülle GmbH • Siemensstraße 2 • D-50170 Kerpen (Sindorf) • Tel.: +49 2273

567-0
www.lucas-nuelle.com www.unitrain-i.com
Copyright © 2008 LUCAS-NÜLLE GmbH.

All rights reserved.
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Training objectives
Training objectives
Welcome to the UniTrain-I course titled Automotive sensors!

The LUCAS-NÜLLE team wishes you lots of fun and success in working
through the course topics and conducting the experiments. The next pages
provide an overview of the course's contents and necessary equipment.
The course contains nine chapters each of which covers a separate sensor. Each of
the sensors communicates with a control unit on the automobile to optimize the
engine's operation. Though a sensor's failure is indicated by the corresponding
control unit, it is up to the car mechanic to identify the actual fault on the sensor.
Course contents
l Physical fundamentals of sensors

l Sensor installation points on automobiles
l Motor control functions
l Identifying connections with the help of wiring diagrams
l Establishing and testing connections
l Sensor functionality checks
l Recording characteristics
l Fault localization
Prerequisites
To work through the course successfully, you need to have the following background:
l Fundamentals of electrical engineering and electronics

l Basic skills in measuring current, voltage and resistance using a multimeter
l Basic skills in using an oscilloscope
l Familiarity with wiring diagrams

Equipment
Equipment
SO4203-
UniTrain-I interface
2A
SO4203- UniTrain-I board:
4V Automotive sensors
UniTrain-I
SO4203-
measurement
2J
accessories
SO4203- Extended power
2D supply
Optional: UniTrain-I
SO4203-
experimenter as a
2B
docking station
Optional: MetraHit
LM2321
multimeter
Optional: Hand
pump
Some animations require an installed Flash player. If your system

does not have a Flash player, you can download the latest version
from Adobe.

Starting up the sensor board
Module SO4203-4V designated "Automotive sensors" incorporates 9 different

sensors.
Every sensor is fully accessible via its connections and needs to be linked to the
voltage supply as well as the necessary measuring devices before the experiments
are conducted.
Move the mouse pointer over the diagram to learn more about the board's
individual components.
Perform the following settings to supply the board with a voltage:
l Select "DC Power Supply" from the menu "Instruments".

l Turn on the POWER key (colour turns red)
Outputs "12V", "5V" und "GND" on module SO4203-4V are now active and ready for

use in the various experiments.
Technical data:
l 12-V, 5-V voltage supply via an interface
l 560 x 268 mm (width x height)
Warning:
The heater for the PTC and NTC resistors can become very hot and cause burns.
While operating the engine for speed measurement by means of an inductive
sensor or Hall sensor, ensure that the measurement leads do not get entangled in
the rotating disc.

Preliminary theory
Preliminary theory
Simply put, an automotive sensor is a gauge which supplies a motor control unit with
the information necessary to calculate ignition times and fuel injection quantities, for
instance.
As one would expect, sensors are also needed in other types of open-loop and
closed-loop control circuits. However, many of these sensors have the same physical
operating principles as automotive sensors. Accordingly, we can concentrate on the
essential operating principles using the motor control unit as a case in point.
Sensors are used to measure variables such as engine speed, camshaft position,
coolant temperature and intake pipe underpressure.
Move the mouse pointer over the diagram to identify the various sensors.
The sensors listed below are used and examined in this course.
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Preliminary theory
l NTC
l PTC
l Knock sensor
l Intake pipe pressure sensor
l Hall sensor
l Inductive sensor
l Throttle valve switch
l Throttle valve potentiometer
l Air mass meter
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NTC temperature sensor
NTC temperature sensor
The owner of a relatively old vehicle has complained that its coolant
temperature gauge no longer works. One of your colleagues performed an
initial test in which the motor control unit issued the following error code:
"Coolant temperature sensor circuit voltage too low." It is your task to
diagnose the coolant temperature sensor.
Let us familiarize ourselves with the function of such an automotive sensor and its
electric circuit before diagnosing it.

NTC sensor theory
NTC sensor theory
An NTC resistor is one whose resistance depends on temperature, i.e. its resistance
drops as the temperature rises. Consequently, an NTC resistor, or thermistor, is
more conductive in the hot state than in the cold state. NTC stands for negative
temperature coefficient, indicating that the resistance is inversely proportional to the
temperature.
Pin 1 Signal
Symbol
Pin 2 Signal
NTC as a coolant temperature sensor,

built into the thermostat housing
An NTC's reference value is its resistance at 20°C (R20) which is defined as the cold
state.
Because it depends on temperature, the resistance need not be calculated, rather
simply read off from characteristics on data sheets.
The circuit symbol's two opposing arrows indicate that the resistance drops as the
sensor temperature rises.
NTC resistors are more conductive at higher temperatures, their resistance being
lower then. This is because a rise in temperature detaches more electrons from their
crystal bonds, making them available for conducting electricity.
NTC sensors on automobiles are frequently used for measuring:
l Coolant temperature
l Oil temperature
l External temperature
l Air-conditioning outlet temperature
l Fuel temperature (in the case of common-rail diesel engines).
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NTC characteristic
NTC characteristic
Where in the circuit diagram is an NTC shunt located?
Between terminals ??? and ???.
Check answer
Set up the experiment as shown next:

NTC characteristic
Remember to turn on the board's power supply (refer to the page on start-up).
Connections:
From To
Multimeter Ohm NTC pin 1
Multimeter GND NTC pin 2
Using the multimeter, measure the NTC's resistance at room temperature:
R = ??? kOhm
Check answer
Using the toggle switch to the NTC resistor's left, turn on the heater and observe the
resultant reading on the multimeter. Note the reading in the table every 30 seconds.

NTC characteristic
Once your measurements are complete, turn the heater off again.
How does the NTC's resistance change on heating?
As the NTC's temperature rises, its resistance drops. Correct.
Check answer

NTC feed line
NTC feed line
Now you know how to test an NTC coolant temperature sensor by measuring its
resistance. However, the fault might not lie in the sensor at all, but in the cabling
between the sensor and motor control unit.
Let us examine the circuit via which an NTC temperature sensor is connected to the
motor control unit:
This control unit contains a series resistor of a fixed value, while the resistance of
the NTC mounted on the engine changes as a function of the coolant temperature.
The control unit analyzes the voltage drop across the series resistor and uses this
value to calculate the coolant temperature.
As the two resistors are connected in series, they together form a voltage divider,
i.e. the applied voltage of 5 V is distributed correspondingly among the two resistors.
According to a voltage divider's principle, the larger a dividing resistance, the greater
the voltage drop across it. Because the control unit's built-in resistor has a fixed value
whereas the NTC has a variable resistance, the ratio between the voltage drops
across these two resistances is also variable.

NTC feed line
How does the voltage measured at pin 3 change as the engine temperature rises
(i.e. as the NTC resistance drops)?
Perform an
The voltage decreases. appropriate
measurement
The voltage remains constant.
if you are not
The voltage increases. sure about the
answer.
What is the reason for the response provided above?

The voltage at pin 3 drops because the NTC's resistance
increases with temperature.
The voltage at pin 3 drops because the NTC's resistance
decreases as the temperature rises.
The voltage at pin 3 rises because the NTC's resistance
increases with temperature.
decreases as the temperature rises.
The voltage at pin 3 drops because the NTC's resistance Several
increases relative to the series resistor. answers may
The voltage at pin 3 drops because the NTC's resistance be correct.
decreases relative to the series resistor.
increases relative to the series resistor.
decreases relative to the series resistor.
The voltage remains constant because the engine
temperature does not influence the value measured at
pin 3.
Check answer

NTC summary
NTC summary
Solving the customer's problem

Now you are able to test the NTC sensor as well as its circuit. It is extremely
important here to note that the sensor visible on the engine forms a series connection
with the resistor built into the motor control unit.
Modern engine management systems are able to indicate error codes related to such
NTC sensors in more detail, permitting direct establishment of the error sources.
Example: The motor control unit issues the following error code: "Coolant temperature
sensor circuit: Insufficient voltage". This means that the voltage measured at output
pin 3 is lower than it should be.
Which conclusions can be drawn from this error code on the basis of the earlier
measurements?
1. The electric circuit is interrupted, e.g. by an open contact on the coolant

temperature sensor.
2. There is a short circuit between the two sensor connections or inside the sensor
itself.
How can the control unit tell whether the voltage is too low?
Again consider the voltage drop across both resistors when the system is OK.
Regardless of the NTC resistor's temperature, there will always be a certain voltage
drop across it, the remaining voltage dropping across the series resistor.
Consequently, the voltage measured at pin 3 should never be precisely 0 V or 5 V; in
practice, this voltage instead lies between approximately 0.7 V and 4 V (variations
between individual systems are possible).
If the control unit measures a voltage of 5 V or 0 V at pin 3, it recognizes the

abnormality and issues a corresponding error code.

PTC temperature sensor
PTC temperature sensor
A customer complained about the engine control lamp burning on their

automobile. A subsequent test revealed an error code indicating a fault on
the exhaust gas temperature sensor.
It is your job to diagnose this sensor. For this purpose, we will first examine
the function of this kind of sensor.
Let us familiarize ourselves with the function of this type of automotive sensor and its
electric circuit before diagnosing it.

PTC sensor
PTC sensor
The exhaust gas temperature sensor makes use of a PTC resistor, whose value
changes as a function of the temperature. By measuring this resistance, the motor
control unit is able to obtain information on the exhaust gas temperature.
A PTC is more conductive at low temperatures than at high ones.
Pin 1 Signal
Symbol
Pin 2 Signal
PTC exhaust gas temperature sensor
PTC resistors (positive temperature coefficient) are materials which conduct electric
current more efficiently at low temperatures than at high ones. A PTC resistor's value
rises with temperature, hence the term "positive temperature coefficient".
Metals generally have a positive temperature coefficient which, however, is much
lower and essentially linear compared with the coefficients of the components
considered further below.
Because PTCs heat up automatically when conducting high currents, the motor
control unit allows only low measurement currents to flow. As the PTC heats up in the
flow of exhaust gas, its resistance rises as a result.
The two co-aligned arrows indicate that the sensor's resistance is directly proportional
to its temperature.

Experiment: PTC
Experiment: PTC
Assemble the circuit shown next.

Using the multimeter, measure the PTC resistance in the cold state (room
temperature).
Connections:
From To
Multimeter Ohm PTC pin 1
Multimeter GND PTC pin 2
What is the resistance of our PTC element at room temperature?
Measure the
The resistance in the cold state (room temperature) is ???
resistance with
kOhm. the multimeter.
Check answer
Turn on the heater using the toggle switch to the left of the PTC resistor and observe

Experiment: PTC
the resultant reading on the multimeter. Note down the reading every 30 s in the
table.
Turn the heater off again once your measurements are complete.
What is the resistance after heating?
Measure the
The resistance now is ??? kOhm. resistance with
the multimeter.
Check answer

Experiment: PTC
As the PTC's temperature rises ...
its resistance remains unchanged.

its resistance decreases.
its resistance increases.
Check answer
At the temperatures attained in the experiment above, the changes in resistance are
very small. The next diagram shows a PTC sensor's temperature response over a
wider temperature range.
General characteristic of a PTC
Interpret this characteristic. How does a PTC sensor's resistance change as its
temperature rises?
Small temperature changes at low temperatures cause

large changes in resistance.
Small temperature changes at low temperatures cause Several
small changes in resistance. answers may
Small temperature changes at high temperatures cause be correct.
large changes in resistance.
Small temperature changes at high temperatures cause

Experiment: PTC
small changes in resistance.

The resistance increases at a constant rate.
Check answer

PTC summary
PTC summary
As you have established by now, a PTC temperature sensor's resistance begins to

change substantially only at very high temperatures. At the low temperatures
generated on our sensor board, the resistance hardly changes at all. For this reason,
PTC sensors are rarely found in automotive applications, instead being employed in
hot environments, e.g. exhaust gas temperature measurement, where NTC sensors
would get damaged.
Though automobiles rarely make use of PTC sensors, they frequently employ
components exhibiting the properties of a PTC sensor. These components comprise
heating elements, e.g. for the rear window, mirrors and washing nozzles. If such a
heating element is activated in the cold state when the PTC heating wire's resistance
is low, a high current initially flows, causing the heating element to warm up rapidly. In
this process, its resistance also increases, causing the current and heating power to
drop. The further the heating wire's temperature rises, the lower the current which is
able to flow through it. This kind of heater is therefore self-regulating.

Knock sensor
Knock sensor
When bringing their car in for inspection, a customer stated that the car's
engine makes a knocking noise during acceleration.
This noise started occurring recently without any apparent cause. For
reasons of economy, though, the customer recently switched over from
premium petrol to standard petrol, which is permissible according to the
manufacturer.
Knock sensor on a 4-cylinder engine
Let us familiarize ourselves with the function of this kind of automotive sensor and its
circuit before diagnosing it.

Knock sensor theory
Knock sensor theory
The term "knocking" signifies uncontrolled combustion inside the cylinder of an

internal combustion engine.
In this case, a part of the mixture ignites spontaneously. Normally, the compressed
mixture in an internal combustion engine is ignited by the spark plug. This generates
a flame front, i.e. the fuel-air mixture bursts into flame starting at the spark plug and
builds up a pressure which pushes the piston down during the power stroke.
Pin 1 Signal
Symbol
Pin 2 Signal
Knock sensor in the engine block housing
During combustion affected by knocking, a part of the fuel-air mixture ignites

uncontrollably without any stimulus from the spark plug, or the mixture is ignited
prematurely by the spark plug. The outcome in both cases is a pressure wave which
pushes against the piston still moving upward. The temperature in the cylinder rises
uncontrollably to peak levels which can melt the piston floor. The excessive heat can
also cause the piston to expand beyond proportion and rub against the cylinder's
walls. This results in major engine damage in the form of piston seizure.
A knock sensor is employed for the motor control unit to detect knocking. This sensor
converts the engine block's mechanical vibrations into electric pulses which can be
evaluated electronically. The knock sensor has decisively changed the nature of
petrol engine management. The ability to move the ignition point closer to the knock
threshold (the control unit detects knocking and can match the ignition point
accordingly) improves fuel consumption, emission levels as well as power and torque.
Also important here is improved self-adaptation as the engine ages.
If an engine management system possesses a knock sensor, it can adapt

automatically to various fuel types. Engines designed to run on premium petrol are
additionally compatible with regular petrol, while super-high octane engines can also
run on premium petrol. However, this conversion is accompanied by a slight rise in
fuel consumption (due to a later ignition point), so that the ultimate cost benefit is
marginal.

Knock sensor theory
Positioning of (1) and (2) knock sensors on an engine.
One knock sensor usually suffices for small engines, two such sensors being needed
for more than four cylinders and V-type or Boxer designs. They are screwed to an
appropriate surface of the cylinder block with the required tightening torque and
connected electrically to the motor control unit by means of two cables (1/2).
Design of a knock sensor:
1. Seismic mass for attenuation

2. Compound
3. Piezo-ceramic
4. Contacts
5. Electrical connections
A usually ring-shaped mass (blue) prestressed to a certain value and lodged inside
the knock sensor counteracts the engine's vibrations. The mass transmits the exerted
forces to a piezo-crystal layer (red) whose two surfaces (black) give rise to different
charges already on exposure to low forces. The control unit interprets these,
differentiating quite accurately between engine standstill, normal operation and
combustion characterized by knocking. Important here is proper positioning of the
sensor so that no knock signal from any cylinder escapes the control unit's notice.

Knock sensor theory
Principle of piezo-electric sensors
Directional deformation of the piezo-electric material gives rises to microscopic

dipoles inside the elementary cells (shift in charge concentration). Summation over all
the crystal's elementary cells results in a measurable voltage. Directional deformation
here means that the applied pressure acts on the specimen not from all sides, but just
from opposite ones, for instance.

Experiment: Knock sensor signal
Set up the experiment shown next.
Open the virtual oscilloscope and perform the settings shown next.
Connections:
From To
Interface A+ Knock sensor pin 1
Interface A– Knock sensor pin 2
Settings:
Oscilloscope settings
Channel A 500 mV / div
Channel B OFF
Time
500 µs / div
base:
Mode: X/T, DC, Single

Channel A / Rising edge / Pre-trigger

Trigger:
25%
Start the oscilloscope, strike the knock sensor firmly with a soft object (e.g. plastic
handle) or your finger, and record the resultant voltage response. Using the mouse,
drag the oscillogram to the placeholder provided for this purpose. Enter all scaling
factors.
Sensor signal oscillogram (soft object):
Time base:
??? µs / DIV
Channel A:
Amplitude
factor:
??? mV / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Now record the voltage characteristic produced by a hard knocking object (e.g.
screwdriver).
Sensor signal oscillogram (hard object):
Time base:
??? µs / DIV
Channel A:
Amplitude
factor:
??? mV / DIV
Coupling:
AC DC

Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
These two oscillograms can be used to explain how the motor control unit is able to
distinguish between normal engine vibrations and knocking by individual cylinders.
How can the measurement results be interpreted?
Normal engine operation is characterized by uniform

combustion inside the cylinders, so that a ???
This frequency is partly suppressed by the knock Fill in the blanks.

sensor's attenuation modules, so that the amplitude
???
of the sensor's output voltage
Combustion characterized by knocking inside a

cylinder causes the knock sensor to emit signals of a ???
These signals can be ???
Check answer

Experiment: Knock sensor diagnosis
Set up the experiment shown next in order to measure the knock sensor's resistance.
Connections:
From To
Multimeter Ohm Knock sensor pin 1
Multimeter GND Knock sensor pin 2
What is the knock sensor's resistance?
Measure the
The resistance is ??? megohms. resistance with a
multimeter.
The material of the piezo-element in the knock sensor is ...
weakly conductive.
strongly conductive.
non-conductive.
Check answer

Recall the customer's original complaint.
The customer complained about a loud knocking in the engine. In the previous
measurement exercise, you checked the sensor using the oscilloscope. On the
basis of the knowledge you have acquired so far, how would you proceed further
in order to localize the fault? Which components would you test/consider
replacing first?
The sensor is defective and needs to be replaced.

The sensor cables are defective; they need to be
measured and repaired if necessary.
Several
The sensor is incorrectly attached (wrong torque); its
answers can
mounting on the engine block needs to be checked.
be correct.
There is another defect (e.g. mechanical problem) on the
engine.
The ignition setting needs to be checked.
Check answer

Pressure sensor
Pressure sensor
A customer's vehicle has been brought in with the complaint that the
engine starts very poorly, hardly responds to the gas pedal, jerks a lot and
develops no power. In view of this, the customer had the car towed away
to your workshop. Because the car is an old model, its motor control unit is
not furnished with a fault diagnosis function.
After a brief initial visual check, the service technician suspects a defect on
the "MAP sensor".
Let us familiarize ourselves with the function of this kind of automotive sensor and its

Pressure sensor theory
A Manifold Absolute Pressure (MAP) sensor measures the absolute pressure in a

suction pipe with respect to the ambient pressure. This sensor is located between the
throttle valve and the inlet valves. When the throttle valve is closed, the piston's
downward motion creates a strong negative pressure (low absolute pressure) in the
suction pipe. When the throttle valve is opened, more air flows into the suction pipe
so that the negative pressure decreases (absolute pressure rises). The suction pipe's
absolute pressure is hence a measure of the engine load.
Pin 1 GND
Pin 2 Signal Symbol
Pin 3 + 5V
Design and function:
A – Piezo-membrane measuring element
B – Reference chamber
C – Measurement pipe for hose

connection
D – Evaluation circuit (signal amplification)
E – Hose connected to the measurement

pipe
The MAP sensor contains a piezo-membrane made of silicon crystal. Attached to the
surface of this membrane are strain-gauges, two in the middle and two more near the
edges.
As the pressure exerted on it rises, the membrane bends, hence increasing the
resistance of the inner strain-gauges and decreasing the resistance of the outer ones.

An internal evaluation (bridge) circuit built into the sensor supplies a voltage signal
ranging between about 0.2 and 4.3 V. In the case of non-supercharged engines, the
pressure ranges from well below 1 bar to about 1 bar; in the case of turbo engines,
the boost pressure can result in values of up to 2 bar. A temperature sensor can also
be built into the same housing.
Pressure sensors are being employed increasingly on motor vehicles. A distinction is

generally made between overpressure and underpressure sensors. Overpressure
sensors are used, for instance, to measure boost pressure on turbo engines,
atmospheric pressure, tyre pressure and fuel pressure in the case of diesel and petrol
engines with direct fuel injection. Though these sensors measure a wide variety of
pressure ranges, they are all based on the same operating principle. The MAP sensor
can be used as a substitute for the air-mass meter.

Experiment: Pressure sensor
Circuit diagram excerpt: Motor control unit and sensors
Most circuit diagrams do not specify the line routing of signals. Nevertheless, signal
assignments can sometimes be inferred logically, as in the case of our circuit
diagram.
Signal line: The signal line leads directly to the control unit without being shared by
other components. Accordingly, it is clear that the signal line must be assigned to
sensor pin 2.
Ground: Reference ground is often shared by other components, as in our case too.
The line at pin 1 of the MAP sensor also supplies the NTC. If you refer again to the
chapter on NTC sensors, you will recall that the NTC signal line is assigned to pin 3
(control unit), while ground is assigned to pin 4 (control unit). Accordingly, the line
shared by the NTC and MAP sensors serves as reference ground.
5-V reference voltage: Only pin 3 (on the sensor) is then left over for the 5-V
reference voltage. This voltage source also supplies the second pressure sensor.

Connect the suction pipe pressure sensor to the 5-V reference voltage and GND.
Open the virtual instrument "Voltmeter A" under the menu item "Instruments ->
Measuring devices -> Voltmeter A". Connect the output signal to the virtual voltmeter
(A+, A-)
From To
5V Pressure sensor pin 3
Interface A+ Pressure sensor pin 2
Interface A– Pressure sensor pin 1
Voltmeter A settings
Measuring range: 5 V DC
Mode: AV
Connect a vacuum hand pump to the MAP sensor's connector.

Measure the voltage signal at various negative pressures and enter the results in the
table.
Analyze the voltage characteristic.
The voltage remains constant.

The voltage increases with the vacuum.
The voltage decreases as the vacuum increases.
Check answer

How does the pressure sensor respond when the ambient pressure is exceeded?
The voltage remains constant. Set the

pressure
The voltage increases with the overpressure.
pump to
The voltage decreases as the overpressure increases. overpressure.
Check answer
You have ascertained that the sensor works properly and its cabling is OK. However,
the customer's automobile still poses the same problem.
What could be the next step in your diagnosis?
Replace the MAP sensor and see what happens.

Several
Check the vacuum hose leading to the suction pipe for
answers may
cracks and porosity.
be correct.
Check whether the suction pipe's connector is clogged.
Check answer

Hall sensor
Hall sensor
A customer brings their vehicle to the workshop with the following

complaint:
The engine control lamp comes on and the vehicle assumes the
emergency operating mode.
In an initial test, you establish that the control unit has issued an error code
indicating a defective camshaft sensor.
What might have caused this sensor to fail?
Hall sensor with camshaft gear
Let's familiarize ourselves with the function of this kind of automotive sensor and its
Name: h, Date: 06.11.2017 Page 1 of 1

Hall sensor theory
Hall sensor theory
Discovered by Edwin Hall in 1879, the Hall effect refers to the occurrence of an
electric field when a conductor carrying an electric current is positioned in a stationary
magnetic field. Perpendicular with respect to the current flow as well as the magnetic
field's alignment, the voltage vector across the conductor is termed Hall voltage (UH)
after its discoverer.
Pin
+ 5V
1
Pin
GND Symbol
2
Pin
Signal
3
As a camshaft sensor, the Hall sensor's main purpose is to precisely reference the
first cylinder (in terms of fuel injection start, knock control, ignition control) in
coordination with the crankshaft sensor. However, the Hall sensor can also perform
the following functions:
l Registration of transmission output speed

l Active speed sensing in ABS systems
l Registration of ignition parameters
1. Rotating
bell in a
distributor
with four
sectors
2. Permanent
magnet
3. Hall
sensor
Name: b, Date: 06.11.2017 Page 1 of 3

Hall sensor theory
Example: Hall sensor in an ignition distributor
Function
Example of a camshaft sensor
A rotor made of magnetic material turns along with the camshaft. The Hall IC is
located between the rotor and a permanent magnet. If a mark (comprising a cog, for
instance) now passes the camshaft sensor element (made of a semiconductor plate),
it changes the intensity of the magnetic field perpendicular to the Hall element. This
produces a Hall voltage in the sensor.
A – Sensor housing
B – Permanent magnet
C – Evaluation circuit
D - Hall IC
However, this voltage is very low, being in the order of a few millivolts. The sensor
contains an integrated evaluation circuit which processes the signals and outputs
them in square-wave form to the motor control unit.
Principle of a Hall sensor:
l I Plate current
l IH Hall current
l IV Input current
l UH Hall voltage / signal
l UR Reference voltage
l B Magnetic field
l a Deflection of electrons by the magnetic
field
As opposed to the inductive sensor, the signal voltage here does not depend on the

Hall sensor theory
relative speed of the sensor and rotor (i.e. engine speed).
Put more simply: The rotation of the gear rim changes the Hall voltage of the Hall IC
in the sensor head, the output comprising square-wave signals. The variable voltage
is routed to the control unit where it is analyzed in order to acquire the necessary
data.
Each time a tooth space or a sector turns past the Hall sensor, it generates a Hall
voltage which is relayed to the motor control unit.
Together with the signal from the crankshaft sensor, the Hall sensor signal allows the
motor control unit to determine which cylinder is currently performing the power
stroke.

Experiment: Hall sensor
This engine is furnished with two Hall sensors each at the front ends of the cylinder
heads.
Take a look at the circuit diagram below.
Which of the control unit's connections does the Hall sensor make use of in this
diagram?
Connections 1 and 2.
Connections 4, 5 and 6.
Which signals are present at the control unit's individual pins?

The Hall sensor's ground connection is assigned

???
to
The Hall supply voltage is assigned to ???
The Hall sensor's signal line is assigned to ???
Check answer
Set up the experiment shown next. For the subsequent measurements, mount the
Hall sensor disc on the motor (top left) and let the motor turn slowly.
Connect the Hall sensor on the board according to the following list:
From To
5V Hall sensor pin 1
Interface A+ Hall sensor pin 3
Interface A– Hall sensor pin 2
Measure the Hall sensor's connected signals and supply voltage using Voltmeter A:

Mode: P
Measure the voltage between the Hall sensor's connections.
The supply voltage is ???V.
The signal voltages are ???V and ???V.
Check answer
Open the virtual oscilloscope via the menu path Instruments -> Measuring devices
and set it as shown in the table below.
Channel A 2 V / div
Channel B OFF
Time
100 ms / div
base:
Mode: X/T, DC
Trigger:
25%
Increase the camshaft disc's speed using the rpm potentiometer to a low setting.
Copy the resultant oscillogram to the placeholder provided for this purpose.
Time base:
??? ms / DIV
Channel A:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC

Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Increase the rpm to a medium value, leaving the oscilloscope settings as they are.
Time base:
??? ms / DIV
Channel A:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Perform a measurement at maximum speed, with the rpm potentiometer at its right
limit. Leave the oscilloscope settings unchanged.
Time base:
??? ms / DIV

Channel A:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Determine the maximum speed in rpm. For this purpose, read the period T of one
rotation, taking into account the oscilloscope's scale factor.
Determine the maximum speed in rpm. For this purpose, read the period T of one
rotation.
Take into
The period is ???ms.
account the
oscilloscope's
The maximum speed is approximately ??? rpm
scale factor.
Check answer
What is the relationship between signal shape and speed?

In relation to the speed, the amplitude is ???
In relation to the speed, the signal shape over the
???
entire range is
An accurate measure of the speed here is ???
Check answer
Now decide on the possible causes of the fault described at the beginning of this

chapter. To help you, the fault is outlined once again below.
l The engine control lamp shines.

l The vehicle assumes the emergency operating mode.
l An initial diagnosis with the tester shows that a fault code has been issued.
l The fault code indicates a defect in the camshaft sensor.
What might be the cause of the defective sensor signal?

A visual check
Mechanical damage to the sensor. and the earlier
Broken sensor wheel or damaged cogs. measurement
with the
Short-circuited sensor line. oscilloscope
Interrupted connection revealed no
faults.
Check answer

Inductive sensor
Inductive sensor
A customer brings their car to the workshop with the following complaint:
The engine control lamp comes on and the vehicle assumes the
emergency operating mode.
In an initial diagnosis with the tester, you find out that an error code has
been issued, indicating a defect on the crankshaft sensor.
A visual check of the sensor reveals no external faults.
What might be the cause of the defect?
Let's familiarize ourselves with the function of this automotive sensor and its circuitry
before diagnosing it.

Inductive sensor theory
As the name suggests, an inductive sensor operates on the principle of induction,

according to which a voltage is produced in a coil when it moves relative to a
surrounding magnetic field.
The inductive sensor makes use of this phenomenon, permitting contactless and
consequently wear-free measurement of angles, distances and speeds.
Pin
Signal
1
Symbol
Pin
Signal
2
Scope of application
l Speed measurement - e.g. on a crankshaft, gearbox or ABS

l Determination of crankshaft position
l Pulse generation for ignition
Description of a crankshaft sensor as an example
Comprising a permanent magnet and an induction coil with a soft iron core, a
crankshaft sensor measures engine rpm. The pulse generator (motion-based)
comprises a gear rim mounted on the flywheel, crankshaft or belt pulley. Only a
narrow air gap separates the inductive sensor from the gear rim.
A – Electrical connections
B – Coil

C – Permanent magnet
D – Soft iron core
The magnetic flux through the coil depends on whether a space or mark is in front of
the sensor. A mark (i.e. cog) concentrates the magnetic field, while a space weakens
the field.
When the crankshaft and gear rim rotate, each passing cog changes the magnetic
field. This change induces a voltage in the coil. The number of pulses per unit of time
are a measure of the engine speed. Dedicated spaces on the gear rim also permit the
control unit to identify the engine's instantaneous position.
Induced voltage
Magnetic field's
intensity

The engine speed serves as a main control variable in calculating the injection and
ignition points.
This arrangement results in the signal shown next.
Inductive sensor's signal: 1 – cog; 2 – space; 3 – reference mark (large space)
If the sensor fails,
l the engine might misfire.

l the engine might stall.
l an error code is saved.
Possible causes:
l Winding short circuit

l Line interruption or short circuit
l Mechanical damage to the gear rim
l Heavy soiling
l Excessively large air gap
Fault localization

l Read out the error memory

l Check the connections
l Check for soiling and mechanical damage
Perform a check with an ohmmeter
Important: A direct check of the crankshaft sensor with an ohmmeter should be

performed only after making sure that the sensor is inductive and not a Hall
sensor, because the latter's electronics can get damaged by an ohmmeter.
Sensors with 3 connections and even those with 2 connections might turn out to
be Hall sensors. Active wheel speed (Hall) sensors forming part of the ABS also
have a 2-pole connector. Caution should be exercised in all such cases.
l Internal resistance: 200 - 1000 ohms (depending on the setpoint value)

l Short circuit at 0 ohms; interruption at very high values
l Ground connection (pin to ground) – setpoint value: > 30 megohms

Experiment: Inductive sensor
The sensor is positioned on the crankshaft housing near the flywheel.
Identify the crankshaft sensor in the circuit diagram.
Where in the circuit diagram is the inductive sensor?
The inductive sensor is connected to terminals ???

???.
Check answer

An inductive sensor can be connected to an oscilloscope, and the sensor's signal

observed as the gear rim turns. Connect the inductive sensor appropriately on the
board.
Mount the accompanying toothed disc on the motor shaft at the top left.
Connection list
From To
Interface A+ Inductive sensor pin 1
Interface A- Inductive sensor pin 2
Open the virtual oscilloscope via the menu path Instruments -> Oscilloscope and set it
as shown in the table below.
Channel A 200 mV / div
Channel B OFF
Time
50 ms / div
base:
Mode: X/T, DC
Trigger:
0%
Turn on the 12-V power supply and increase the crankshaft disc's speed by means of
the "rpm" potentiometer to a low setting. Copy the resultant oscillogram to the
placeholder provided for this purpose.

Time base:
??? ms / DIV
Channel A:
Amplitude
factor:
??? mV / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
After that, conduct a measurement at maximum speed with the rpm potentiometer set
to its right limit.
Time base:
??? ms / DIV
Channel A:
Amplitude
factor:
??? mV / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Compare the two measurement results. Which statements are correct?
The frequency and amplitude depend on the speed.

The frequency and amplitude do not depend on the

speed.
The value of the induced voltage depends on the spacing
between the sensor and gearwheel, as well as the
speed. Several
answers may
The value of the induced voltage depends only on the
be correct.
speed.
The induced voltage is inversely proportional to the
speed.
The induced voltage is directly proportional to the speed.
Check answer
If the voltage drops below a minimum level or a space is not detected, the control unit
can no longer reliably evaluate the signal and assumes the emergency mode.
Decide on the possible causes of the fault based on its description at the beginning of
the exercise. As an aid, the fault is outlined once again below.
l The engine control lamp comes on.

l The vehicle assumes the emergency operating mode.
l An initial diagnosis with the tester reveals that an error code has been issued.
l The code indicates a fault on the crankshaft sensor.
A visual check of the sensor reveals no external faults.
What might have caused the sensor to fail?
The sensor is mechanically damaged.

The sensor wheel is soiled or damaged. Several
The supply line is short circuited. answers may
The supply line is interrupted. be correct.
The voltage supply is malfunctioning.
Check answer

Throttle valve switch unit
A customer brings their car to the workshop with the complaint that the
engine responds poorly and jerks on attempts to accelerate rapidly.
Based on their long years of experience, the workshop supervisor
assumes that this is due to a faulty throttle valve switch.
before diagnosing it.

Design of a throttle valve switch unit
A throttle valve switch unit serves to reflect the throttle valve's setting and is mounted
directly on the valve axis. The switch settings are signalled to the motor control unit
and used to help calculate the required fuel supply.
1–
Throttle
valve axis Pin
Signal
1
2 – Idle
contact – Pin
COM Symbol
micro- 2
switch
Pin
Signal
3 – Full 3
load
contact
The throttle valve switch unit houses two switches operated via a shifter mechanism.
Both switches provide the motor control unit with information on the engine's idle and
full-load states to ensure precise calculations of the required fuel quantity and firing
angle.
In the idle state, the throttle valve switch unit essentially performs the function
described next.
l It permits fuel cut-off during self-propulsion, thus notably lowering the

consumption of fuel injection engines compared with carburettor models.
When the automobile is in the self-propulsion mode (i.e. rolling under its own
momentum with the gas pedal closed), the switch notifies the motor control unit
that the throttle valve is closed, so that the control unit stops fuel injection at an
engine speed above 1800 rpm. When the speed drops below 1200 rpm, fuel
injection is resumed again to prevent the engine from stalling. The precise
threshold values depend on the fuel injection system.
In the full-load state, the throttle valve switch unit performs the function described
next.
l It notifies the control unit that full load is being exerted, whereupon the control
unit enriches the fuel mixture to ensure smooth acceleration.
Effects of failure:
A defective throttle valve switch can have the effects described next.

l The engine stalls in the idle state

l The engine jerks under full load
A defective throttle valve switch is attributable to the following causes:
l Mechanical damage (e.g. through vibrations)

l Faulty electrical contact (e.g. through corrosion, moisture)
l Faulty internal switch contact (e.g. through moisture, soiling)
Variants
A throttle valve switch unit's mechanical makeup varies according to its

manufacturer, i.e. the two switches for the idle and full-load states can differ in
design. A micro-switch and sliding contact are always used for indicating the idle
and full-load states. Any possible combination of these components can be found
in a throttle valve switch depending on the manufacturer.
Let's assume that our switch unit uses one micro-switch for the idle state and one
sliding contact for the full-load state.
Include the measures listed below when localizing faults.
1. Check the throttle valve switch unit for proper assembly.

2. Check whether the shifter mechanism is operable via the valve shaft (when the
engine is at a standstill, move the throttle valve from its idle limit to its full-load
limit, listening whether the switches are actuated in this process).
3. Check whether the plug connection is firm and clean.
4. Check the switching contacts with a multimeter:
¡ Idle switch closed: Measurement value = 0 ohms.
¡ Idle switch open (important: slowly open the throttle valve until the idle
switch opens): Measurement value = > 30 megohms.

¡ Full-load switch open: Measurement value = >30 megohms.
¡ Full-load switch closed: Measurement value = 0 ohms.

Experiment: Throttle valve switch unit
Set up the experiment shown next and connect the throttle valve switch unit to the
oscilloscope.
From To
Interface A+ Throttle valve switch unit pin 1
5V Throttle valve switch unit pin 2
Interface B+ Throttle valve switch unit pin 3
GND A- and B-
Open the oscilloscope and perform the settings shown next.
Channel A 2 V / div
Channel B 2V / div
Time
1 s / div
base:
Channel B / Rising edge / Pre-trigger
Trigger:
25%

Test the switch unit's response by turning the rotary knob from the centre leftward and
rightward respectively to the limit, and copy the resultant oscillogram to the
placeholder provided for this purpose.
Time base:
??? s / DIV
Channel A:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Interpret the measurement result.
On attainment of the left limit, one hears a quiet click

like that made by a button or micro-switch, and
???
channel B indicates 5 V.
During approach to the right limit, the contact is

closed already before the end of travel, channel A
then being connected to 5 V over a certain range. ???
This suggests the presence of a sliding contact.
Check answer
Detach the connection leads from the sensor board and use the multimeter to
measure the resistance between the terminals on each switch setting.
Left limit:
Resistance between terminals 1, 2: ???


Centre setting:
Right limit:
Check answer
If the switch unit and throttle valve are imagined together on an axis, what are the
resulting functions and what all does the throttle valve switch unit indicate to the
control unit?
Terminal 1 is a micro-switch (normally open contact)
indicating the idle state.
Terminal 1 is a sliding contact (normally open) indicating
the full-load state.
Terminal 2 is a joint contact for supplying both switches Several
with a voltage. answers may
Terminal 2 is a joint ground terminal. be correct.
Terminal 3 is a micro-switch (normally open contact)
indicating the idle state.
Terminal 3 is a sliding contact (normally open) indicating
the full-load state.
What is especially important to ensure during installation and adjustment of a

throttle valve switch unit?
Precise adjustment so that the idle contact is actuated

only after the throttle valve has closed.

Precise adjustment so that the full-load contact is

actuated only after the throttle valve has closed.
Nothing requires special attention during installation.
Check answer

Throttle valve potentiometer
A customer's vehicle has been brought in with the following problem:

The engine jerks during slow acceleration under partial load, but operates
smoothly under full load.
One of the suspected causes is a defective throttle valve potentiometer.
Let's familiarize ourselves with the function of such an automotive sensor and its
circuitry before diagnosing it.

Throttle valve potentiometer theory
A throttle valve potentiometer serves the same purpose as a throttle valve switch, i.e.
it indicates the throttle valve's current setting to the motor control unit. Being able to
precisely determine valve's setting, the potentiometer is an advancement of the
throttle valve switch. Furthermore, the potentiometer notifies the motor control unit of
the rate at which the throttle valve is being opened / closed by the driver's actuation of
the accelerator pedal. This information allows the motor control unit to adjust the fuel
mixture's rich / lean level more accurately than using signals from a throttle valve
switch.
Pin
+ 5V
1
Pin
GND Symbol
2
Pin
Signal
3
A potentiometer is a variable resistor comprising a sliding contact, or tap, which can

be moved along a conductive track. The tap is linked to the throttle valve's shaft, so
that a change in the sliding contact's position correspondingly changes the throttle
valve's setting.
1 Conductive track
2 Sliding contact (armature)
3 +5 V
4 Signal
5 Ground

According to Ohm's law, the applied voltage of 5 V drops fully over the length of the
resistor's path (i.e. the conductive track in this case). In other words: 5 V are present
on the signal line if the sliding contact is at its left limit, 0 V if the contact is at its right
limit, and 2.5 V if the contact is in the middle.
In practice, the tap's travel is truncated by stops which restrict the effective voltage
range to 0.7 – 4.3 V (this range can vary depending on design). The restriction is
meant to facilitate an identification of short circuits and line interruptions.
To calculate load, the throttle valve potentiometer's signal is used together with the
signal from the lambda probe in the case of single-point fuel injection, and together
with the signal from the air-mass meter or MAP sensor in the case of multi-point fuel
injection.
In the emergency mode, the potentiometer signal also serves to replace the signal
from the air-mass meter if it is defective.
In systems incorporating an electronic accelerator function (E-gas), the potentiometer

signal is used for closed-loop control in conjunction with the servo motor for the
throttle valve.
It is important for a potentiometer to supply a continuous signal without any

interruptions. As a potentiometer wears, gaps can occur in the conductive track. Such
gaps lead to invalid signals which are not always identifiable during self-diagnostics.
This happens when a normal voltage reading between 0.7 V and 4.3 V is obtained
despite the presence of an invalid value.

Such gaps in a potentiometer's conductive track can be detected by means of a noise

test.
During this test, the voltage values measured at the tap are visualized on an
oscilloscope.

Experiment: Throttle valve potentiometer
Connect the throttle valve potentiometer to the 5-V voltage supply.
Connections:
From To
5V Throttle valve potentiometer pin 1
GND Throttle valve potentiometer pin 2
Interface A+ Throttle valve potentiometer pin 3
Interface A- GND
Voltmeter settings:

Mode: AV
Measure the output voltage with the throttle valve on the open and closed
settings.
When the throttle valve is open, the measured voltage

is ??? V.
When the throttle valve is closed, the measured voltage

is ??? V.
Why are 0 V and 5 V readings not obtained respectively at the potentiometer's

two terminal positions?
Series resistors limit the measured voltage values.

The limit values of 0 V and 5 V are reserved to enable
the control unit to identify short circuits and line
interruptions.
The control unit only recognizes line interruptions, the Several
upper limit being short of 5 V. answers may
be correct.
The control unit can only recognize short circuits, the
lower limit being short of 0 V.
The control unit is defective.
The measurement unit's internal resistance is too low.
Check answer
Noise test
Conduct a noise test in order to detect rifts in the potentiometer's conductive track.
The test involves recording the voltage characteristic over the entire conductive path
on an oscilloscope. The experiment configuration can remain unchanged here.
Channel A 2 V / div

Channel B Off
Time
1 s / div
base:
Trigger:
25% / Level approx. 2 V
After turning on the oscilloscope, move the throttle valve from its fully open
setting to its fully closed setting and back again. Evaluate the resultant
oscillogram.
Time
base:
??? s /
DIV
Channel
A:
Amplitude
factor:
??? V /
DIV
Coupling:
AC
DC
Channel
B:
Amplitude
factor:
??? V /
DIV
Coupling:
AC
DC
Noise test diagram:
Interpret the measurement result.

The voltage range is ???

The potentiometer's conductive track is ???
Check answer

Air-mass meter
Air-mass meter
A customer comes to the workshop with the complaint that their car loses a
lot of power and assumes the emergency operating mode. An initial
diagnosis reveals a malfunction on the air-mass meter. The first symptoms
appeared some time ago, when the car's starting and accelerating
properties began to deteriorate on a regular basis.
before diagnosing it further.

Air-mass meter theory
An air-mass meter or mass air-flow sensor (MAF) measures the amount of air
flowing past per unit of time.
Because the quantity of oxygen in the air stream is proportional to the measured
mass flow, this variable can be used to control combustion processes, especially in
internal combustion engines.
The air-mass meter is installed between the air filter and the engine's intake pipe.
Pin Air mass

1 signal
Pin
+5 V
2
Pin
GND
3 Symbol
Pin
+12 V
4
Intake air
Pin
temperature
5
signal
The air drawn in by the engine flows through the air-mass meter. The motor control
unit needs to know the intake air flow rate in order to calculate the required fuel
injection quantities. Engine systems without an air-flow meter instead make use of a
MAP sensor (refer to the chapter on pressure sensors).
Air-mass meter's installation point
Motor vehicles are usually furnished with a hot-film air-mass meter. In this case, a
measuring surface (the hot film) is heated to a setpoint temperature by an internal
circuit of the air-mass meter (PTC). When air flows past this surface, it is cooled. The
film is then re-heated by the internal electronics to the setpoint temperature with the

help of a Wheatstone bridge.
The value of the current needed to re-heat the film indicates the mass of air drawn in.
This current value is converted by the air-mass meter's internal electronics into an
output voltage signal.
Advantages:
l Very fast reaction

l Very precise measurements of flow rates, especially low ones (0 to 1 m/s)
l Cost-effective
Disadvantages:
l Susceptible to soiling
l Very susceptible to mechanical damage
To make the air-mass meter less susceptible to soiling and mechanical damage, a
partial air flow is frequently employed. In this case, only a part of the air stream drawn
in by the engine is routed past the air-mass meter's measuring surface, thus reducing
the potential for damage / soiling.
A=
Electrical
connections
B=
Housing
C = Air inlet
D=
Measuring
element
Most air-mass meters also incorporate an intake air temperature sensor which
supplies its signal via a dedicated line to the motor control unit. When performing
measurements on such air-mass meters, care must be taken not to mix up the two
signals.
How to differentiate:
If the throttle valve is opened during engine operation, the voltage of the signal
indicating the quantity of the intake air changes, whereas the voltage of the signal
indicating the temperature of the intake air remains nearly constant.

An air-mass meter accordingly has the following connections:
l Ground
l +12 V (for the heating element)
l +5 V (supply voltage for the evaluation electronics)
l Air-mass signal line
l Air-temperature signal line

Experiment: Air-mass meter
Our air-mass meter has the following connections:
¡ Ground
¡ +12 V (heating element)
¡ +5 V (supply voltage for the evaluation electronics and temperature sensor)
¡ Air-mass signal line
¡ Intake-air temperature signal line
Try to identify the air-mass meter's connections in the circuit diagram below.
How are the various lines assigned?

Pin 9 = +12 V; the circuit diagram does not permit a clear
determination of the remaining pin assignments because
the air-mass meter's internal circuit is not displayed.
Pin 9 = +5 V; the circuit diagram does not permit a clear
determination of the remaining pin assignments because
the air-mass meter's internal circuit is not displayed.
Pin 9 = ground; the circuit diagram does not permit a
clear determination of the remaining pin assignments
because the air-mass meter's internal circuit is not
displayed.

Check answer
The assignments of the remaining lines can only be determined with the help of
appropriate legends.
It must be pointed out that not all automobile manufacturers include such legends
in their circuit diagrams. If the legends are missing, voltage measurements must
be performed to ascertain the various line assignments.
Connections:
From To
Interface A+ Air-mass meter pin 1
5V Air-mass meter pin 2
Interface A-, GND Air-mass meter pin 3
12V Air-mass meter pin 4
Turn on the fan with the toggle switch (ON); open and close the valve several times

and record the air-mass meter's signal response on the oscilloscope.
Channel A 1 V / div
Channel B Off
Time
1 s / div
base:
Trigger:
25% / Level approx. 1.5 V
Copy the measurement result to the placeholder below.
Time base:
??? s / DIV
Channel A:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Which voltage levels are measured on the air-mass meter's signal line?
With the fan off (no air stream), the voltage is
approximately ???V.
Read the voltage
With the fan on and the valve closed, the voltage is values from the
approximately ???V. oscillogram.
With the fan on and the valve open, the voltage is

approximately ???V.
Check answer
How does the voltage signal respond when the valve is opened and closed rapidly,
and what is the motor control unit's reaction?
Time base:
??? s / DIV
Channel A:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Channel B:
Amplitude
factor:
??? V / DIV
Coupling:
AC DC
Fill in the blanks below.

When the valve is opened and closed rapidly, the
voltage signal of the air-mass meter follows ???
The air-mass meter responds very quickly to

???
When the valve setting is changed, the motor control
unit ???
Check answer

Air-mass meter summary
Air-mass meter summary
Possible faults on air-mass meters
As mentioned earlier, air-mass meters are very susceptible to dirt and moisture. If
an air-mass meter gets soiled (e.g. by an oil filter whose replacement is overdue or by
oil mist), it might start supplying deviant signals. Strong deviations are recognized by
the motor control unit, when then activates the motor control lamp and the emergency
mode in which the engine power usually drops significantly.
A fault occurring on an air-mass meter does not necessarily generate a

corresponding error code. If the signal output by the air-mass meter fluctuates within
a plausible range (= considered normal by the motor control unit), no fault is
assumed, no error code issued, and the motor control lamp remains off. In such
situations, the engine performance also drops but the source of the problem is much
more difficult to pinpoint.

Test
Test
How does the resistance of the sensors below change in dependence on

temperature?
An NTC's resistance
???
A PTC's resistance
???
Which of the following automotive functions can NTC sensors perform?
Coolant temperature measurement

Ambient temperature measurement Several
Exhaust-gas temperature measurement answers may
Speed measurement be correct.
Oil temperature measurement
How is an NTC operated in conjunction with the motor control unit?

Select
The one of the
NTC is ??? text
operated options
here.
Which material property does a knock sensor make use of?
Ferro-electricity
Piezo-electricity
Ferro-magnetism
Which factors determine whether or not a knock sensor functions correctly?
The installation point on the engine block Several

Constancy of the ambient temperature answers may
Mounting at the specified torque be correct.

Test
Installation point on the cylinder head
Which other sensor function can a pressure sensor (MAP) assume when installed
in the engine intake?

Air-mass meter
Knock sensor
Which supply voltage does a pressure sensor need?
A pressure sensor needs ??? V.
Which of the following statements about the Hall sensor are correct?
The Hall voltage is in the millivolt range.

The Hall sensor is used for temperature measurement.
The Hall voltage is generated by changes in a magnetic
field. Several
answers may
The Hall voltage is generated by changes in engine be correct.
speed.
The Hall sensor has a sinusoidal output signal.
The Hall sensor has a square-wave output signal.
Complete the following statements concerning inductive sensors.
Inductive sensors require

???
During measurements with an ohmmeter, inductive
sensors ???
Speed in this case is measured by means of a

???
Mark the sensors which need a supply voltage.

Test
Hall sensor
Knock sensor
Inductive sensor
NTC resistor
PTC resistor
Air-mass meter
How can a throttle valve potentiometer's conductive track be examined?
With the help of a frequency test

With the help of a noise test
With the help of a speed test
Which purposes do an air-mass meter's supply voltages serve?
The voltage of ??? V is used to power the evaluation

circuit.
The voltage of ??? V is used to power the heating

element.
Check answer

Sensor pin assignments
Speed sensor (Hall)
Pin 1 +5 V
Pin 2 GND
Pin 3 Signal
Speed sensor (inductive)
Pin 1 Signal
Pin 2 Signal
Throttle valve switch unit (idle / full-load sensor)
Pin 1 Signal
Pin 2 COM
Pin 3 Signal
Throttle valve potentiometer (valve angle sensor)
Pin 1 +5 V
Pin 2 GND
Pin 3 Signal
Air-mass meter
Pin 1 Air-mass signal

Pin 2 +5 V
Pin 3 GND
Pin 4 +12 V
Pin 5 Intake-air temperature signal

Suction pipe pressure sensor (MAP sensor)
Pin 1 GND
Pin 2 Signal
Pin 3 +5 V
Knock sensor
Pin 1 Signal
Pin 2 Signal
Temperature sensor (PTC)
Pin 1 Signal
Pin 2 Signal
Temperature sensor (NTC)
Pin 1 Signal
Pin 2 Signal

Copyright
Copyright © 2002-2008 LUCAS-NÜLLE GmbH
Congratulations!
This is the last page. You have completed the course "Automotive
Engineering 6: Automotive sensors".
Copyright © 2008 LUCAS-NÜLLE GmbH.
This course "Automotive Engineering 6: Automotive sensors" is protected by

copyright. All rights pertaining thereto are reserved. Any reproduction of the
document as a file or in written form be it photocopy, microfilm or any other method or
conversion into a machine-compatible language, in particular for data processing
systems, without the expressed written approval of the LUCAS-NÜLLE GmbH is
strictly forbidden.
The software as described above is made available on the basis of a general

licensing agreement or in the form of a single license. The use or reproduction of the
software is only permitted in strict compliance with the contractual terms stated
therein.
If changes have been performed in a manner which was not strictly authorised by the
LUCAS-NÜLLE GmbH, any product liability or warranty claims pertaining thereto are
null and void.

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Automotive sensors

Course number: SO4204-7F Version 1.0

Author: Hermann Kircheis

Lucas-Nülle GmbH • Siemensstraße 2 • D-50170 Kerpen (Sindorf) • Tel.: +49 2273

Copyright © 2008 LUCAS-NÜLLE GmbH.

Name: hhggglf, Date: 03.11.2017 Page 1 of 1

Welcome to the UniTrain-I course titled Automotive sensors!

l Physical fundamentals of sensors

l Fundamentals of electrical engineering and electronics

Name: hhggglf, Date: 03.11.2017 Page 1 of 1

Some animations require an installed Flash player. If your system

Name: hhggglf, Date: 03.11.2017 Page 1 of 1

Starting up the sensor board

Module SO4203-4V designated "Automotive sensors" incorporates 9 different

Perform the following settings to supply the board with a voltage:

l Select "DC Power Supply" from the menu "Instruments".

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use in the various experiments.

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NTC temperature sensor

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NTC sensor theory

NTC as a coolant temperature sensor,

NTC sensors on automobiles are frequently used for measuring:

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Where in the circuit diagram is an NTC shunt located?

Between terminals ??? and ???.

Set up the experiment as shown next:

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Using the multimeter, measure the NTC's resistance at room temperature:

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How does the NTC's resistance change on heating?

As the NTC's temperature rises, its resistance drops. Correct.

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NTC feed line

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What is the reason for the response provided above?

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Solving the customer's problem

1. The electric circuit is interrupted, e.g. by an open contact on the coolant

If the control unit measures a voltage of 5 V or 0 V at pin 3, it recognizes the

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PTC temperature sensor

A customer complained about the engine control lamp burning on their

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A PTC is more conductive at low temperatures than at high ones.

PTC exhaust gas temperature sensor

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Assemble the circuit shown next.

What is the resistance of our PTC element at room temperature?

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What is the resistance after heating?

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As the PTC's temperature rises ...

its resistance remains unchanged.

General characteristic of a PTC

Small temperature changes at low temperatures cause

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small changes in resistance.

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As you have established by now, a PTC temperature sensor's resistance begins to