Making Sense

Out of Sensors
Jim Halderman
Sinclair Community College
Dayton, Ohio
Where Is Sinclair?
Dayton, Ohio.
142 miles north of
Lexington, Ky.
116 miles east of
Indianapolis, In.
75 miles west of
Columbus, Ohio.
142 miles south of
Toledo, Ohio.
Virtual Tour of the Automotive
Technology Center
Main Lobby
Offices and Classrooms on
the Second Floor
Student Lounge Area
Automotive Department
Computer Lab
Seminar Room
GM Training Center
Main Vehicle Lab
Engine Lab
High-Performance Engine
Course
Donated Engines and
Transmissions
Automatic Transmission Lab
Manual Transmission Lab
Fuel and Emissions Lab
Engine Dyno
Chassis Dyno
Race Vehicle Fabrication
We started communicating
by writing on the cave walls.
As the years went by we
progressed. We invented tools
to make communication better.
The chalk board was an
effective tool for many
years for communications.
Communication through Sensors
The PCM uses sensors to learn what is
happening in the engine.
Sensor Basics
How does a computer know what is
going on under the hood?

How does the voltage change inside
the PCM if changes occur at the other
end?
Pull Up
Resistors
The voltage
changes at the
sense terminal
inside the
PCM after the
resistor.
Pull Down
Resistor
The voltage
changes if the
switch is open or
closed.
Resistor Network
Resistances
can be used
to simplify
inputs.

Ford Manual
Lever
Position
(MLP) is an
example.

What would happen if some resistance
were added to the circuit?
If the resistance increases, what will
happen if you are driving at highway
speeds in drive?
Temperature Sensors
Use a semiconductor material that becomes more
conductive as the temperature increases.

This is called a Negative Temperature Coefficient
(NTC) thermistor.



Temperature Sensors
PCM
What will the
PCM read if
unplugged?

What will the
PCM read if
the wire going
to the sensor
is shorted to
ground?
ECT
ECT should
read the
same at IAT
at key on
engine off
(KOEO).
A GM Stepped ECT
Switches at 1.0 volt (120F).
Throttle Position Sensors
Three-wire
potentiometer

Five volts
from PCM

Signal return

Ground
Testing the TP sensor
Great location to check for five-volt
reference (Vref).

General Motors recommends checking
for PCM ground voltage drop at the TP
sensor. (There should be less than
0.035 volts between the TP sensor
ground terminal and the negative
terminal of the battery.)

TP Sensor Waveform
(Defective)
MAP versus Vacuum
MAP Sensor
Manifold Absolute Pressure (MAP)

A decrease in manifold vacuum
means an increase in manifold
pressure.

Compares manifold vacuum to a
perfect vacuum.
Silicon-Diaphragm Strain Gauge
Design MAP Sensor
Most commonly used.

Silicon wafer is exposed to engine vacuum.

This results in changes in resistance due to
strain on the resistors attached to the wafer
(called Piezo-resistivity).

Resistors are connected to a Wheatstone
bridge and then to a differential amplifier,
which creates a voltage in proportion to the
vacuum applied.

Silicon-Diaphragm MAP Sensor
MAP Voltage
Normal engine Vacuum is 17-21 in. Hg.

MAP sensor voltage is normally between 0.88
volts to 1.62 volts (GM).

17 in. Hg. is equal to about 1.62 volts.

21 in. Hg. is equal to about 0.88 volts.

Therefore, a good reading should be about 1
volt.
Capacitor-Capsule MAP Sensor
Used by Ford.

Uses two alumina plates with an insulating
washer spacer to create a capacitor.

The deflection due to engine vacuum
changes the capacitance.

The electronics in the sensor translate this
into a frequency output.
Ford Frequency versus Vacuum

KOEO. 156-159 Hz (0 in. Hg.)

Idle (sea level).. 102-109 Hz (17-21 in.
Hg.)

WOT. 156-159 Hz (Almost 0
in. Hg.)
Ceramic Disc MAP

Used by DaimlerChrysler.
Ceramic disc converts manifold
pressure into a capacitive discharge.
The discharge controls the amount of
voltage drop delivered by the sensor to
the PCM.
The output is the same as the
previously used strain
gauge/Wheatstone bridge design.
Ceramic Disc MAP
MAP versus BARO

KOEO MAP should equal BARO.
Will vary with altitude and weather
conditions.
The BARO reading is set at key on and
updated if the throttle is detected to be
at WOT and will update the BARO
reading.
Testing a MAP Sensor
Key on engine off (KOEO). Voltage should
be 4.6 to 4.8 volts at sea level.

Check for vacuum to the sensor.

Check the hose.

Replace the MAP sensor if anything comes
out of the sensor.
Speed Density MAP
The MAP sensor is a high-authority
sensor on an engine that uses the
Speed-Density method of fuel control.
If the exhaust is rich, try disconnecting
the MAP sensor.
If the engine now runs OK, then the
MAP sensor is skewed or giving the
PCM wrong information.
Air Vane Sensor
Usually contains an internal IAT
sensor.

Airflow moves the vane, which
causes a switch to close to power
the fuel pump.
Air Vane Sensor
This is not a mass air flow sensor.
Karman-Vortex
Named for Theodore Van Karman, a
Hungarian scientist (1881 1963).

He observed the vortex phenomenon in
1912.

This type of sensor has proven to be
very reliable and not subject to dirt.
Karman-Vortex
This is not a mass air flow sensor.

Ultrasonic Karman Vortex

Used by Mitsubishi in many vehicles.

Very reliable.

Early versions used LEDs and
phototransistors, which were subject
to dirt.
Pressure-Type Karman Vortex
DaimlerChrysler uses a Karman Vortex
sensor that uses a pressure sensor to
detect the vortexes.
As the flow increases, so do the
number of pressure variations.
The electronic circuitry in the sensor
converts these pressure variations to a
square wave signal that is proportional
to the airflow through the sensor.
Mass Air Flow
A hot wire is used to measure the mass of the
air entering the engine.

The electronics, in the sensor itself, try to
keep the wire 70 C above the temperature of
the incoming air.

The more current (amperes) needed to heat
the wire, the greater the mass of air.

The current is converted to a frequency.

MAF Sensor
Normal MAF Readings
Use a scan tool to look at the grams per
second.

Warm the engine at idle speed with all
accessories off. Should read 3 to 7 grams per
second.

GM 3800 V-6 should read 2.37 to 2.52 KHz.

If not within this range, check for false air or
contamination of the sensor wire.
MAF Sensor Diagnosis
If the MAF sensor wire were to become coated,
it cannot measure all of the incoming air.

To check for this condition, use a scan tool.

A normal warm engine at idle should be 3 to 7
grams per second.

Rapidly depress the accelerator pedal to WOT.
It should read over 100 grams per second.
MAF and Altitude Reading
Barometric pressure (BARO) is determined
by the Powertrain Control Module (PCM)
software at WOT. (There is no actual BARO
sensor on MAF-equipped vehicles.) At high
airflows, a contaminated MAF sensor will
under estimate airflow coming into the
engine, and therefore, the PCM determines
that the vehicle is operating at a higher
altitude. The BARO reading is stored in Keep
Alive Memory (KAM) after it is updated.
Visual Inspection
Look for an off-brand
air filter or a very dirty
filter.

Look for a K&N filter
that has been over-
oiled.

Look carefully for
fuzz on the sensing
wire.

Cleaning a MAF Sensor

Can clean the
sensing wire using
alcohol and a Q-tip,
if you are careful.

Brake clean = ?

Mass Air Flow (MAF)-False Air
Usually affects operation in drive; may run OK if driving in reverse.
If in Doubt, Take It Out

If the MAF sensor is disconnected, the
PCM substitutes a backup value.

If the engine runs OK with the MAF
disconnected, then the MAF has been
supplying incorrect information.
Oxygen Sensors
Oxygen sensors react to the presence or
absence of oxygen in the exhaust.

The voltage signal is used by the PCM
for fuel control.

The mixture must switch from rich to
lean for the three-way catalytic (TWC)
converter to work.
O
2
Sensor
Oxygen Sensors
An absence of
oxygen results
in a voltage of
higher than 450
mV.

The presence of
oxygen results
in a voltage
lower than 450
mV.
Mud-Coated O2S
Do Not Solder O2S Wires
Universal oxygen sensors are often
used when replacement becomes
necessary.
Many O2S breathe through the wiring
itself.
If the wires are soldered, then the
sensor cannot detect outside oxygen.
Use crimp connectors if a universal
sensor is used.
Oxygen Sensor Diagnosis
If the fuel system is functioning correctly, the
oxygen sensor voltage should fluctuate from
above 800 mV to below 200 mV.

As the oxygen sensor degrades, the range
narrows.

A sensor should at least be capable of
reading above 600 mV and go below 300 mV.
O
2
Sensor Diagnosis (Continued)
Use a digital multimeter (DMM) set to read
DC volts and use the min/max feature.

Back probe the signal wire and operate the
engine normally while recording the readings
using min/max.

The maximum reading should be above 800
mV and the minimum reading below 200 mV.

O
2
Sensor Diagnosis (Continued)
Check the average of the O
2
sensor
readings:

If the average is above 450 mV, then the
engine is operating rich or the sensor is
skewed high.

If the average is below 450 mV, then the
engine is operating lean or the sensor is
skewed low.
Rich to Lean
Should switch in less than 100 ms.
CAT Food

In order for the catalytic converter
to function correctly, it must have
an alternating rich and lean exhaust.
If the exhaust is
lean for too long,
the CAT dies due
to lack of fuel.
Rich Mixture
A rich exhaust all the time
will also kill the CAT.
False Lean Readings
False Lean Readings
A cracked exhaust manifold can cause
oxygen to be drawn into the exhaust
upstream from the oxygen sensor.

An ignition misfire can also cause a
false low-oxygen sensor reading.

Remember that the oxygen sensor
looks at the oxygen in the exhaust, not
the unburned fuel!
Antifreeze Contamination
If the engine has had a blown head
gasket, be sure to check or replace the
oxygen sensor.

The silicates can coat the sensor.

Dexcool and other organic acid
technology (OAT) coolants do not
cause this problem.
Antifreeze on an O
2
Sensor
High Authority Sensor
The O2S is a high-authority sensor
when the engine is operating in closed
loop.
If the sensor is skewed, it can create a
driveability problem.
If in doubt, take it out.
If the sensor voltage is not connected,
the PCM will go into open loop.
Position Sensors
Two Types:

Analog sensors - such as magnetic or
variable-magnetic sensors

Digital sensors - such as Hall-Effect
magnetic-resistive or optical sensors.
The first magnetic sensors were called
pulse generators (pickup coils).
Magnetic
Sensor
Operation
Magnetic Sensors
Used for Crankshaft
Position (CKP)

Used for Camshaft
Position (CMP)

Used for wheel
speed sensors
(WSS)

Magnetic Sensors
First,
be sure
they are
magnetic.

A cracked
magnet
becomes
two weak
magnets.
Magnetic Sensor
The
sensor
housing
should
not be
cracked
or melted.
Ford Probe Story (2.5 liter V-6)
Problem occurred at highway speed.

Stopped running.

Was towed to shop.

Runs, but at idle only.

Dies as soon as accelerator is depressed.

Everything checks out OK.

Magnetic Sensor
Found a
loose
CKP
sensor.

Magnetic Sensors
Produce
an AC
voltage
signal
when the
magnetic
field
strength
changes.

Magnetic Sensor (Continued)
The Soldering Gun Trick
Hold a soldering gun near a magnetic
sensor and the changing magnetic field
around the soldering gun will induce a
voltage into the windings of the
magnetic sensor,
The frequency will be 60 Hz.
If used on a VSS and the ignition is on,
the speedometer will read 54 mph (GM).
Hall-Effect Sensors
Effect discovered by Edwin H. Hall in 1879.

He discovered that a voltage is created if a
magnetic field is exposed to an element.

The voltage goes to zero if the magnetic field
is shunted or blocked.

Very accurate.

Hall-Effect
Three-wire sensor
Power
Ground
Signal

Output is a square wave.

Very accurate and will work at lower
speeds than a magnetic sensor.
Hall-Effect
Hall-Effect
Optical Sensor
Optical Sensor
Produces a square wave signal.

Very accurate can be used to show every
1 degree of crankshaft rotation.

Optical sensors do not like light; must be
shielded (sparks inside the distributor can
cause problems if the sensor is not
shielded).

Optical Sensor
Magnetic-Resistive Sensors
Generates a
digital signal
using two
magnets.

Electronics in
the sensor
generate a
square-wave
output signal.

CKP and CMP Waveforms
What type of sensor is used for the CKP?

What type of sensor is used for the CMP?
Toyota Wheel Speed Sensor
Can
detect
forward
or reverse
motion.

Questions?
Thats All Folks!
For a copy of this presentation, go to http://storage.jameshalderman.com
Jim Halderman
Sinclair Community College
444 West Third Street
Dayton, OH 45402
(937) 512-2726
James.halderman@sinclair.edu
jim@jameshalderman.com